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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method and system for controlling trolling motors used by fishermen, and more particularly to a microcontroller-based trolling motor system operating a plurality of transducers organized to transmit and receive sonar signals in order to set the direction and speed of the trolling motor and cause it to follow a user-specified depth contour of the underwater bottom terrain, or to maintain a user-specified distance from the shore, or to find the deepest area of the underwater bottom terrain.
2. Brief Description of the Prior Art
In fishing, once the angler runs the boat to the desired vicinity, the boat is operated by a smaller outboard motor, a "trolling motor", powered by a battery to provide maneuverability and to minimize disturbance to the fishing environment.
The angler, knowing the temperature of the water, can determine the depth at which the object fish prefers to swim. The angler would then wish to maintain the boat over this depth and fish at this depth. In another scenario, the angler may simply wish to fish at the deepest part of a creek that may or may not be at the middle of the creek. Furthermore, in another scenario, the angler may wish to fish at a relatively fixed distance from the shore.
In two of the three scenarios mentioned above or variations thereof, the angler would have to manually activate the sonar to find the depth of the current boat location, steer the boat in one direction, read the sonar again to see if the boat is being steered in the correct direction for the desired depth, and adjust the steering again if necessary. This process is repeated continuously until the angler is content with the location of the boat. If there is a drift current or strong wind, the boat would be pushed downwind or downstream and the angler would have to account for the drift current and constantly readjust and operate the boat. In all three scenarios, between monitoring the sonar and operating the motor, the angler has very little time left for fishing.
Thus, it is desirable to have an automated system whereby the angler sets the desirable mode once, is free from operating the sonar and the motor, and is allowed to spend most of his or her time on fishing.
Transducer systems operating in conjunction with microcontroller have been used in fish finder systems and bottom detection systems. However, there are no known microcontroller based systems operating transducers and a motor similar to the invention disclosed herein.
SUMMARY OF THE INVENTION
The present invention utilizes a microcontroller, a plurality of transducers, a steering motor, and an outboard motor. The user is allowed to input commands via a keypad and the selected mode of operation is displayed via a LCD screen. The microcontroller operates the transducer to transmit sonar signals, and the return signals are received and processed accordingly. In the preferred embodiment, there are five transducers arranged in a manner such that the port (left side of the boat) and starboard (right side of the boat) sides, as well as the bottom of the boat, may be scanned continuously.
The microcontroller processes the signals according to the user-selected mode, determines the steering degree and the motor speed, and transmits these values to the Steering Motor and Position controller and the Power Drive and Motor controller.
In the preferred embodiment, there are three automatic modes of operation: creek-tracking mode, depth-tracking mode, and shore-tracking mode. In the creek-tracking mode, the microcontroller finds the deepest area in a creek or channel and maintains the boat on that course; in the depth-tracking mode, the microcontroller maintains the boat on a certain contour of the bottom terrain; and in the shore-tracking mode, the microcontroller maintains the boat at a desired distance from the shore. In each of these modes, the user may increase or decrease the speed of the boat and has the option to do an automatic U-turn of the boat. There is also a manual mode where the user controls the direction and speed of the boat.
Once one of the automatic modes is selected, the microcontroller operates the troller and the angler can concentrate on fishing and does not need to be concerned with operating the boat.
Accordingly, it is an object of the present invention to provide an improved method and apparatus for depth tracking using transducers.
It is another object of the present invention to provide an improved method and apparatus for shore tracking using transducers.
It is another object of the present invention to provide an improved method and apparatus for tracking deepest terrain of an underwater surface.
It is another object of the present invention to provide for an improved method and apparatus to provide an automated transducer troller system that frees anglers from constantly operating the boat.
It is another object of the present invention to provide for an improved method and apparatus to allow automatic U-turns.
These and other objects and advantages of the present invention will no doubt become apparent to those skilled in the art after having read the following detailed description of the preferred embodiment which is illustrated in the several figures of the drawing.
IN THE DRAWING
FIG. 1 is a side view of an embodiment of the present invention in the form a trolling motor, shaft, head unit, and foot pedal controller.
FIG. 2 is a perspective view of the head unit showing a display.
FIG. 3 is an enlarged view of the display having a keypad and a LCD screen.
FIG. 4 is a perspective view of the foot pedal controller of the preferred embodiment.
FIG. 5a is a side view of the trolling motor, detailing the transducers.
FIG. 5b is a bottom view of the nose cone of the trolling motor showing the layout of the transducers.
FIG. 6a is a side view of the nose cone showing the geometric relationship of the transducers' placements.
FIG. 6b is a front view of the nose cone showing the geometric relationship of the transducers' placements.
FIG. 7 is a functional block diagram showing the principal operative and detection and control components of an embodiment of the present invention.
FIGS. 8a, 8b, 8c, 8d, 8e, and 8f are flow chart diagrams illustrating the shore-tracking mode of the present invention.
FIGS. 9a, 9b, 9c, 9d, 9e, and 9f are flow chart diagrams illustrating the creek-tracking mode of the present invention.
FIGS. 10a, 10b, 10c, 10d, and 10e are flow chart diagrams illustrating the depth-tracking mode of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is a head unit 10 with a handle 24 and the head unit is mounted on a shaft sleeve 12. The shaft 14 is rotatable within the shaft sleeve and is controlled and actuated by a mechanism within the head unit. A trolling motor unit 18 having a fin 26 and a propeller 28 is attached to the other end of the shaft. There is a user-controlled foot pedal unit 20 communicatively attached via an electrical cord 22 to the head unit. Through this foot pedal unit, the user can, in addition to other features, manually steer the trolling motor unit and control its speed. There is a mounting bracket 16 attached to the shaft sleeve via an attachment bracket 30. The entire trolling motor unit can be attached to a boat via the mounting bracket. The mounting bracket allows the trolling motor unit to be lifted out of the water or to be submerged in the water.
In FIG. 2, the head unit 10, having a display and keypad 32, is mounted on the shaft sleeve 12 and attached to the shaft 14. Referring to FIG. 3, the preferred display and keypad 32 has six buttons on the keypad and one screen. There is an ON/OFF button 34 to power the unit, a DISPLAY button 36 allowing toggling between display of temperature and depth on the screen, a MANUAL MODE button 38 allowing the user to manually control the steering and speed of the trolling motor, a DEPTH TRACK button 40 to activate the Depth-Tracking Mode, a SHORE TRACK button 42 to activate the Shore-Tracking Mode, and a CREEK TRACK button 44 to activate the Creek-Tracking Mode. The screen 46 displays a bar 48 for battery strength, numbers 50 to show temperature (or depth), and a short bar 52 to indicate the selected mode.
Referring to FIG. 4, the foot pedal unit 20 has a foot pedal 60, a speed control dial 62, and an option button 64. By pressing the pedal away from the user, the trolling motor is steered toward port side; and by pressing the pedal toward the user, the trolling motor is steered toward starboard side. By maneuvering the foot pedal while in one of the three automatic modes, the transducer trolling system is returned to the manual mode. By pressing on the option button while in the manual mode, the system is returned to the previously activated automatic mode. By pressing on the option button while in the automatic mode, the system is instructed to command a U-turn.
The trolling motor unit 18, referring to FIG. 5a, has a nose cone 70 housing five transducers. The port 72 and port-down 74 transducers are illustrated. Behind the nose cone 70 is the front casting 76 containing the Power Drive and Motor controller. The motor shell 78 houses the motor and the propeller 80 is after the rear casting 82. In FIG. 5b, the arrangement of the transducers on the nose cone is illustrated. There is the port transducer 72, starboard transducer 90, port-down transducer 74, starboard-down transducer 88, and the down transducer 86.
Referring to FIG. 6a, in the preferred arrangement of the transducers in the nose cone, the port-down 74 and starboard-down transducers are angled at 15 degrees from a horizontal axis 92 running along the cone 70. Referring to FIG. 6b, a front view of the nose cone 70 shows that the down transducer 86 is positioned straight down, the port 72 and starboard 90 transducers are positioned 85 degrees from the down transducer 86, and the port-down 74 and starboard-down 88 transducers are positioned 21 degrees from the down transducer 86.
Referring to FIG. 7, a functional block diagram illustrates the relationship between the processing blocks. In the head unit 10, the main microcontroller 100 receives user commands regarding mode selection and display options via the keypad 32 and displays the selection and other information on the display screen 32. Once the mode is selected, the microcontroller activates the Transducer Transmit and Receive Controller 106 to send and receive signals to and from the selected transducers 108. With the information obtained from the transducers, the microcontroller calculates the appropriate steering and speed values. The steering value is sent to the Steering Motor and Position controller 102, and this controller instructs the Steering Subsystem 104 to actuate the steering motor (not shown) to turn the shaft in the proper direction and in the right amount. The Shaft Position Feedback System 104, using infrared transmitters and receivers (not shown) to read off decals on the shaft and gears (not shown), determines the actual amount of the turn by the shaft. The speed value is transmitted to the Power Drive and Motor controller 110 to effectuate the proper amount of power to the motor 112 for the given speed value. In any of the modes, the user can control the speed and direction of the trolling motor via the foot pedal unit 20.
The present invention offers three automatic modes in which the steering and speed of the trolling motor is entirely managed by an embodiment of the present invention. The three automatic modes are the shore-tracking mode, creek-tracking mode, and depth-tracking mode. In each mode, the transducers are activated and the returned values are processed through a series of program logic and look-up tables to output steering and speed values for the trolling motor.
The look-up tables are particularly important. They are developed based upon observed relationships between the different variables and empirically refined. There are several look-up tables for each mode. The look-up tables are not history tables and their values do not change.
In the shore-tracking mode, the microcontroller will steer the boat to travel at a fixed distance from the shore. In this mode, in addition to the boat-to-shore distance reading by the port or starboard transducer, the depth of the bottom terrain is also used to assist the program logic in determining the steering value. Here, the depth of the bottom terrain at a constant distance along the shore is assumed to be relatively unvarying or slow in varying as the boat travels along the shore.
The program flow for the shore-tracking mode is as follows:
Step 1: Initiation and Set-Up
Step 2: Error Processing Step
Step 3: Terrain Trend Adjustment Routine
Step 4: Steering Feedback Routine
Step 5: Steering Processing Step
Step 6: Large Turn Compensation Routine
Step 7: Drift Mode Routine
Step 8: U-Turn Routine
Step 9: Output Speed and Steering values to each of the controllers
Step 10: Go to Step 2 if Mode is not Cancelled
Referring to FIG. 8a, when the user selects the shore-tracking mode 120, a number of initiation steps are taken and a number of variables are initialized 122. The port side distance from shore ("P") and the starboard side distance from shore ("S") are obtained by activating the port and starboard transducers 122. If the port distance value is greater than the starboard distance value 124, the shore ("BANK") is on the port side and BANK is set to 1 to so indicate 126. Otherwise, shore is on the starboard side and BANK is set to 0 to so indicate 128. The user desired distance from shore ("RANGE") is set accordingly as well 126 or 128.
After initialization, a number of variables 130 necessary for calculating the error index and ultimately used in calculating the steering correction value ("STEERING") are obtained. First, the difference between the current distance from shore (P or S depending on BANK 132) and the desired distance from shore (RANGE) is determined ("ERROR") 134 or 136. The system will produce STEERING and SPEED values to reduce ERROR to a minimum. At this point, the program flows to connector "A" 138.
Referring to FIG. 8b, from connector "A" 138, the difference between ERROR and error from the last program cycle ("ERROR -- LAST") defines the change in ERROR ("DELTA -- ERR") . The Position Error Index ("POS -- ERR -- IND") is where the value for ERROR is quantified into an index by using the Position Error Index Look-Up table ("LU -- POS -- ERR") 140. Using a Delta Error Index Look-Up Table ("LU -- DELTA -- E -- I"), the Delta Error Index ("DELTA -- ERR -- IND") is where the value for DELTA -- ERR is quantified into an index value 140, and the DOWN value is used to reflect the fact that in deeper water the corresponding reading will be less accurate than in shallower water. Similarly, the Steering Index ("STEERING -- IND") is where the Steering value ("STEERING") from the last program cycle is quantified into an index value by looking up the Steering Index table ("LU -- STEERING -- IND") 140. SLOPE is the difference between the distance values PD and SD read from the port-down transducer and the starboard-down transducer. SLOPE -- IND is an index obtain from the Slope Index Look-Up Table ("LU -- SLOPE").
The next processing step is the beginning of the Terrain Trend Adjustment Routine. In the shore-tracking mode, the assumption was made that the terrain remains non-varying or slow varying at a fixed distance along the shore. Thus, by tracking depth, the distance from the shore is being tracked to certain extent. In order to account for the change in the terrain, this routine allows resetting of depth relative to the shore ("DOWN -- TRACK").
The initial depth relative to shore ("DOWN -- TRACK") value is set to the downward depth ("DOWN") reading when the user activated this mode. As the boat travels along the shore, the depth reading ("DOWN") will either increase and continue to increase, decrease and continue to decrease, or reverse depth direction from increase to decrease or decrease to increase. The change in depth ("DELTA -- DEPTH") is defined as the difference between current depth reading (DOWN) and ("DOWN -- TRACK"). When DELTA -- DEPTH changes sign 142, there is a reverse in direction and the depth to shore value (DOWN -- TRACK) is reset to the current reading of DOWN 144. By reset DOWN -- TRACK, the program is recognizing the change in terrain in relation to the shore.
If DELTA -- DEPTH did not change sign, DOWN -- TRACK can also be reset if conditions checked by the Shore Look-Up Table permits reset 146. DOWN -- TRACK will be reset if the boat is being steered into deeper water as indicated by STEERING -- IND, the boat is getting further from the shore as indicated by DELTA -- ERR -- IND and DDEPTH -- IND, and the distance of the boat from shore as indicated by POS -- ERR -- IND is getting larger. If all four conditions are true, DOWN -- TRACK will be reset to the current reading of DOWN 148 and 144. In this case, where the terrain is getting shallower (or deeper), the system is mistakenly steering the boat further away from the shore. To correct this situation, the Shore Look-Up Table ("LU -- SHORE") is designed to allow this change in terrain by resetting DOWN -- TRACK to allow the system to steer the boat back along the desired distance from the shore. In any case, DELTA -- DEPTH is reevaluated, and this ends the Terrain Trend Adjustment Routine.
Going on to connector B of FIG. 8c, this is the beginning of the Steering Feedback Routine. The goal of this routine is to avoid oscillation created by over-steering. Oscillation may occur when the boat is over steered in one direction and the microcontroller determines that the boat needs to be steered in the other extreme, resulting in the boat traveling in a zig zag, rocking manner. The routine will damp over steering to allow the boat to travel in a smooth, gradual manner.
First, the maximum change in depth previously detected ("MAX -- DDEPTH") is compared with the absolute value of the current change in depth (DELTA -- DEPTH) 152. If the absolute value of DELTA -- DEPTH is greater than MAX -- DDEPTH, MAX -- DDEPTH is set to DELTA -- DEPTH 154 and thus recognizing maximum damping is necessary.
Otherwise, a reduction in damping is achieved by reducing MAX -- DDEPTH by Maximum Delta Depth Reduction ("MAX -- RED"). MAX -- RED is determined from the MAX -- RED Look-Up Table, quantifying the MAX -- DDEPTH into an index value which is affected by POS -- ERR -- IND that is larger than a pre-set error margin. A larger Position Error Index (keeping MAX -- DDEPTH constant), which indicates that a large steering adjustment is needed to return the boat back on course, will create a larger MAX -- RED and thereby allowing a smaller MAX -- DDEPTH 158 and subsequently a larger Error Index ("ERR -- IND"). A larger Error Index will result in a larger Steering value. On the other hand, keeping POS -- ERR -- IND constant, a larger MAX -- DDEPTH will result in a larger MAX -- RED. After MAX -- RED is determined, MAX -- DDEPTH is correspondingly reduced by that amount 158, and this is the end of the Steering Feedback Routine.
The next processing step calculates for steering correction ("STEERING") 160. First, the Error Index ("ERR -- IND") is determined from the Error Index Look-Up Table ("LU -- ERRIND") by quantifying POS -- ERR -- IND into another index that is affected by MAX -- DDEPTH. A larger MAX -- DDEPTH will result in a smaller ERR -- IND. The Acceleration Index ("ACC -- IND") is calculated from the difference between the current Change in Depth Index (DDEPTH -- IND) and the previous Change In Depth Index ("DDEPTH -- IND -- LAST"). Change In Depth Index (DDEPTH -- IND) is obtained from the Change In Depth Look Up Table ("LU -- DDEPTH -- IND") by quantifying DELTA -- DEPTH that is influenced by ACC -- IND. A larger ACC -- IND will result in a larger DDEPTH -- IND, which tends to result in a larger steering correction.
Finally, Steering direction and magnitude ("STEERING") is determined from a Steering Look-Up Table ("LU -- STEERING") with five inputs. By keeping other variables constant and varying one input at a time, the relationships between the variables are explained. There is an inverse relationship between ERR -- IND and STEERING where a larger ERR -- IND will call for a larger steering correction to correct the distance of the boat to the shore. There is a direct relationship between DDEPTH -- IND and STEERING where a larger DDEPTH -- IND will call for a smaller steering correction to account for the rapid movement of the boat over the bottom contours line. STEERING -- IND has an inverse relationship with STEERING where a larger STEERING -- IND will call for a smaller steering correction in order to reduce the possibility of oscillation. DELTA -- ERR -- IND has a direct relationship with STEERING where a larger DELTA -- ERR -- IND value will show the need for a more severe steering correction to steer the boat along the shore. Lastly, there is an inverse relationship between SLOPE -- IND and STEERING where a large SLOPE would tend to indicate the need for a smaller steering correction to get the boat over to the correct contour. The STEERING value can be either a positive value demonstrating a port side steering correction or a negative value demonstrating a starboard side steering correction. Other numbering methods may be used as well.
Moving to connector C on FIG. 8d 162, this is the beginning of the Large Turn Compensation Routine, which is a routine to allow a more severe steering correction every three program cycle in order to provide a faster turn. If the absolute value of STEERING is larger than sixty degrees 164, this is considered as a large turn and COUNT -- LT is clear to initiate the count for compensation 166. For every three program cycles 168, STEERING is increased by a constant value ("CNST -- CMPN") if STEERING is positive and decreased by CNST -- CMPN if STEERING is negative 170. CNST -- CMPN is about eight degrees in the preferred embodiment.
Next, the DRIFT ROUTINE calculates compensation of the given speed in order to account for drift current or wind. In any of the automatic modes, the user may set the desired speed of travel via the speed dial on the foot pedal unit. If there is a strong drift current, this speeding setting will need to be compensated in order to made headway in the water. First, the selected speed ("SPEED") is quantified into an index ("SPEED -- IND") via the Speed Index Look Up Table. Then, the Drift Index ("DRIFT -- IND") is obtained from the Drift Index Look-Up Table ("LU -- DRIFT -- IND") which has three input variables 174. The relationship between the variables and DRIFT -- IND is illustrated through the following examples. In a case where the user sets a low speed, the system commands a large steering correction, and the ERR -- IND is greater than some error margin, the DRIFT -- IND will be higher and will be ever higher as ERR -- IND increases. In another case where the user sets a high speed, the system commands a large steering correction, and the ERR -- IND value is low, moderate, or even none existent, the DRIFT -- IND will be low also. Finally, if the steering correction is low or nonexistent, DRIFT -- IND will always tend to be lower than SPEED, which indicates that the boat is on or approaching its course. If DRIFT -- IND is larger than SPEED 176, SPEED is set to DRIFT -- IND 178.
Referring to connector D 180 of FIG. 8e, this is the start of the U-Turn Routine. If the user enables automatic U-turn 182, STEERING is set to a constant value 184, here about 80 degrees. Note that the U-turn will always be executed away from the shore so STEERING is set to a positive or negative value depending on the shore. STEERING is set to (+ or -) CNST -- UTURN for a predetermined number ("CNST -- UTCNT") of program cycles in order to come close to completing the U-turn. Here, CNST -- UTCNT is initialized to sixteen with the expectation that the U-turn will be close to completion in sixteen program cycles 186. When the U-turn constant count (CNST -- UTCNT) is reached, if the boat is still heading into deeper water (DELTA -- DEPTH>0) 188 which indicates that the turn is not yet close to completion because is not yet going toward the shore, the program will continue to allow STEERING be set to CNST -- UTURN to complete the U-turn. If the boat is steering toward shallower water 188 which indicates that the boat is coming to completion of the U-turn, and if the U-Turn Steering ("UT -- STEERING") is within the Straight Ahead Constant value ("CNST -- SA") 190, which is twelve degrees in the preferred embodiment, the U-turn is completed and the mode is disabled 192. Otherwise, if the boat is steering toward shallower water but UT -- STEERING is greater than CNST -- SA, UT -- STEERING is reduced by CNST -- SA 194, and steering is set to UT -- STEERING. Over a few program cycles, the UT -- STEERING value will be reduced to within CNST -- SA value range and the U-turn mode will be disabled 192.
After the U-Turn Routine 196, the value of SPEED is transmitted to the Power Drive And Motor controller and the value of STEERING is transmitted to the Steering Motor and Position Controller to carry out the output values.
At this point, referring to FIG. 8f, certain variables are initialized 195 if the mode is not cancelled by the user, and program flow goes back to connector START 129 on FIG. 8a. Otherwise, the program ends 198.
The program logic for the creek-tracking mode is substantially the same as in the shore-tracking mode. In this mode, the microcontroller will find the deepest terrain for the given body of water. The program flow for the creek-tracking mode is as follows:
Step 1: Initiation and Set-Up
Step 2: Error Processing Step
Step 3: Terrain Trend Adjustment Routine
Step 4: Steering Feedback Routine
Step 5: Steering Processing Step
Step 6: Large Turn Compensation Routine
Step 7: Drift Mode Routine
Step 8: U-Turn Routine
Step 9: Output Values Speed and Steering to each respective controller
Step 10: Go to Step 2 if Mode is not Cancelled
Referring to FIG. 9a, when the user selects the creek-tracking mode 200, a number of initiation steps are taken and a number of variables are initialized 202. The port-down ("PD") and starboard-down ("SD") transducers are activated to find the distance from the bottom terrain on both sides 204. These distance values are used to determine the location of the shore ("BANK") 206 or 208.
After Initialization, a number of variables necessary for calculating the error index 210 and ultimately used in calculating the steering correction value ("STEERING") are obtained. First of all, the difference between the PD value and SD value defines the error ("ERROR") 212 or 214. Because the program is searching for the deepest part of the terrain, ideally PD and SD should be about the same. The program now flows to connector A 216.
Referring to FIG. 9b, from connector A 216, the difference between ERROR and error from the last program cycle ("ERROR -- LAST") defines the change in error ("DELTA -- ERR") 218. The Position Error Index ("POS -- ERR -- IND") is where the value for ERROR is quantified into an index by using the Position Error Index Look-Up table ("LU -- POS -- ERR -- IND") 218; the Delta Error Index ("DELTA -- ERR -- IND") is where the value for DELTA -- ERR is quantified into an index value 218; and similarly the Steering Index ("STEERING -- IND") is where the Steering value ("STEERING") from the last program cycle is quantified into an index value by looking up the Steering Index table ("LU -- STEERING -- IND") 218.
From this point 220 on, with only two exceptions, program processing steps 6 through 10 as illustrated in FIGS. 9b, 9c, 9d, 9e, and 9f are the same as in the Shore-Tracking Mode. The first exception is that all the look-up tables in Creek-Tracking Mode are tailored to this mode and are therefore different from the look-up tables in the Shore-Tracking Mode. The second exception is that while Shore-Tracking Mode refers to SLOPE and SLOPE -- IND values, Creek-Tracking Mode does not refer to them.
Likewise, the programming logic of Depth-Tracking Mode is similar to that in Shore-Tracking Mode. In this mode, the microcontroller will maintain the boat on a certain contour of the bottom terrain. The program flow for the Depth-Tracking Mode as follows:
Step 1: Initiation and Set-Up
Step 2: Error Processing Step
Step 3: Steering Feedback Routine
Step 4: Steering Processing Step
Step 5: Large Turn Compensation Routine
Step 6: Drift Mode Routine
Step 7: U-Turn Routine
Step 8: Output Values Speed and Steering (steering correction) to each respective controllers
Step 9: Go to Step 2 if Mode is not Cancelled
Referring to FIG. 10a, when the user selects the depth-tracking mode 230, a number of initiation steps are taken and a number of variables are initialized 232. The port-down ("PD") and starboard-down ("SD") transducers are activated to find the distance from the bottom terrain on both sides 234. These distance values are used to determine the location of the shore ("BANK") 236 or 238. Furthermore, the desired depth range ("RANGE") is set to the distance value obtained from the Down transducer (DOWN) 240.
After initialization, a number of variables necessary for calculating the error index 242 and used in calculating the steering correction value ("STEERING") are obtained. First of all, the difference between the desired range (RANGE) and current depth reading (DOWN) defines the error ("ERROR") 244. Because the program is searching for a certain depth, ideally RANGE and DOWN should be about the same. The Position Error Index ("POS -- ERR -- IND") is where the value for ERROR is quantified into an index by using the Position Error Index Look-Up table ("LU -- POS -- ERR") 244; similarly the Steering Index ("STEERING -- IND") is where the Steering value ("STEERING") from the last program cycle is quantified into an index value by looking up the Steering Index table ("LU -- STEERING -- IND") 244; and the Change in Depth (DELTA -- DEPTH) is defined as DOWN subtracting DOWN -- LAST 244, DOWN -- LAST being the DOWN distance value from the last program cycle. This now ends the Error Processing Step, and the program flows to connector A 246.
Referring to FIG. 10b, connector A 246, this is the beginning of the Steering Feedback Routine of the above modes. This routine is the same as the Steering Feedback Routine with the only difference being an additional decision box 250 that is added. If the absolute value of DELTA -- DEPTH is greater than MAX -- DDEPTH 248 and if DELTA -- DEPTH is favorable, meaning the boat is heading toward the desired depth, reduction of MAX -- DDEPTH is necessary and the program flows to the Steering Processing step 258.
In this step, the steering correction ("STEERING") is calculated. First, the Error Index ("ERR -- IND") is determined from the Error Index Look-Up Table ("LU -- ERRIND") by quantifying POS -- ERR -- IND into another index that is affected by MAX -- DDEPTH. A larger MAX -- DDEPTH will result in a smaller ERR -- IND. Change In Depth Index (DDEPTH -- IND) is obtained from the Change In Depth Look Up Table ("LU -- DDEPTH -- IND") by quantifying DELTA -- DEPTH that is influenced by MAX -- DDEPTH. A larger MAX -- DDEPTH will result in a smaller DDEPTH -- IND. MAX -- DDEPTH has an inverse relationship with DDEPTH -- IND and it damps DDEPTH -- IND by to normalizing DELTA -- DEPTH in the sense that DELTA -- DEPTH is taken as a percentage of MAX -- DDEPTH. The Acceleration Index ("ACC -- IND") is calculated from the difference between the current Change In Depth Index (DDEPTH -- IND) and the previous Change In Depth Index ("DDEPTH -- IND -- LAST"). Finally, Steering direction and magnitude ("STEERING") is determined from a Steering Look-Up Table ("LU -- STEERING") with three inputs. Of the three variables, two of them, ERR -- IND and DDEPTH -- IND, have the same relationship as previously described in the shore-tracking mode. As with ACC -- IND, it has an inverse relationship with STEERING and it buffers large change in DDEPTH -- IND in order to prevent oscillation.
After calculating STEERING, the remaining steps 5 through 9 as illustrated in FIGS. 10c, 10d, and 10e are the same as previously described in the shore-tracking mode and the creek-tracking mode.
Although the present invention has been described above in terms of a specific embodiment, it is anticipated that alterations and modifications thereof will no doubt become apparent to those skilled in the art. It is therefore intended that the following claims be interpreted as covering all such alterations and modifications as fall within the true spirit and scope of the invention.
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A trolling motor system and method for controlling the trolling motor, including a microcontroller, a plurality of transducers, a steering motor, and an outboard motor. The user is allowed to input commands via a keypad and the selected mode of operation is displayed via an LCD screen. The microcontroller operates the transducer to transmit sonar signals and the return signals are received and processed accordingly. In the preferred embodiment, there are five transducers arranged in a manner such that the port (left side of the boat) and starboard (right side of the boat) sides as well as the bottom of the boat are scanned continuously.
The microcontroller processes the signals according to the user-selected mode, determines the steering degree and the motor speed, transmits these values to the Steering Motor And Position controller and the Power Drive And Motor controller. In the preferred embodiment there are three automatic modes of operation: creek-tracking mode, depth-tracking mode, and shore-tracking mode.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to printing devices and more particularly to a web infeed device for rotary printing devices.
[0002] U.S. Pat. No. 5,967,036 describes a web infeed device for rotary printing presses, which permits a web to be fed through the printing press. A flexible, finite infeed element for holding a lead edge of a web runs in a guide or track. Balls are inserted in openings of the infeed element at spaced-intervals, and travel within a cross-cut in the guide. Drive elements can drive the balls and thus move the infeed element through the printing press to feed the web. U.S. Pat. No. 5,967,036 is hereby incorporated by reference herein. It has been known for the tip of the infeed element described therein to jam in the guide, for example in curves or gaps.
[0003] U.S. Pat. No. 5,320,039 discloses a web engagement system for an off-reel printing press in which a guide piece is accommodated in a guide channel. The guide piece preferably is a flexible plastic section with a square cross-section. The front part is tapered and a rear part is split.
[0004] U.S. Pat. No. 4,987,830 discloses a paper feed device for rotary presses having a spindle shaped linear member. The linear member is made of synthetic resin or leather, with caps being made of a rather hard material.
[0005] The devices of the '039 and '830 are long flexible members that ran in guides and contact the guides over a large length. The friction generated by flexible members passing over a curved section is subject to what is known as the capstan effect, which causes frictional forces to increase exponentially as the flexible member wraps around the surface.
BRIEF SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a web infeed device with reduced friction and improved feeding properties.
[0007] The present invention provides a web infeed device for rotary printing presses comprising an infeed element having a flexible section and a pointed nose piece having concave side portions; a guide, the flexible infeed element being received in the guide; and driving elements for driving the infeed element along the guide.
[0008] The nose piece of the present invention with the concave side portions provides for excellent feeding while reducing friction with the guide.
[0009] The flexible section preferably includes a flat band-shaped metal piece. The band-shaped piece may include holes, and balls located in the holes.
[0010] The pointed nose piece preferably is made of rigid material, and preferably has a cut out at a rear end for receiving the band-shaped metal piece.
[0011] A rear section of the nose piece preferably is curved, to aid in rearward movement of the infeed element.
[0012] Preferably, the nose piece is symmetrical about a longitudinal plane, preferably a plane defined by the flexible section. Most preferably, the nose piece is fully symmetrical about a longitudinal axis.
[0013] The present invention also provides a web infeed device for rotary printing presses comprising an infeed element having a flexible band-shaped section and a rigid pointed nose piece connected to the flexible band section; a guide, the flexible infeed element being received in the guide; and driving elements for driving the infeed element along the guide.
[0014] By using a rigid pointed nose piece in conjunction with the flexible band section, excellent feeding with reduced friction can be provided.
[0015] The present invention also provides a web infeed device for rotary printing presses comprising an infeed element having a first flexible section, a second flexible section and a connecting piece having concave side portions connecting the first flexible section to the second flexible section; a guide, the flexible infeed element being received in the guide; and driving elements for driving the infeed element along the guide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Preferred embodiments of the present invention are described below by reference to the following drawings, in which:
[0017] [0017]FIG. 1 shows view of a guide according to the prior art;
[0018] [0018]FIG. 2 shows a cross-sectional view of the guide of FIG. 1;
[0019] [0019]FIG. 3 shows a top view of one embodiment of an infeed element of the present invention;
[0020] [0020]FIG. 4 shows a perspective view of the FIG. 3 embodiment;
[0021] [0021]FIG. 5 shows a side view of the FIG. 3 embodiment;
[0022] [0022]FIG. 6 shows the nose piece of the FIG. 3 embodiment;
[0023] [0023]FIGS. 7 and 8 show alternate embodiments of the nose piece of the infeed element; and
[0024] [0024]FIG. 9 shows the connecting piece of the present invention.
DETAILED DESCRIPTION
[0025] [0025]FIG. 1 shows a prior art guide 10 , similar to example to the guide shown in incorporated-by-reference U.S. Pat. No. 5,967,036. As shown in FIG. 2, guide 10 has a hexagonally-shaped guide area 12 with band-shaped section receiving areas 14 , 16 extending from the sides of area 12 .
[0026] [0026]FIG. 3 shows a top view of one embodiment of an infeed element 50 of the present invention. Infeed element 50 includes a flexible band-shaped section 30 , for example made of metal tape, and has holes through which balls 32 pass. Infeed element 50 also includes a nose piece 20 , preferably made of a rigid material. Nose piece 20 has a tapered, in other words pointed, front 22 , and a concave side portion 24 . The rear 26 may be a spherical lobe, which can permit backward movement of the nose piece 20 .
[0027] As shown in FIGS. 4 and 5 as well, a tapered front end of section 30 passes through a slit 29 in the rear 26 of nose piece 20 , and is fastened to nose piece 20 by a pin 28 . A driving element 40 is provided in a cut out in guide or track 10 . Driving element 40 has a hollow section through which the nose piece 20 and balls 32 may pass, and nips the edges of the section 30 against the guide 10 to move the flexible band-shaped section 30 and nose piece 20 in direction D. A connecting piece 60 may be provided to connect a second flexible band-shaped section 62 to section 30 . Connecting piece 60 with concave side potions also may pass through the hollow section of driving element 40 . A plurality of driving elements 40 are spaced along guide 10 .
[0028] [0028]FIG. 6 shows the nose piece in more detail, with a hole 21 being provided for pin 28 . Pin 28 and hole 21 may be threaded for example. Slit 29 in rear 26 may include a wider section 23 , which permits flexible band-shaped section to bend with respect to nose piece 20 when passing curves in guide 10 .
[0029] [0029]FIG. 7 shows an alternate embodiment of nose piece 20 . Nose piece 120 has a pointed front end 122 , concave side portions 124 , a pin hole 121 and a rear slit 129 .
[0030] [0030]FIG. 8 shows another alternate embodiment of nose piece 20 . Nose piece 220 has a pointed front end 222 , concave side portions 224 , a pin hole 221 and a rear slit 229 .
[0031] [0031]FIG. 9 shows the connecting element 60 with concave side portions 64 , 66 and pin holes 68 and 69 for fastening the two flexible sections.
[0032] “Pointed” as defined herein means any tapered section, and can include a spherical or bulbous section.
[0033] The concave side portions of the present permit the nose piece to negotiate curves without creating excess friction, and also reduce friction during normal travel of the nose piece.
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A web infeed device for rotary printing presses includes a pointed nose piece having concave side portions. The flexible infeed element is received in a guide, and driving elements are provided for driving the infeed element along the guide.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application s a continuation-in-part of U.S. patent application, Ser. No. 014,434, filed Feb. 13, 1987, now U.S. Pat. No. 4,762,496.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a medical tissue phantom for use in simulating surgical procedures, and more particularly to an ophthalmologic system, wherein a lens tissue phantom and/or a corneal tissue phantom are placed within a structure generally resembling a human eye, which is itself mounted in a simulated human head.
Description of the Prior Art
The human eye and the eyes of vertebrates in general, although distinguished by a variety of evolutionary modifications, share the same basic anatomical pattern. An anterior, transparent portion, the cornea, is the first ocular component traversed by incoming light, and, for those vertebrates living in air, provides the greatest source of refraction towards focusing the light on the sensory portion of the eye. Nearsightedness (myopia), farsightedness (hyperopia), and astigmatism are all visual disabilities caused primarily by corneal curvature problems Inward from the cornea lies the iris, a spongy, circular diaphragm of loose, pigmented connective tissue separating the anterior and posterior chambers. An opening, the pupil, is formed in the center of the iris and enables passage of light energy therethrough. The anterior and posterior chambers are continuous with one another at the pupil, and are filled with a fluid, the aqueous humor. Intraocular pressure created by this fluid normally will maintain the eye in a distended state. A pair of muscles, the dilator and sphincter pupillae, located behind the iris, control the diameter of the pupil and thus the amount of light passing the iris.
Interiorly from the iris, and supported by thin suspensory fibers, termed ciliary zonule, lies the crystalline lens. Surrounded by an elastic capsule, which is attached to the ciliary zonule, the lens is completely cellular, and by altering shape, functions to accommodate or provide ocular adjustments for the sharp focusing of objects viewed at different distances. After passing through the lens, light energy traverses a semisolid, gelatinous vitreous body, and strikes the retina, the anterior, light-sensitive nerve membrane of the eye.
Any clouding or opacity of the eye lens is termed a cataract. The degree of cloudiness can vary markedly in cataractous lenses, and may be the result of many causes, although the majority are associated with aging, (termed senile cataracts). The essential biochemical change in an affected lens is the sclerosis of its protein, with the primary symptom one of progressively blurred vision. Cataracts are presently the leading cause of adult blindness.
Once a lens is sufficiently clouded so as to impair vision, the only treatment for cataracts is surgical removal. As is discussed in U.S. Pat. No. 4,078,564 to Spina, et al., the Egyptians are believed to be the ones to first surgically treat cataract patients by thrusting a rose thorn through the cornea and pushing the cataractous lens into the vitreous of the eye. In the 1880s, another technique was brought to bear on those senile cataracts that had advanced from the dense, hard phase to the "ripe" or soft and runny phase. Such a progression would frequently occur, over time, and when "ripe", incisions through the cornea and the anterior capsule, would permit the soft material to be flushed out. A major drawback of this procedure was the requirement that the patient wait until the cataract became "ripe", a process that might take 10-20 years, with the patient blind during this entire waiting period.
Beginning in the 1930s, a surgical technique known as Intracapsular Cataract Extraction (ICCE) was introduced, wherein the lens and its surrounding capsule are entirely removed from the eye through a large, 12-to-14 mm incision in the eye. Removal of the posterior portion of the lens capsule under the ICCE technique lays bear the vitreous, which, together with the large incision, may necessitate an extended period of post-surgical care. Additionally, with the posterior lens capsule removed, the posterior chamber implant lenses cannot be used. A subsequently developed surgical technique, Extracapsular Cataract Extraction (ECCE) also requires a large incision in the eye, but results in the removal of only the lens and its anterior covering; the posterior lens covering remains in the eye, protecting the vitreous.
The ICCE and ECCE techniques both require the use of large incisions made in the eye to permit the removal of the lens nucleus or the lens nucleus, the cortex, and the lens capsule, en masse. Beginning in 1967, a new surgical technique was described wherein the lens was fragmented into particles or emulsified by an ultrasonically vibrated tip, while still within the eye. The lens, now emulsified, would thereafter be aspirated from the anterior chamber through an incision in the cornea of much smaller chord length. This new technique, termed "Phacoemulsification" (KPE) by its originator, C. Kelman, provides insertion of the ultrasonically-vibrated tip into the eye through an incision of approximately 3 mm, with the vibrating tip thereafter placed against the cataract. The high frequency vibrations are subsequently used to emulsify the cataract.
As initially taught, the KPE procedure required the prolapse or transfer of the cataract's nucleus into the anterior chamber prior to phacoemulsification. Anterior chamber emulsification is not necessarily safer for the eye. Corneal clarity is maintained in substantial part by an endothelial cell layer that pumps water against an osmotic gradient. This cell layer is apparently unable to repair/replace damaged cells by cell division, and thus when cells are damaged, a burden is placed on the remaining healthy cells to expand and migrate to "fill the void". During the course of cataract surgery, by any method, a proportion of endothelial cells is lost/damaged, primarily through direct or indirect operative trauma. Endothelial cell counts have been made, both pre- and post-operatively, and reported cell losses for anterior chamber phacoemulsification is about 34%, while the ICCE and ECCE techniques reduce this cellular loss to approximately 15%.
The large increase in endothelial cell loss, combined with the challenging maneuvers required to obtain nuclear prolapse, has led to the development of posterior chamber phacoemulsification. In this procedure, after removal of the anterior lens capsule, the central portion of the lens is emulsified, in situ, forming a saucerized nucleus. In the more common bimanual technique, a second instrument is inserted into the anterior chamber and is used to manipulate the lens in combination with the phaco tip until a superior pole of the nucleus prolapses anteriorly into the iris plane, whereupon the prolapsed portion is emulsified. The second instrument then rotates successive portions of the nuclear periphery to the phaco tip where emulsification occurs. Eventually, the residual nucleus, now much reduced in diameter, prolapses spontaneously into the anterior chamber, and the phacoemulsification can be completed. Thereafter, the phaco tip is removed and replaced by an irrigation/aspiration tip for clean up and removal of any remaining cortex and any debris on the posterior lens capsule. If indicated, a lens implant insertion can then be initiated. Under the posterior chamber emulsification technique, endothelial cell loss improves from the anterior chamber value of 34% to a 9% loss rate.
Phacoemulsification is a procedure that is very demanding of the surgeon in terms of both surgical skill and intraoperative vigilance. A surgeon skilled in the ICCE and ECCE techniques is not automatically skilled in phaco surgery. The margin for error in KPE is small, for example, extending the initial incision 1 mm too long makes it difficult to maintain the anterior chamber in KPE, but would be irrelevant in ICCE or ECCE. A phaco surgeon must receive instructions regarding the technique and must be able to repeatedly practice the motor coordination skills required to manipulate and emulsify a lens through incisions of small chord length using both hands with equal dexterity. The advent of new intraocular lens designs, such as the "foldable" and "injectable" lenses, has further enhanced the value of KPE, since, for the first time both the cataract lens removal and the new lens replacement can be accomplished through the smaller incision that KPE affords.
The phacoemulsification technique by its very nature complicates the lens phantom-selection process. Not only is it necessary to duplicate the general ocular structure to enable practice in a simulated, controlled environment, it is also necessary to duplicate the "texture" of the cataract If the lens phantom is unable to duplicate the ability of a cataractous lens to be emulsified and the reactions of a cataractous lens to mechanical displacement within the lens capsule as exists in a typical patient, the value of the phantom for providing phacoemulsification practice is severely reduced.
Such shortcomings are readily illustrated by the presently used animal eyes, (e.g., geese, rabbits, cows and pigs). The overall eye structure is only generally similar to a human eye. These animals, at the time of slaughter, or, when used while still alive, do not have developed cataracts. The soft lenses cannot be used to adequately demonstrate the emulsification and rotation techniques required by posterior chamber KPE. In addition, anatomical problems that are aggravated by tissue storage include corneas that are cloudy, tissue that is too tough, and chambers that are difficult to keep from collapsing.
The texture/density of some cataractous lenses resembles that of carrots, and some surgeons have resorted to the implantation of carrot disks in a silicone practice eye (Sheets Design), presently sold by the McGhan Medical Corporation Division of 3M Company. The McGhan eye was designed to enable practice of the techniques required for replacement lens implantation, and is wholly unsuited for the practice of KPE procedures. The McGhan eye has no lens and, equally as important, has no lens capsule - nor a provision for one. Additionally, the carrot discs clog the Phaco aspiration port and tubing because they are not water soluble.
Encouraged by the continuing success of corneal implants, beginning in the late 1970's surgeons began attempting to treat a nearsighted eye by altering the curvature of the outer corneal surface, and thereby lessening the amount of refractive light bending. Termed refractive surgery, these early efforts have developed into two separate forms of surgery, radial keratotomy wherein a selected number of radial incisions are made in the cornea, and keratomileusis, which involves removing the top layer of the cornea, reshaping the removed portion, and suturing the reshaped corneal fragment back into place. Both techniques are extremely detailed, requiring the utmost skill on the part of the surgeon, both with respect to an understanding of the entire technique(s) and with respect to the motor skills required for their implementation.
SUMMARY OF THE INVENTION
The present invention has, as an underlying objective, the improvement in the known ophthalmic phantoms by utilizing a simulated lens that duplicates the texture of a cataractous lens and its ability to be mechanically rotated within a simulated lens capsule. Additionally, this invention enables the use of the actual surgical equipment to aspirate the "emulsified" phantom lens without the danger of clogging or otherwise ruining the machine. Also, since refractive procedures are becoming a more common ophthalmic treatment, the present invention, through simulated corneas, enables the surgeon to gain practice in these techniques as well.
This goal is inventably achieved by encapsulating a structured, water-sensitive composition within an outer, vinyl or vinylidene chloride copolmyer capsular wall. The water solubility enables dissolution by phacoemulsification. Anchoring the outer capsular bag within an inner eye structure retains the inner cataract phantom in a manner permitting the mechanical manipulations required to simulate KPE techniques. The ophthalmologic system is completed by providing an appropriately formed, simulated eye, including a cornealike, outer structure, to receive the encapsulated cataract phantom and a head casting or face mask in which the eye is supported and on which the surgeon can obtain the hand positioning required for the delicate lens and corneal operations.
The surrounding base for the simulated eye consists of an outer orb, with an inner sealed posterior chamber, filled with a gel-like substance, used to simulate the vitreous body. A central opening is formed in the upper portion of the orb, with a shelf provided in the opening to receive a peripheral edge of the encapsulated lens phantom. The simulated cornea and iris are joined together to form the outer closure and are received within the orb opening in a manner that places the peripheral edge of the lens capsule between the cornea/iris cap and the orb shelf. In this manner, the lens capsule is anchored, with the inner lens restrained only as it is generally held by and within the outer capsule.
Various other objects, advantages, and features of the present invention will become readily apparently from the ensuing detailed description, and the novel features will be particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view, with portions in phantom, showing the simulated eye structure in accordance with the present invention;
FIG. 2 is an exploded perspective view showing the simulated cornea and iris cap in accordance with the present invention;
FIG. 3 is an exploded, partial side elevational view, in section, showing a disassembled simulated eye, including a cataract phantom, in accordance with the present invention;
FIG. 4 is a view similar to FIG. 3 showing the simulated eye as assembled in accordance with the present invention;
FIG. 5 is a perspective view showing the simulated eye structure in accordance with the present invention as placed within a facial mask;
FIG. 6 is a partial side elevational view, in section, taken substantially along the lines 6--6 of FIG. 5, showing the simulated eye-receiving socket in the facial mask, in accordance with the present invention;
FIG. 7 is a partial side elevational view, with portions in section and portions broken away, showing a two-piece facial casting in accordance with the present invention;
FIG. 8 is an enlarged elevational view, partially in section taken along the lines 8--8 of FIG. 7, showing a possible mechanism for adjustably attaching the two-piece facial casting together and the impact of such adjustable attachment on the extent to which the simulated eye projects from the eye-receiving socket;
FIG. 9 is a partial elevational view, similar to FIG. 8, showing an alternative facial casting position and its effect on the extent of projection by the simulated eye;
FIG. 10 is a partial elevational view, similar to FIGS. 8 and 9, showing a simulated eye received by the eye-receiving socket in a canted manner;
FIG. 11 is a perspective view showing a chin support wedge in accordance with the present invention; and
FIG. 12 is a perspective view, partially in phantom, the facial casting as placed upon the chin support wedge in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a phantom designed to partially simulate many of the structural characteristics of a cataractous eye. In an effort to avoid unnecessary confusion in describing the structure of this phantom, the commonly used anatomical terms will be referred to in describing the individual elements making up the ocular phantom.
To recreate/simulate the various structures and cavities of a human eye, a number of elements are fitted together within a surrounding outer orb 5. Formed in a flattened spheroid shape, the orb 5 is provided with an aperture 8 at a flattened portion thereof, with the aperture 8 communicating between the exterior of the orb 5 and a chamber 11 formed within the orb 5. The aperture 8 has a shelf 14 formed therein, of a size that cooperatively receives a posterior membrane 17, thereby sealing the chamber 11. The central portion of the posterior membrane 17 is concave towards the chamber 11, and is suitable towards receiving a double convex-shaped encapsulated lens 21. The ocular simulation is completed by an outer corneal cap 23.
As shown by FIG. 2, the corneal cap 23 in fact consists of two separate membranes, an outer cornea 26 and an iris 29 that is receivable within an inner surface of the cornea 26. As is the case with a human iris, a central opening or pupil 33 is formed therein, and in the case of the present invention, is designed to simulate a dilated pupil, which is the opening through which the cataract removal technique is performed. To assist the surgeon in this regard, every effort is made to completely dilate the pupil. However, responsiveness to the dilating drugs can vary, and to enable surgeons to practice the techniques required for such an eventuality, the iris 29 may be provided with pupil openings of varying sizes, such as 5, 71/2, and 91/2 mm.
For purposes of simulation, it is preferred that the cornea 26 be flexible and moisture tight. An appropriate material for the cornea 26 is a molded, clear and transparent silicone, 40-50 shore D. Likewise, a preferred composition for the iris portion, resulting in a less rigid construction, is a high elongation, molded silicone that is appropriately pigmented. Although the present lens phantom system is designed to teach posterior chamber KPE, it is also possible to practice the techniques of anterior chamber KPE, in which case the iris 29 can be constructed out of materials more closely simulating the mechanical properties of a human iris. Likewise, when this ocular phantom system is used to simulate refractive procedures, such as astigmatic keratotomy and radial keratotomy, the cornea can be manufactured out of a material(s) that more closely duplicates the surgical responses of a human cornea. Such material includes, for example, a material that is used in the fabrication of contact lenses and has the fabrication of contact lenses and has the following constituents:
______________________________________Reagent Parts by Weight______________________________________2-hydroxyethy-methacrylate 78%N--vinyl-2-pyrrolidone 20%ethylene glycol dimethacrylate 1%2,2-azobis isobutyronitrile (AIBN) 1/2%______________________________________
For ease of fabrication, the iris 29 and the cornea 26 also may be bonded together subsequent to their original manufacture, and thereafter be utilized in conjunction with the ocular simulation as the unitary corneal cap 23.
As shown best in FIG. 3, each of the individual ocular elements is arranged to receive and be received in a compact, stacked manner. A posterior membrane ledge 37 is formed about the periphery of the posterior membrane 17 and is received by the shelf 14 within the aperture 8. The peripheral edge of the encapsulated lens 21 is likewise flattened and mates with the flattened peripheral edge of the posterior membrane 17 when both are received within the aperture 8. The simulated anterior and posterior chambers are completed by the corneal cap 23, which is likewise received within the aperture 8. A flattened lower edge 41 of the corneal cap 23 is received and supported by the orb shelf 14, with an inner corneal wall 43 of sufficient diameter to receive both the encapsulated lens 21 and the posterior membrane 17 when the lower corneal edge 41 abuts the orb shelf 14. In this manner, the encapsulated lens 21 is securely retained about its peripheral edge between the corneal cap 23 and the posterior membrane 17, which is itself attached to the shelf 14 of the orb 5 (also see FIG. 4).
The chamber 11 corresponds generally to the vitreous in a human eye. The simulation under the present invention is further obtained and the practicing of vitrectomy techniques made possible by providing a vitreous body 47 within the chamber 11. Any type of viscous fluid can function as the vitreous body 47, and a silicone gel is certainly appropriate. Whichever material is selected, the vitreous body 47 is maintained in place within the chamber 11 by the posterior membrane 17, which, in a preferred embodiment, is adhesively attached to the shelf 14. To enable the surgeon to monitor progress utilizing the red reflex, it is preferred to color either the vitreous body 47 or the back wall of the chamber 11, with red the appropriate color in either circumstance.
As is best shown in FIG. 3, the encapsulated lens 21 consists of a clear, outer capsular wall 51, such as a vinyl film (e.g., saran) or vinylidene chloride copolymer film, and an inner cataract phantom 53, composed of a structured, water-soluble composition, designed to be similar to that found in the natural occurring cataract. In order to retain the same emulsification characteristics under the phaco instrument, a permanent hydrogel material is provided utilizing a cross-linked gelatin. This material is "hydrate" or provided with the proper water sensitivity by the incorporation of a water-soluble polymer, such as sodium alginate, polyethylene glycol or a guar gum--e.g., Gelactasol 211 manufactured by the Henkel Corporation, Minneapolis, Minn.
The term "cataract" merely refers to a lens suffering some degree of opacity. The cataractous lens can vary from being soft to extremely hard as maturity increases. The soft and runny phase exists typically in only very advanced stages (hyper-mature), and such patients are exceedingly rare. Eye surgeons must normally contend with cataracts varying from very hard to merely soft, and the techniques required under phacoemulsification will understandably differ according to the "hardness" of the cataract. A soft cataract is much easier to emulsify, but can be more difficult to manipulate. On the other hand, a cataract can become sufficiently hard that it tends to fragment rather than to emulsify. In such an event, the damage to the endothelial cornea cells of the eye suffered by rebounding pieces of lens, in addition to the prolonged intraocular phaco-time, was traditionally sufficient to warrant converting mid-operation to a different technique for cataract removal, i.e., ECCE. The advent of viscoelastic coating materials for the inner surface of the cornea has lessened the necessity for converting to a non-phacoemulsification method. These materials are sold under various trade names such as "Healon,""Viscoat," and "Amvisc," and may be used with the present ocular phantom system to enable the surgeon to practice the technique of performing Phaco in the presence of these substances, and PKE on a hard lens using such coating materials.
Under the present invention, the hardness of the phantom cataract is controlled by the addition of fillers such as 50 to 200 micron-sized glass beads or 50 to 200 micron organic fillers having solubilities of less than 5% in water, such as tetramethyl-1,3-cyclobutanediol. Alternatively, phantom "soft" cataracts can be prepared without gelatin using a calcium chloride, cross-linked sodium alginate. It is important that the phantom cataracts resemble human cataracts both in emulsification characteristics, (or "disintegration characteristics" for whichever removal technology is employed), and in translucency to ensure that the simulation will be as close to an actual removal procedure as is possible.
The following examples illustrate some preferred embodiments of the present invention:
Three stock solutions (A, B, and C) of gelatin in water were prepared in advance and heated to 40° C. to melt.
______________________________________ STOCK SOLUTIONS, (% by weight)Reagent A B C______________________________________Gelatin 26 26 10Hyamine - 1622 0.2 0.2 0.2Sodium Benzoate 0.2 0.2 0.2Napthol Green B -- 0.038 --Red CAS -- 0.048 --Methyl Orange 0.005 -- 0.004______________________________________
EXAMPLE 1
______________________________________SOFT CATARACTReagent Parts by Weight______________________________________Gelatin stock solution "A" 1Sodium alginate (5% aqueous solution) 2Water 5Formalin 0.2______________________________________
After cooling, the resulting material provided an excellent simulation of a soft cataract.
EXAMPLE 2
______________________________________MEDIUM-HARD CATARACTReagent Parts by Weight______________________________________Gelatin stock solution "A" 1Sodium alginate (5% aqueous solution) 5Tetramethyl-1,3-cyclobutanediol 2Formalin 0.2______________________________________
This material, after cooling, provided a simulation of a medium-hard cataract.
EXAMPLE 3
______________________________________HARD CATARACTReagent Parts by Weight______________________________________Gelatin stock solution "A" 1Sodium alginate (5% aqueous solution) 3Tetramethyl-1,3-cyclobutanediol 5Formalin 0.2______________________________________
After cooling, this material provided an excellent simulation of a hard cataract.
EXAMPLE 4
______________________________________CLEAR, SOFT CATARACTRegeant Parts by Weight______________________________________Gelatin stock solution "C" 2Polyethylene glycol - 200 337% Formaldehyde solution 0.4______________________________________
After cooling, this material provided an excellent, clear simulation of a soft cataract.
EXAMPLE 5
______________________________________TRANSPARENT, MEDIUM-HARD CATARACTRegeant Parts by Weight______________________________________Gelatin stock solution "B" 2Polyethylene glycol - 200 2.5Tetramethyl-1,3-cyclobutanediol 137% Formaldehyde solution 0.4______________________________________
Upon cooling, this material provided a transparent simulation of a medium-hard cataract.
EXAMPLE 6
______________________________________TRANSLUCENT, HARD CATARACTRegeant Parts by Weight______________________________________Gelatin stock solution "A" 2Polyethylene glycol - 200 2.5Tetramethyl-1,3-cyclobutanediol 2.537% Formaldehyde solution 0.4______________________________________
When cool, this material provided an excellent simulation of a translucent, hard cataract.
Regardless of the material used to form the cataract phantom 53, once placed in the assembled form for simulating the human eye, as shown in cross-section in FIG. 4, this simulated ocular system is ready for use by one desiring to practice all refractive procedures, the phacoemulsification techniques, and any other technique that makes use of a cornea, or a cataract or lens capsule, such as the small incision implants. The corneal material also enables the surgeon to practice suture placement, either with respect to refractive procedures or for lens replacement.
In a preferred embodiment, a completed ocular system 55 is placed within a casting 57 that is generally designed to resemble a human head. As is shown in FIG. 6, a socket 61 is formed within the casting 57, and receives the simulated ocular system 55. In an embodiment shown in FIG. 7, a two-piece casting is utilized to enable the variable positioning of the ocular system 55. One or preferably both pieces are formed out of polyurethane, but of course could be manufactured out of a wide variety of materials, and it is not essential that both pieces are formed out of the same material. An inner casting 62 is received within an outer mask 63, with fastening means such as one or more pins 64 (only one shown) used to maintain the inner casting 62 and the outer mask 63 in a nested relationship.
As is best shown by FIG. 8, the inner casting 62 and the outer mask 63 are substantially, but not completely, in a nested relationship prior to utilization of the fastening pins 64. In the presently preferred embodiment, when first placed within the outer mask 63, the inner casting 62 is not fully received by the outer mask 63, to the extent that an aperture 66 formed in the inner casting 62 is slightly offset with respect to a pin-receiving opening 67 formed in the outer mask 63.
This slight offset serves as an adjustment mechanism for controlling the extent to which the optical system 55 projects or hyperextends from the surrounding surface of the outer mask 63. In this manner, different internal ocular pressures can be simulated by the present system. As the pin 64 is inserted into the outer mask 63 and then the aperture 66, the inner casting 62 is forced further into a nested relationship with the outer mask 63. Where the pin 64 is provided with threads (as is shown in FIG. 8), upon tightening the pin 64, the slight angle of the aperture 65 causes the inner casting 62 to move further into the outer mask 63. The net result of this relative forward movement is a pressing of the ocular system 55 against a peripheral restraining seat 69 formed in the outer mask 63. This pressure causes a bulging of the ocular system 55, as measured by the dimensional changes denoted by the distances A and B in FIGS. 8 and 9, respectively.
The angular position of the ocular system 55 with respect to the outer mask 63 may be preset, or a rotating insert 70 (FIG. 7) may be provided as part of the inner casting 62. In such circumstances, the ocular system 55 may be placed in selectively rotated positions with respect to the adjacent non-rotating portions of the inner casting 62 and the outer mask 63. FIG. 1 illustrates an alternative to the rotating insert 70, wherein the ocular system 55 is placed within casting 57 in a canted position, shown as angle in FIG. 10. In either case, the angular positioning of the ocular system 55 can be varied, which resembles the variations possible during actual operations to assist the surgeon in performing many of the removal techniques.
Whether in regard to the phacoemulsification techniques, practicing suture placement(s), or in perfecting the skills required for refractive surgery, one of the more important benefits provided by the present invention relates to the realistic spatial relationship provided by the ocular system 55 within the casting 57. In such delicate surgery, hand positioning is of utmost importance, and the ability to perform the necessary techniques on tissue phantoms positioned in a proper spatial relationship as compared to their normal environment in vivos, is a significant achievement.
The head of a patient is not angularly fixed with respect to body, and it is sometimes desirable to perform one or more of the foregoing techniques at varying head angles. Variations in chin positioning are made possible through the use of a chin wedge 71. As is shown in FIG. 11, the chin wedge 71 is generally block-like, with a planar receiving surface 74 recessed from and partially surrounded by an outer surface 75. The receiving surface 74, being recessed, is defined by and defines a retaining wall 77 of a shape corresponding to a portion of the circumference of the outer mask 63 adjacent the simulated chin. The outer mask 63 may this be received by the receiving surface 74 and held in place by the retaining wall 77. Such a complete construction is illustrated in FIG. 12. The purpose of the chin wedge 71 is to vary the tilt angle of the simulated head. This is accomplished by placing the outer surface 75, (and thus the recessed receiving surface 74), in a plane that forms an angle φ with respect to the plane containing a base surface 79 of the chin wedge 71. The simulated head, (the outer mask 63 and the inner casing 62), is thus received by the receiving surface 74, which is displaced by the angle φ from the supporting surface for the base surface 79 and the remainder of the simulated head. In this manner, the tilt angle of the simulated head has been altered in preparation for the practicing of one or more of the foregoing techniques. The angle φ preferably lies between 15°-35°, but other angles are acceptable.
One of the removal techniques is schematically demonstrated in FIG. 5. A surgeon's hand 86 is resting upon the casting 57 in a manner permitting the manipulation of an emulsification tool 88 according to a particular cataract removal technique. The emulsification tool 88 can be an ultrasonic tip, but, of course, the present invention is not limited to the precise mechanism of lens emulsification or disintegration, and any other technology resulting in lens or corneal destruction or modification would be appropriate, e.g., lasers. The preferred embodiment also provides a pre-formed incision in the cornea 26 to allow for the proper tension in the cornea, and to limit the opening to a specific size, 3 mm is traditional for KPE, but other opening dimensions are possible depending upon the application. For example, larger pre-formed incisions are provided to enable the simulation of a lens transplant surgical procedure. Whatever the incision length, the posterior chamber phacoemulsification technique may then be performed through the pupil 33 in the iris 29. The outer capsular wall 51 (the anterior lens membrane) is removed and the cataract phantom 53 subsequently emulsified and removed through aspiration.
While we have disclosed exemplary structures to illustrate the principles of the present invention, it should be understood that we wish to embody within the scope of the patent warranted hereon, all such modifications as reasonably and properly come within the scope of our contribution to the art.
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A simulated human ocular system for practicing the surgical techniques required for the removal of cataractous lenses utilizing posterior chamber lens emulsification and, optionally, the techniques required from small incision implantation and refractive surgery is provided. A human eye is generally imitated by an outer orb having three inner, connected chambers separated by membranes that correspond to the cornea, the iris, and the posterior chamber membrane. A lens phantom is releasably attached to the orb within the chamber located between the iris and the posterior chamber membrane. The lens phantom consists of a structured, water-sensitive composition, such as a cross-linked gelatin to which a water soluble polymer has been added, and is thereafter encapsulated within a transparent vinyl or vinylidene chloride copolymer film. Placement of the ocular system in a structure that duplicates the outside features of a human head, with provisions for varying the rotation and degree of ocular projection, completes this ocular model.
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The present application claims benefit of U.S. Provisional Application Ser. No. 60/869,488, filed Dec. 11, 2006, which is hereby incorporated by reference for all purposes.
FIELD OF THE INVENTION
The present invention is directed to compositions comprising substantially pure fluorescein, processes for preparing substantially pure fluorescein, substantially pure fluorescein prepared by such processes, analytical methods for determining the purity of fluorescein, and a pharmaceutical compositions for use in angiography.
BACKGROUND OF THE INVENTION
Fluorescein is an orange-red compound, C 20 H 12 O 5 , that exhibits intense fluorescence in alkaline solution and is used in applications such as medicine for diagnostic purposes, in oceanography as a tracer, and as a textile dye.
Fluorescein was first synthesized by German chemist Adolf Von Baeyer in 1871, from the petroleum derivatives resorcinol (1,3-dihydroxybenzene) and phthalic anhydride. Paul Erlich, a German bacteriologist, employed the fluorescent dye (as sodium salt fluorescein), then known as “uranin”, to track the pathway of secretion of aqueous humor in the eye. This is said to be the first instance of fluorescent dye use in vivo to study physiology.
Fluorescein angiography is an important diagnostic tool that permits study of the condition of the blood vessels of the back of the eye. These vessels are a factor in many diseases that involve the retina. Angiography is performed by injecting fluorescein into a vein in the subject's arm. Within a short time (i.e., typically from a few to several seconds), the dye travels to the vessels in the back of the eye, and a camera with special filters is employed to image the dye as it circulates in the ocular blood vessels. Through examination of the images so produced, an assessment can be made about any circulation problems, for example, vessel leakage, swelling, abnormal or new vessels, and so on.
Fluorescein absorbs blue light, with peak absorption and excitation occurring at wavelengths between 465-490 nm. Fluorescence occurs at the yellow-green wavelengths of 520-530 nm. Although commonly referred to as fluorescein, the dye used in angiography is fluorescein sodium, the soluble disodium salt of fluorescein.
The normal adult dosage of fluorescein is 500 mg injected intravenously. It is typically packaged in doses of 5 mL of a 10% solution or 2 mL of a 25% solution. Upon entering the circulatory system, approximately 80% of the dye molecules bind to serum protein. The remaining unbound or free fluorescein molecules fluoresce when excited with light of the appropriate wavelength. The dye is metabolized by the liver to form fluorescein monoglucuronide, and is ultimately eliminated through the urine within 24 to 36 hours subsequent to administration.
It has been reported that the purity of fluorescein in fluorescein formulations may be correlated to side effects and tolerance to injection. (“Effective differences in the formulation of intravenous fluorescein and related side effects” by Yannuzi et al. in Am. J. Ophthalmol. 1974, 78 (2) pages 217-221). The elimination of all or substantially all impurities from fluorescein compositions utilized for angiography is therefore a primary objective of the present invention.
The following publications may be referred to for additional information regarding fluorescein compositions and processes for preparing and purifying fluorescein.
German Patent No. 136498 (Friedrich et al.) entitled “Process for Preparing Highly Purified Fluorescein for Injection Purposes” describes a process for preparing fluorescein using pyridine.
U.S. Patent Application Publication No. US2006/0106234A1 (Tran-Guyon et al.), entitled “High Purity Phthalein Derivatives and Method for Preparing Same”, describes a process for preparing fluorescein using an anhydrous solvent.
The following patents or publications may also be consulted for further background: U.S. Pat. No. 5,637,733 (Sujeeth), entitled “Synthesis of Fluorescein Compounds with Excess Resorcinol as a Solvent” and U.S. Pat. No. 1,965,842 (Kranz) entitled “Production of Hydroxybenzene-Phthaleins”.
Highly purified fluorescein is necessary for the preparation of solutions for injection purposes. The purified fluorescein used should ideally be: (i) free from impurities, which may be toxic and/or lack fluorescence; (ii) low in salt, which can lead to an unacceptably high osmolality or hypertonicity of the injectable fluorescein product; and (iii) low in color. Certain impurities are strongly colored. Absence of color at particular frequencies may therefore indicate the absence of such impurities. The color profile of fluorescein compositions is therefore considered a significant quality attribute and a visual marker of purity.
A method is needed to identify and quantify very low levels of impurities that may be present in fluorescein compositions. Such a method should be able to separate, identify, and quantify those impurities which may be present.
Thus, there is a need for a fluorescein composition that is highly pure, low in color, low in sodium chloride content and a process to produce such fluorescein that does not require the use of pyridine or other non-aqueous (and potentially noxious) solvent, as well as a method for determining the purity of such fluorescein. The present invention is directed to satisfying this need.
SUMMARY OF THE INVENTION
The present invention is directed to compositions comprising substantially pure fluorescein, to new and improved processes for the preparation of purified fluorescein, and to compositions of fluorescein produced via these processes. The present invention is also directed to a pharmaceutical composition for use in angiography comprising substantially pure fluorescein, and to a method of determining the purity of a fluorescein composition. The highly purified fluorescein produced by the method of the invention has a lower level of related-substance impurities than prior fluorescein compositions. The fluorescein produced by these new processes is also lower in color (at 590 nm) than other known compositions, providing a plainly visible maker for purity. The fluorescein of the present invention is also lower in sodium chloride content and therefore more easily formulated for pharmaceutical use than other known compositions. The processes of the invention improve on other known processes by eliminating the use of pyridine in the purification process, by not requiring the use of anhydrous solvent, by reducing the amount of acetic anhydride required to acetylate the crude fluorescein, and by improving the yield of highly purified fluorescein. The present invention also advances the state of the art by providing a reliable method for separating and quantifying related-substance impurities in fluorescein compositions, and for therefore determining the purity of fluorescein compositions.
The present invention may be embodied in various applications, including (without limitation) those summarized below:
One embodiment of the invention is directed to a composition comprising substantially pure fluorescein; more particularly, fluorescein that is substantially free of pyridine.
Another embodiment of the invention is directed to substantially pure fluorescein that does not contain any related-substance impurity at a concentration of greater than about 0.1% by weight; more preferably, 0.01% by weight.
Another embodiment of the invention is directed to substantially pure fluorescein having a color number of from about 0.015 to about 0.050 AUC.
Another embodiment of the invention is directed to substantially pure fluorescein having a residual chloride content of less than about 0.25% by weight.
Another embodiment of the invention is directed to substantially pure fluorescein where the total amount of substance-related impurities is less than about 0.6% by weight; preferably, less than 0.06% by weight.
Another embodiment of the present invention is directed to a process for preparing substantially pure fluorescein. The process comprises hydrolyzing diacetylfluorescein to form fluorescein, treating the fluorescein with charcoal, filtering, adding ethanol to the filtrate, adjusting the pH using an acidic solution to form a precipitate, filtering, and washing. In one aspect of this embodiment, the pH level is adjusted from about 1.0 to about 2.5. In other aspects, a cooling temperature is maintained of from about 20° C. to about 25° C. while adjusting the pH level, and the pH level is adjusted during a period of about 2 to 4 hours. The invention is also directed to substantially pure fluorescein compositions produced by such processes.
Another embodiment of the invention provides an HPLC method for quantifying the levels of fluorescein related-substance impurities. The method comprises obtaining a high-pressure liquid chromatogram of the composition; identifying peaks in the chromatogram corresponding to related-substance impurities and taking area measurements of the peaks to determine a relative concentration thereof. In one aspect of this embodiment, the peaks have relative HPLC retention times of about 0.75, 1.19, 1.23, 1.68 and 1.71. Another embodiment provides an HPLC/MS method for identifying related-substance impurities in fluorescein.
A preferred embodiment of the invention is directed to a pharmaceutical composition for use in angiography comprising substantially pure fluorescein; more particularly, a composition wherein the fluorescein is substantially free of pyridine.
Another preferred embodiment of the invention is directed to a pharmaceutical composition for use in angiography comprising substantially pure fluorescein wherein the composition does not contain any substance-related impurity at a concentration of greater than about 0.1% by weight; more preferably, 0.01% by weight.
Another preferred embodiment of the invention is directed to a pharmaceutical composition for use in angiography comprising substantially pure fluorescein wherein the total amount of related-substance impurities present in the composition is less than about 0.6% by weight; more preferably, less than about 0.06% by weight.
Another preferred embodiment of the invention is directed to a pharmaceutical composition for use in angiography comprising substantially pure fluorescein wherein the fluorescein has a color number of from about 0.015 to about 0.050 AUC.
Another preferred embodiment of the invention is directed to a pharmaceutical composition of fluorescein for use in angiography wherein the composition has a residual chloride amount of less than about 0.25% by weight.
The present invention is more fully discussed with the aid of the following figures and detailed description.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schema of an experimental design for fluorescein washing experiments.
FIG. 2 is a schema of an experimental design for fluorescein pH/precipitation experiments.
FIG. 3 is a UV/VIS Spectrum showing the color intensity of fluorescein drug substance as described in Example 3.
FIG. 4 is an HPLC chromatogram of diluent blank as described in Example 5.
FIG. 5 is an HPLC chromatogram of 1% USP Fluorescein Reference Standard as described in Example 5.
FIG. 6 is an HPLC chromatogram of Supplier A Fluorescein Raw Material as described in Example 5.
FIG. 7 is an HPLC chromatogram of Fluorescein Raw Material Spiked with 0.8% Resorcinol as described in Example 5.
FIG. 8 is a diagram of the Structure of Fluorescein and Proposed Structures of Related-Substance Impurities, as described in Examples 5 and 6.
FIG. 9 is a representative HPLC Chromatogram of fluorescein from the LC/MS system.
FIG. 10 is: (a) a chromatogram of fluorescein with UV detection; and (b) a thermospray mass spectrum of the HPLC peak of fluorescein sampled at 13.65-14.45 minutes.
FIG. 11 is: (a) a chromatogram of Impurity A in fluorescein with mass selective detection at m/z 259 using the mass spectrometer; and (b) a thermospray mass spectrum of the HPLC peak of Impurity A sampled at 11.95-12.05 minutes.
FIG. 12 is: (a) a chromatogram of Impurity B in fluorescein with mass selective detection at m/z 285 using the mass spectrometer; and (b) a thermospray mass spectrum of the HPLC peak of Impurity B sampled at 15.45-15.55 minutes.
FIG. 13 is: (a) a chromatogram of Impurity C in fluorescein with mass selective detection at m/z 347 using the mass spectrometer; and (b) a thermospray mass spectrum of the HPLC peak of Impurity C sampled at 16.10-16.50 minutes.
FIG. 14 is: (a) a chromatogram of Impurity D in fluorescein with mass selective detection at m/z 347 using the mass spectrometer; and (b) a thermospray mass spectrum of the HPLC peak of Impurity D sampled at 18.20-18.65 minutes.
FIG. 15 is: (a) a chromatogram of Impurity E in fluorescein with mass selective detection at m/z 333 using the mass spectrometer; (b) is an APCI mass spectrum of the HPLC peak of Impurity E sampled at 13.23-13.52 minutes; (c) a chromatogram of Impurity E in fluorescein with detection by the total absorbance scan from 220-500 nm; and (d) a UV-Vis spectrum of the Impurity E peak.
FIG. 16 is: (a) a chromatogram of Impurity F in fluorescein with mass selective detection at m/z 425 using the mass spectrometer; (b) is an APCI mass spectrum of the HPLC peak of Impurity F sampled at 19.10-19.32 minutes; (c) a chromatogram of Impurity F in fluorescein with detection by the total absorbance scan from 220-500 nm; and (d) a UV-Vis spectrum of the Impurity F peak.
FIG. 17 is: (a) a chromatogram of Impurity G in fluorescein with mass selective detection at m/z 375 using the mass spectrometer; (b) is an APCI mass spectrum of the HPLC peak of Impurity G sampled at 21.27-21.54 minutes; (c) a chromatogram of Impurity G in fluorescein with detection by the total absorbance scan from 220-500 nm; and (d) a UV-Vis spectrum of the Impurity G peak.
FIG. 18 is: (a) an APCI mass spectrum of the HPLC peak of Impurity H-1 sampled at 51.75-51.85 minutes; and (b) a chromatogram of Impurity H-1 in fluorescein with detection by total absorbance scan from 220-500 nm.
FIG. 19 is: (a) an APCI mass spectrum of the HPLC peak of Impurity H-2 sampled at 52.67-52.79 minutes; and (b) a chromatogram of Impurity H-2 in fluorescein with detection by total absorbance scan from 220-500 nm.
FIG. 20 is the UV-Vis absorbance scan of Impurity H-2.
DETAILED DESCRIPTION OF THE INVENTION
As utilized herein, the following abbreviations and terms, unless otherwise indicated, shall be understood to have the following meanings:
The abbreviation “APCI” means atmospheric pressure chemical ionization.
The abbreviation “M/S” or “MS” means mass spectrometer.
The abbreviation “HPLC” means high performance liquid chromatography.
The abbreviation “UV-Vis” means ultra violet visible.
The abbreviation “LC/MS” means liquid chromatography/mass spectrometer.
The term “charcoal” encompasses activated carbon agents that are effective at reducing color number. Exemplary agents include, but are not limited to, Norit® SA Plus and Norit® SX Ultra, commercially available from supplier Univar USA, Dallas, Tex. Forms of charcoal capable of reducing color number can be determined through routine experimentation. (It has been determined, for example, that another commercially available form of charcoal is not effective in reducing the color number, i.e., Darco® KB.)
The term “color number” is the absorbance of a 1.0% solution of fluorescein raw material prepared in an aqueous sodium hydroxide and sodium bicarbonate solution at pH 9.4, when measured at 590 nm.
The terms “fluorescein drug substance” and “fluorescein raw material” are used interchangeably herein.
The term “related-substance impurity” encompasses synthetic impurities, isomers, oxidation products, dimerization products and decomposition products of fluorescein and/or fluorescein reactants. Exemplary structures of such related-substance impurities are shown in FIG. 8 .
The term “substantially free of pyridine” means that the fluorescein composition is at least 99% free of pyridine. More preferred is where the analytical purity is at least 99.9%; even further preferred is where the fluorescein composition is completely free of pyridine.
The term “substantially pure fluorescein” refers to the total absence, or near total absence, of impurities, such as related-substance impurities. For example, when a fluorescein composition is said to be substantially pure, there are either no detectable related-substance impurities, or if a single related-substance impurity is detected, it is present in an amount no greater than 0.1% by weight, or if multiple related-substance impurities are detected, they are present in aggregate in an amount no greater than 0.6% by weight
The processes of the present invention produce fluorescein products with low related-substance impurity profiles. It is generally known that even purified fluorescein material may contain low levels of certain impurities, for example, resorcinol and 2-(2′,4′-dihydroxybenzoyl)benzoic acid. However, it was not previously known that commercial samples of fluorescein may contain a number of impurities in addition to resorcinol and 2-(2′,4′-dihydroxybenzoyl)benzoic acid. The amount of these potential impurities is reduced substantially via the processes of the present invention. Such impurities are collectively referred to herein as “related-substance impurities”.
Experiments were conducted to determine the molecular weights of these related-substance impurities by LC/MS, and, although not desiring to be bound by theory, structures for these impurities are proposed herein (see FIG. 8 ). A process to resolve and quantify the low level of related-substance impurities which may be present even in purified fluorescein compositions was discovered and is described in detail below. It was discovered that the processes of the present invention provide a highly purified fluorescein that has substantially reduced levels of related-substance impurities. This can be seen in the impurity profiles of purified fluorescein drug substance of the present invention, as shown below in Table 1, compared to the impurity profile of technical grade fluorescein from various manufacturers, as shown in Table 2 below, and the impurity profile of fluorescein drug substance from various manufacturers as shown below in Tables 3 through 5.
TABLE 1
Impurity Profiles of Validation Batches of the Present Inventive Method Fluorescein Drug Substance a
Reference
RRT
Impurity
Impurity
RRT
Total
No.
Impurity A
1.10
Impurity C
Impurity D
Impurity E
Impurity F
Impurity G
H-1
H-2
1.74
(%)
1
ND b
ND
ND
ND
ND
ND
ND
ND
ND
ND
0.0
2
ND
ND
ND
ND
ND
<LOQ c
ND
<LOQ c
<LOQ c
ND
0.0
3
ND
ND
ND
ND
ND
ND
ND
ND
<LOQ c
ND
0.0
a Resorcinol was analyzed by a separate method in each of the three lots. The resorcinol concentration in each lot was less than 0.05%.
b ND = Not detected, <0.01%. c
c LOQ = Less than limit of quantitation of 0.025%; estimated at 0.01%.
TABLE 2
Impurity Profiles of Technical Grade Fluorescein from Various Manufacturers
Supplier
Impurity A
RRT
Impurity
Impurity
Impurity
Impurity F
Impurity
Impurity
Impurity
RRT 1.74
Total
Reference No.
(%)
1.10 (%)
C (%)
D (%)
E (%)
(%)
G (%)
H-1 (%)
H-2 (%)
(%)
(%)
Supplier B
0.3
—
—
0.1
—
0.7
—
0.3
0.3
—
4.4 a
4
Supplier B
0.4
—
—
0.06
—
0.6
—
0.2
0.2
3.8 a
5
Supplier B
0.2
—
—
0.01
—
0.5
—
0.2
0.2
1.5 a
6
Supplier B
0.6
—
—
0.07
—
0.07
—
0.06
0.1
—
0.9
7
Supplier B
0.7
—
—
0.07
—
0.08
—
0.06
0.1
—
1.0
8
Supplier B
0.6
—
—
0.7
—
0.7
—
0.4
0.1
—
0.9
9
Supplier B
0.45
—
—
0.59
—
0.15
—
0.21
0.22
—
4.21 b
10
Supplier B
0.64
—
—
0.53
—
0.14
—
0.18
0.19
—
4.15 b
11
Supplier C
0.68
—
—
0.54
—
0.14
—
0.18
0.19
—
4.20 b
12
Supplier C
—
—
—
1.22
—
0.11
—
0.97
0.98
0.11
5.57 c
13
Supplier D
5.9
—
—
0.2
—
0.8
—
0.01
0.01
—
9.4 d
14
Supplier D
5.6
—
—
0.1
—
0.9
—
0.01
0.02
—
9.6 d
15
Supplier D
5.3
—
—
0.2
—
1.0
—
0.01
0.02
—
9.5 d
16
Supplier D
5.3
—
—
0.2
—
1.0
—
0.01
0.03
—
9.7% d
17
a Unknown impurities also present ranging in concentration from 0.06% to 0.9%.
b Unknown impurities also present ranging in concentration from 0.06% to 0.7%.
c Unknown impurities also present ranging in concentration from 0.05% to 0.5%.
d Unknown impurities also present ranging in concentration from 0.06% to 0.8%.
TABLE 3
Impurity Profile of Fluorescein Drug Substance Manufactured by Supplier A
Supplier
Reference
Impurity
RRT
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
RRT
Total
No.
A (%)
1.10 (%)
C (%)
D (%)
E (%)
F (%)
G (%)
H-1 (%)
H-2 (%)
1.74 (%)
(%)
Supplier A
<0.05
—
—
—
0.1
0.3
—
—
—
—
0.4
18
Supplier A
<0.05
—
—
—
<0.05
0.09
—
—
—
—
0.09
19
Supplier A
0.2
—
—
—
0.06
0.09
—
—
—
—
0.4
20
TABLE 4
Impurity Profile of Fluorescein Drug Substance Manufactured by Supplier E
Supplier
Reference
Impurity
RRT
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
RRT
Total
No.
A (%)
1.10 (%)
C (%)
D (%)
E (%)
F (%)
G (%)
H-1 (%)
H-2 (%)
1.74 (%)
(%)
Supplier E
<0.05
—
<0.05
—
<0.05
<0.05
0.08
—
—
—
0.08
21
Supplier E
<0.05
—
<0.05
—
<0.05
<0.05
0.07
—
—
—
0.07
22
Supplier E
<0.05
—
<0.05
—
<0.05
<0.05
0.1
—
—
—
0.1
23
Supplier E
—
—
—
<0.05
—
<0.05
—
0.06
<0.05
—
0.06
24
Supplier E
0.07
—
—
0.05
—
0.2
<0.05
0.1
0.2
—
0.6
25
Supplier E
0.06
—
—
0.05
—
0.2
<0.05
0.1
0.2
—
0.6
26
Supplier E
0.07
—
—
0.05
—
0.2
<0.05
0.1
0.2
—
0.6
27
TABLE 5
Impurity Profile of Fluorescein Drug Substance Manufactured by Supplier F
Supplier
and
Reference
Impurity
RRT
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
Impurity
RRT
Total
No.
A (%)
1.10 (%)
C (%)
D (%)
E (%)
F (%)
G (%)
H-1 (%)
H-2 (%)
1.74 (%)
(%)
Supplier F
0.1
0.03
—
0.05
—
0.2
—
0.1
0.1
0.03
0.7
28
Supplier F
0.03
<0.025
—
0.03
—
0.05
—
0.05
0.06
<0.025
0.2
29
Supplier F
0.05
<0.025
—
0.04
—
0.1
—
0.1
0.1
0.04
0.5
30
Supplier F
0.04
<0.025
—
0.04
—
0.07
—
0.09
0.1
0.03
0.4
31
Supplier F
0.04
—
—
0.04
—
0.1
—
0.07
0.08
—
0.3
32
Supplier F
0.03
—
—
0.04
—
0.09
—
0.07
0.07
—
0.3
33
Supplier F
0.04
—
—
0.03
—
0.08
—
0.05
0.05
—
0.3
34
Supplier F
0.03
—
—
0.04
—
0.08
—
0.07
0.08
—
0.3
35
Supplier F
0.03
—
—
0.04
—
0.1
—
0.08
0.1
—
0.4
36
Supplier F
0.03
—
—
0.04
—
0.08
—
0.07
0.09
—
0.3
37
Supplier F
0.03
—
—
0.04
—
0.1
—
0.08
0.07
—
0.3
38
Supplier F
0.03
—
—
0.0
—
0.1
—
0.09
0.07
—
0.3
39
Supplier F
0.03
—
0.03
0.04
—
0.08
—
0.08
0.07
—
0.3
40
Supplier F
0.03
—
0.03
0.04
—
0.07
—
0.07
0.07
—
0.3
41
Supplier F
0.03
—
0.03
0.04
—
0.09
—
0.07
0.07
—
0.3
32
Supplier F
0.04
—
—
0.03
—
0.09
—
0.07
0.09
—
0.3
43
An outline of the general process involved in this invention is illustrated below. Commercial-grade fluorescein is diacetylated via reaction with acetic anhydride at reflux temperatures. The so-produced diacetylated fluorescein is isolated, and then reacted with base to produce the deacetylated fluorescein, which is then treated with charcoal to produce a low-color fluorescein of high purity and low chloride content. The reaction scheme is illustrated below:
The particular solvents, reaction times and temperatures, and pH values used to prepare the pure fluorescein of this invention have been determined based on a series of experiments. The goals of these experiments were to obtain a high purity pharmaceutical grade fluorescein of low color and salt content, and to avoid the use of a noxious solvent used in prior known methods, namely pyridine. Additional goals were to minimize the expense and time involved in the processes, by, for example, using the minimum amounts of solvents, or reducing the reaction cycle time(s) of the necessary steps.
The process of purifying fluorescein begins with converting fluorescein to O,O′-diacetylfluorescein. For this purpose acetic anhydride is used as both solvent and reagent, avoiding altogether the use of pyridine, a noxious solvent used in a prior art process. Thus, a mixture of fluorescein and acetic anhydride is stirred for several hours at reflux, and the resulting suspension is allowed to cool. Further cooling to freezing or just below effects full crystallization. The crystallized material is collected and washed first with cold acetic anhydride and then with cold acetone. The material is then resuspended in acetone with stirring and gentle heat. After cooling, the white crystalline material is collected, washed with cold acetone, and air dried, to provide high purity O,O′-diacetylfluorescein.
Next, the O,O′-diacetylfluorescein is converted back to fluorescein, with the formation of the sodium salt and removal of final impurities. To effect this conversion, the acetyl groups of O,O′-diacetylfluorescein are hydrolyzed using a caustic solution. Thus, O,O′-diacetylfluorescein and methanol are charged to a suitable vessel, a prepared solution of sodium hydroxide in deionized water is added, and the mixture is heated to reflux with agitation. The mixture is then cooled, filtered using a filter aid, and then washed with methanol. The volume of the filtrate is then reduced by vacuum distillation, water is added, and the reaction mixture is cooled. The pH of the reaction mixture is then adjusted to between 8.5 and 8.7. A suitable charcoal, for example, Norit® SX Ultra is added with agitation for one hour. If necessary, the charcoaling step is repeated. Next follow the critical precipitation steps. First, ethanol is added to the filtrate so that a 2:1 proportion of ethanol to water is obtained. This proportion is based upon the unexpected discovery that a higher proportion of organic solvent to water in the precipitation procedure yields a lower chloride content in the fluorescein product. The experiments conducted to discern this effect are described further below. Next, to acidify the fluorescein, a diluted hydrochloric acid solution is added so that a calibrated pH range is established. This range is based upon the unexpected discovery that a lower pH provides a product with a more desirable color. More specifically, it was determined through experimentation that the optimum pH range of the filtrate should be between 1.0 and 2.5, and that the acidification should be conducted slowly, for example, over a time period of two to four hours, so as to avoid aggregation of the product, and with cooling. After further agitation and cooling, the fluorescein is then isolated by filtration. The product is washed with a solution of water and ethanol, and the product dried to provide an 80-90% yield of very high quality fluorescein. The high-purity fluorescein may be used in the preparation of fluorescein for injection. For this purpose, the fluorescein is converted to the soluble disodium salt form using sodium hydroxide, and filled into ampoules for subsequent sterilization.
One example of the experimentation conducted to achieve the process of the invention is the calibration of the pH range at which the fluorescein product is precipitated. This pH range was adjusted from a higher to a lower range based in part on empirical observations regarding the color spectrum of the product formed. Thus, it was determined that the optimal pH range at which the fluorescein product should be precipitated in order to achieve the goal of a low color product is from about pH 1.0 to about pH 2.5.
It was also unexpectedly discovered that higher proportions of organic solvent to aqueous solvent, in the precipitation procedure, yield a lower chloride content in the fluorescein product. This result was not anticipated, as it was expected that a low organic/aqueous ratio would have been necessary to reduce the sodium chloride level. The use of higher proportions of organic solvent has an added benefit of improving the filtration rate, thereby reducing the time required to process the material.
Further precipitation experiments were conducted to develop processes for the present invention and are described below, and shown in FIGS. 1 and 2 . In particular, experiments were conducted to reduce the chloride level by changing the precipitation process, as shown in Table 6 below.
TABLE 6
Precipitation Experiments
Experiment
Ratio of
Washed*
Chloride
Reference
Water:Ethanol
Volumes
(Y or N)
(% wt)
Comment
A
1:1
10
N
0.91
Yellow-red solid
1:1
15
N
0.87
Yellow-red solid
B
1:1
10
N
0.80
Yellow-red solid
2:1
15
N
0.97
Yellow-red solid
C
1:1
10
N
0.76
Yellow-red solid
1:2
15
N
0.65
Dark red solid
D
1:1
10
N
1.45
86% yield Yellow-red solid
E
1:2
15
N
0.45
92% yield Dark red solid
F
1:1
10
Y
0.10
87% yield Yellow-red solid
G
1:2
15
Y
0.0056
78% yield Dark red solid
H
1:1
10
N
1.05
Yellow-red solid
I
1:2
15
N
0.49
Dark red solid
J
1:1
10
Y
0.13
Yellow-red solid
K
1:2
15
Y
0.026
Dark red solid
*Water:Ethanol, 3:1, 2 × 1 volume wash
Table 6 shows that a change in the solvent ratio of the precipitation medium affects the amount of chloride present. In particular, increasing the ratio of ethanol to water in the precipitation medium produces a lower chloride content. Experiment A shows a marginal decrease in the chloride content when the volume of the water:ethanol (1:1) precipitation medium is increased from 10 volumes (reference) to 15 volumes (See Table 6). Experiment B compares the precipitation from water:ethanol (1:1, 10 volumes, reference) to precipitation from water:ethanol (2:1, 15 volumes). The result from the experiment is counter-intuitive in that the reference reaction having a lower water content and less volume produces a lower chloride content.
Experiment C compares the precipitation from water:ethanol (1:1, 10 volumes, reference) to precipitation from water:ethanol (1:2, 15 volumes). The results of Experiment C show that the higher organic content precipitation medium produces lower chloride content.
The trend that the higher organic content in the precipitation medium produces a lower chloride content is reproduced in Experiments D, E, F and G, and Experiments H, I, J and K for both the unwashed and the washed product. Although the results appear counter-intuitive, it is believed, without being bound by theory that the higher organic content allows for a faster and more efficient wash of the product cake.
Another aspect considered is whether fluorescein color is dependent upon the pH of the precipitation medium; see Table 7 below, wherein a precipitation medium of ethanol:water in a ratio of 2:1 is used.
TABLE 7
Fluorescein Color as a Function of pH
[Precipitation Medium of Ethanol:Water (2:1)]
Experiment
Reference
pH 1.0-1.5
pH 2.0-2.5
pH 3.0-3.5
pH 4.0-4.5
L
Red Solid
Red Solid
Maroon Solid
Brown Solid
The results indicate that fluorescein color is sensitive to pH changes. For example, at a pH of about 3.0, the appearance of the product begins to take on a maroon hue, which is deemed to be undesirable.
Examples 1-8 below are provided to further illustrate certain embodiments of the invention. Representative data obtained from Examples 5, 6, 7 and/or 8 are shown in FIGS. 9 to 19 .
The data for FIGS. 9-14 were obtained with an LC/MS using a thermospray mass spectrometer interfaced with an HPLC. Peaks were observed by use of a UV detector (280 nm) and a thermospray mass spectrometer. Experimental Conditions: Instrument=Vestec Model 201B Thermospray mass spectrometer interfaced to a Waters Model 600 MS HPLC system and a Waters Model 486MS UV detector (280 nm); Column=Waters Symmetry C-8, 5μ, 3.9×150 mm; Mobile Phase=Linear gradient programmed from 0% B to 100% B over 25 minutes; Mobile Phase A=0.1 M ammonium acetate in 10:90 V:V methanol:water; Mobile Phase B=0.1 M ammonium acetate in methanol; Flow rate=1.0 mL/minute; Sample concentration=Neat; and Injection Volume=20 μL.
The data for FIGS. 15-20 was obtained with an LC/MS using a mass spectrometer interfaced with an HPLC. The mass spectrometer was used with the atmospheric pressure chemical ionization (APCI) interface and the spectrometer was operated in the positive ion mode of detection. Peaks were observed by use of a UV-Vis detector monitoring the total absorbance from 220-500 nm and the mass spectrometer. A Waters Symmetry C-8 column (3.9×150 mm) was used at a flow rate of 0.6 mL/minute and was programmed from 0% mobile phase B to 100% mobile phase B over 30 minutes. Mobile phase B was 0.01 M ammonium acetate in methanol and mobile phase A was 0.01 M ammonium acetate in 10:90/methanol:water.
EXAMPLE 1
To a 5 liter, 3 necked round bottom flask Fluorescein (1000 g, 3.01 mol) and acetic anhydride (1622 g, 15.9 mol) were added. The resulting mixture was stirred for 3-5 hours at reflux and the resulting suspension was allowed to cool to room temperature. With continuous stirring, the reaction mixture was further cooled to −5 to 3° C. to effect full crystallization. The crystallized material was collected on a Buchner filter, washed with cold acetic anhydride (2×500 mL) and then cold acetone (1×600 mL). The material was partially dried and re-suspended in acetone (1000 mL) with stirring and gentle heat. Once cooled, the white crystalline material was collected on a filter, washed with cold acetone (2×700 mL) and was air dried. Yield: ˜75%-85%; Single spot via TLC; MP=203-205.5° C.; and Purity 99.7%.
EXAMPLE 2
Formation of Fluorescein from Diacetyl Fluorescein, Formation of Sodium Salt and Removing Final Impurities
O,O′-diacetylfluorescein (1000 g) and methanol (4000 mL) were charged into a suitable reactor. Separately, a solution of sodium hydroxide solution (480 g, 50% caustic) was prepared in deionized water (620 mL). The sodium hydroxide solution was charged into the reactor containing the O,O′-diacetylfluorescein and methanol. The mixture was heated to reflux and agitated at reflux for 90 minutes. The reaction mixture was cooled to between 20° C. and 25° C. The mixture was filtered using filter aid (100 g) and followed by a wash with methanol (500 mL). The filtrate (5000 mL) was distilled under vacuum to a residual volume of between 1400 mL to 1700 mL and the reaction mixture was then cooled to between 20° C. and 25° C. Deionized water (5000 mL) was added to the distillation concentrate. Separately, a solution of sodium hydroxide solution (56 g, 50% caustic) was prepared in deionized water (72 g). The freshly prepared sodium hydroxide solution (100 mL) was used to adjust the pH of the reaction to between 8.5 and 8.7. Norit SX Ultra (100 g), filter aid (100 g) and deionized water (500 mL) were charged to the reaction at room temperature and the mixture was subsequently agitated for 1 hour. The batch was filtered and additional Norit SX Ultra (100 g) and deionized water (500 mL) was charged to the filtrate at room temperature and the mixture was subsequently agitated for 1 hour. The batch was filtered and was washed with deionized water (2000 mL). Ethanol (10000 mL) was charged to the filtrate. Separately a hydrochloric acid solution was prepared by dissolving muriatic acid (32%, 820 g) in deionized water (320 mL). The diluted acid solution was used to adjust the pH of the filtrate to between 1.0 and 2.5 while the temperature of the batch was maintained between 20° C. and 25° C. The batch was agitated between 20° C. and 25° C. for 1 hour and was then isolated by filtration. The cake was washed with a solution of (Water for Injection:Ethanol):(3:1), (2×1000 mL). The product was dried to give a typical 80-90% yield of very high quality fluorescein.
EXAMPLE 3
Fluorescein Drug Substance Color Intensity
Equipment
Spectrophotometer capable of accepting 1 cm cells and scanning from 660 nm to 570 nm.
Spectrophotometer cells (1 cm path length) of a material appropriate for wavelengths 660 nm to 570 nm, such as quartz.
The intensity of the color of fluorescein drug substance was measured, as described below. The procedure was used to determine the color of a 1.0% solution of fluorescein raw material prepared in an aqueous of sodium hydroxide and sodium bicarbonate solution at pH 9.4 by measuring its absorbance at 590 nm. This value may also be referred to as the “color number”. An increase in the absorption measurement at 590 nm corresponds to an increase in the visible color intensity of the finished drug product.
Fluorescein (250 mg±5 mg, accurately weighed) and sodium bicarbonate (50 mg) were weighed into a 25 mL beaker. Sodium hydroxide (5 ml of 1%) was added. The solution was warmed gently while stirring. Sodium hydroxide (1%, up to 1 additional mL, a total of 6.0 mL) was added until all material was dissolved and the solution clear. The reaction was cooled to room temperature. The pH was adjusted the pH to 9.4, using 1% sodium hydroxide dropwise if necessary. If pH was above 9.4, the solution was discarded and re-prepared using less sodium hydroxide. The solution was quantitatively transferred to a volumetric flask (25 mL) and QS to 25.0 mL with purified water. The final concentration was 10 mg/mL, or 1%.
Method
The spectrophotometer was zeroed by establishing a blank user baseline with purified water in both the sample and reference cell cuvettes, scanning from 660 nm to 570 nm at a rate of 100 nm/min. Fluorescein solution (1%) was added to the sample cuvette. The sample solution was scanned from 660 nm to 570 nm, at a rate of 100 nm/min. The absorbance reading was recorded at 590 nm. A duplicate measurement was performed on a separate aliquot of sample. Table 1 lists typical color number results for several fluorescein raw material sample testing using this method. The results were corrected using the equation shown in Section below. FIG. 3 shows a typical spectrum obtained from a fluorescein raw material sample.
Calculations
The absorbance readings were corrected for sample concentration as follows:
Absorbance corrected = Absorbance × ( Target Weight ) ( Actual Weight )
Color intensity measurements on sample fluorescein lots were obtained as described in Example 2, and listed in Table 8 below.
TABLE 8
Color Number for 1% Fluorescein Solutions
Sample
Color Number
1
0.028 A.U.
2
0.032 A.U.
3
0.018 A.U.
4
0.025 A.U.
EXAMPLE 4
Fluorescein Residual Chloride Determination Using Potentiometric Titration
Equipment
Brinkman 716 DMS Titrino Automated Titrator or equivalent
Brinkman 730 Sample Changer and 759 Swing Head Autosampler or equivalent
Ag Titrode electrode
5-Place analytical balance or equivalent
Sonicator
Hot plate
Centrifuge capable of 3,000 rpm
Culture tubes, 16×125 mm, VWR Cat #47729-578 or equivalent
White caps for 16 mm culture tubes, VWR Cat #60828-760 or equivalent
Blood serum filters, 6.×16 mm, VWR Cat #28295-556 or equivalent
The following method was used to quantitate residual chloride amounts in fluorescein using potentiometric silver nitrate titration, an automatic titrator and a silver electrode.
(1) Reagent Solution Preparation, Ammonium Hydroxide (5N)
To purified water (˜600 mL), concentrated ammonium hydroxide (˜338 mL) was added and diluted to 1000 mL with purified water. This solution was used for the autotitrator to rinse and store the silver electrode.
(2) Standardized Solution Preparation, Silver Nitrate, 0.10 N, Aqueous
Use 0.10 N silver nitrate commercially prepared as a solution with a certificate of analysis is preferred. If, however, a commercially certified solution of silver nitrate is not available, then silver nitrate (17.0 g) may be weighed and dissolved in purified water (1000 mL) and standardized. Potassium chloride reference standard (dry, 50 mg) was weighed and dissolved in purified water (˜30 mL) in a titration cup. Nitric acid (1 mL) was added to this solution. The solution was titrated potentiometrically using a silver billet electrode. Each mL of 0.10 N of silver nitrate was equivalent to 7.455 mg of potassium chloride. The normality of the silver nitrate was calculated using the following equation: N AgNO 3 =(mg KCl×Purity KCl)/(mL AgNO 3 ×74.55).
(3) Sample Preparation and Titration
Fluorescein raw material (2 g) was weighed into culture tubes (16×125 mm). Purified water (hot, 10 mL) was added. Nitric acid (1 mL) was added and all tubes were capped, shaken for 2 minutes and sonicated for 15 minutes. All tubes were centrifuged for 30 minutes (˜3,000 rpm). The precipitant was separated from the supernatant using blood serum filters. The solution was decanted into a titration cup. The blood serum was rinsed and filtered using purified water (5 mL portions). The rinses were poured into the titration cup. The blood serum filters were removed and discarded. The above procedure was repeated a second time except that all tubes were capped and shaken for 1 minute, and all tubes were centrifuged for 20 minutes (˜3,000 rpm). The solutions from the first and the second extracts were combined and the serum filter was rinsed with purified water. The combined solution was titrated with 0.10 N Ag NO 3 to its potentiometric end point. The titration parameters include using a wash cycle (5N ammonium hydroxide) and a rinse cycle (5N ammonium hydroxide) after each sample. A list of parameters is shown below.
(4) Calculations
Percent
Chloride
=
(
V
)
×
(
N
)
×
35.453
×
100
W
V=Volume of 0.10 N AgNO 3 titrated
N=Normality of AgNO 3 titrant
35.453=Molecular weight of chloride
W=Weight of fluorescein example taken
TABLE 9
Residual Chloride
Sample
Residual Chloride
1
0.023%
2
0.018%
3
<0.01%
4
<0.01%
EXAMPLE 5
In this procedure, a solution of fluorescein raw material was prepared in methanol and separated from its related-substances using a high performance liquid chromatography (HPLC) system, gradient mobile phase programming, and a C-18 column. The related-substances were quantitated against a 1% solution of fluorescein reference standard. An ultraviolet HPLC detector was used to measure the peak responses at a wavelength of 280 nm. Mobile Phase A is 0.01M Ammonium Acetate, 10% Methanol/90% Water, and 0.5% Acetic Acid. Mobile Phase B is 0.01M Ammonium Acetate, 100% Methanol; 0.5% Acetic Acid. The reference standard was a 0.5 mg/mL solution of fluorescein in methanol, diluted to a final concentration of 0.005 mg/mL in methanol, or 1% of the sample final theoretical concentration of 0.5 mg/mL of fluorescein prepared similarly. A high-performance liquid chromatography system capable of programmed gradient operation was used, with an HPLC UV/VIS detector and the ability to monitor 280 nm. Column: 3.9×150 mm Waters Symmetry C-18 column, 5 μm, (or equivalent) capable of at least 20,000 plates/column for fluorescein. Flow Rate: 0.6 mL/min. The Gradient Program was as follows:
Time (min)
% Mobile Phase A
% Mobile Phase B
0
80%
20%
60
20%
80%
Column wash:
61
0%
100%
66
0%
100%
Equilibration:
67
80%
20%
Using peak areas, the percent concentration of known and unknown impurities equal to or greater than 0.025% were calculated, as shown in the calculation section below. Although the limit of quantitation for this method is 0.025%, impurities are generally reported at concentrations ≧0.05%. Nine impurities were found in the analysis of fluorescein and their molecular weights were determined by LC/MS. Their proposed structures are presented in FIG. 8 . Impurity H was found as two diastereomers, H-1 and H-2. Typical relative retention times (RRT), capacity factors (k′), and gradient composition at time of elution (% B) for the impurities identified in the fluorescein lots cited in this procedure using this chromatographic method are as follows:
RRT
k′
B (%)
Impurity A
0.75
11.1
43.0
Impurity D
1.19
18.2
56.5
Impurity F
1.23
18.8
57.7
Impurity H-1
1.68
26.0
71.0
Impurity H-2
1.71
26.5
72.0
A peak in the fluorescein chromatogram may be identified as related substance A, D, F, H-1 or H-2 if the relative retention times, capacity factor and approximate mobile phase composition of the peak correspond to the related substances listed above. However, each of the relative retention time values can vary by approximately 0.02 between chromatographic systems. Modifications to the chromatographic system may also impact the values listed above. Although Impurities B, C, E and G were not identified in the four fluorescein lots assayed here, prior LC/MS analysis of Supplier A fluorescein suggests that Impurities B, C, E and G would have approximate RRT's of 1.09, 1.11, 1.20, and 1.44. Two unknown impurities, with RRT's of 1.10 and 1.74, respectively, were present in the four lots of fluorescein raw material reported in this document. Their concentrations were between 0.025% and 0.05%. It is possible that the unknown peak at RRT=1.10 could be either Impurity B or C. A chromatogram of a fluorescein raw material sample is shown in FIG. 6 . Diacetylfluorescein has been observed in fluorescein drug substance and appears at a retention time relative to fluorescein of 1.35.
Resorcinol is a known common impurity of fluorescein. Resorcinol is used as a starting material in the synthesis of fluorescein and is a potential degradation product. Resorcinol has been found to elute at a RRT of 0.14, k′ of 2.9, and % B of 24.6 as presented above. Resorcinol may be observed to elute as an unresolved doublet on occasion. A chromatogram of fluorescein drug substance containing resorcinol is presented in FIG. 7 .
Any nonrelated peaks (i.e., solvent front, system peaks) plus resorcinol were identified and omitted from the following calculations. Resorcinol eluted at RRT about 0.14 (see FIG. 7 ). The percent concentrations for each related substance were calculated as shown below.
% Related Substances = Related Substance Area Standard Area × Standard Cone Sample Cone × 100 % Total Related Substances = ∑ ( Individual Impurities ≥ 0.025 % )
Calculate the total impurities by summing impurities with a concentration of 0.025% or above.
Calculate the relative retention according to the following formula:
R R T = t i t f t i =the retention time of the impurity peak t f =the retention time of the fluorescein peak
The limit of quantitation for the method was established as 0.127 μg/mL of fluorescein (0.025% of the sample preparation concentration). The limit of detection was determined to be 0.05 μg/mL of fluorescein (0.01% of the sample preparation concentration).
Four lots of Supplier A fluorescein raw material were analyzed using this method. Seven impurities were detected and five impurities (A, D, F, H-1 and H-2) were identified. The total percent of reportable impurities (≧0.025%) ranged between 0.2% and 0.7%. The results are listed in Table 10 below.
In an alternative to this procedure, the diluent for the sample and standard preparations are changed to permit simultaneous analysis of resorcinol and other related substance impurities. To prepare the diluent, first dissolve 0.77 g of ammonium acetate in 1000 mL of water, adjust pH to 3.9 with acetic acid, then add equal volumes of ammonium acetate buffer and methanol. After initially dissolving fluorescein in methanol at a ratio of 50 mg to 15 mL, this diluent is then used instead of methanol to dilute standards and samples as in the procedure described in Example 5, and the blank is changed as well to diluent from methanol. Protect the fluorescein standard and sample preparations from light after dilution with the diluent. Typical relative retention times (RRT) for resorcinol and phthalic acid are as follows:
RRT
k′
B (%)
Resorcinol
0.13
1.21
24.2%
Phthalic Acid
0.16
1.53
24.9%
An RRF (Relative Response Factor) may also be added to the calculation for the impurities, where the RRF represents the response relative to fluorescein.
Impurity
RRF 1
Resorcinol
1.7
Phthalic Acid
2.6
Impurity A
0.43
Impurity D
1.0
Impurity F
1.0
Impurity H-1
1.0
Impurity H-2
1.0
1 The relative response factors for impurities D, F, H-1, and H2- have not been determined. Their relative response factors are assumed to be 1.0.
The percent concentrations for each related substance can be calculated as shown below:
%
Related
Substances
=
Related
Substance
Area
Standard
Area
×
Standard
Cone
Sample
Cone
×
R
R
F
×
100
TABLE 10
HPLC Assay Results for Supplier A Fluorescein Raw Material
Unknown at
Total
Lot
Impurity A
Unknown at
Impurity D
Impurity F
Impurity H-1
Impurity H-2
RRT 1.74
Impurity
Reference
(%)
RRT 1.10 a (%)
(%)
(%)
(%)
(%)
(%)
(%)
A
0.1
0.03
0.05
0.2
0.1
0.1
0.03
0.7
B
0.03
<0.025
0.03
0.05
0.05
0.06
<0.025
0.2
C
0.05
<0.025
0.04
0.1
0.1
0.1
0.04
0.5
D
0.04
<0.025
0.04
0.07
0.09
0.1
0.03
0.4
The limit of quantitation of the method is 0.025%.
The limit of detection of the method is 0.01%.
a Peak at RRT 1.10 is probably Impurity B or C
EXAMPLE 6
An investigation was conducted to determine the identity of fluorescein-related substance impurities. Samples of fluorescein were analyzed for the presence and concentration of impurities. Identification analysis was conducted by high performance liquid chromatography/mass spectrometry (LC/MS).
A representative HPLC chromatogram from the LC/MS system is reproduced in FIG. 9 . Fluorescein produced the major peak in the chromatogram. The thermospray mass spectrum of fluorescein, shown in FIG. 10( b ), produced a M+H molecular ion at m/z 333 which is consistent with the molecular weight of 332.
The thermospray mass spectrum of Impurity A, as shown in FIG. 11( b ), produced an M+H molecular ion at m/z 259, indicating a molecular weight of 258. The structure proposed in FIG. 8 for Impurity A, [2-(2′,4′-dihdyroxybenzoyl)benzoic acid], has been previously reported as an impurity in fluorescein preparations.
The thermospray mass spectrum of Impurity B, as shown in FIG. 12( b ), indicates an M+H molecular ion at m/z 285, suggesting a molecular weight of 284. A molecular weight of 284 may correspond to elemental formulas of C 15 H 8 O 6 , C 16 H 12 O 5 , or C 17 H 18 O 4 . A proposed structure shown for Impurity B in FIG. 8 may arise from the reaction of resorcinol with succinic acid (as an impurity in the phthalic acid precursor for fluorescein).
The thermospray mass spectrum of Impurity C, as shown in FIG. 13( b ), indicates an M+H molecular ion at m/z 347. This represents a molecular weight of 346, and corresponds to a gain of 14 mass units over fluorescein.
The thermospray mass spectrum of Impurity D, as shown in FIG. 14( b ), also produced an M+H molecular ion at m/z 347, which is likely an isomer of Impurity C. The structures proposed for Impurities C and D are tautomers of each other, both being quinine-type oxidation products of fluorescein.
The APCI of Impurity E, as shown in FIG. 15( b ), produced an M+H molecular ion at m/z 333 M+H, suggesting a molecular weight of 332, and a UV spectrum with a UV max at 492. Thus, it appears that Impurity E may be a positional isomer of fluorescein.
The APCI of Impurity F, as shown in FIG. 16( b ), produced an M+H molecular ion at m/z 425 suggesting a molecular weight of 424, and a UV max greater than 400 nm. The spectra appears to be consistent with an additional resorcinol molecule added to the parent compound. Thus, Compound F may form from three resorcinols, while the parent may form from two resorcinols.
The APCI of Impurity G, as shown in FIG. 17( b ), produced an M+H molecular ion at m/z 375, suggesting a molecular weight of 374, and a UV max at 484 nm. Both spectra and the lipophilicity appeared to be consistent with the acetate ester of fluorescein.
The APCI of Impurities H-1 and H-2, as shown in FIGS. 18( a ) and 19 ( a ), produced an M+H molecular ion at m/z 739 for both compounds, suggesting a molecular weight of 738 for each. The UV-Vis absorbance spectrum of both compounds was the same, with an UV max at 233 nm, and weaker absorbance maxima at 462 and 488 nm. The absorbance spectrum of Impurity H-2 is shown in FIG. 20 .
EXAMPLE 7
Preparation of Fluorescein for Injection, or Fluorescite 25%
In 60% of the required water for injection in the compounding tank, the required amount of sodium hydroxide was dissolved and weighed. The fluorescein was added and dissolved. Additional water for injection was added if required to dissolve, but the volume was not brought to more than 90% of total volume. If fluorescein did not completely dissolve after 30 minutes stirring, proceeded to next step to adjust pH. The pH was adjusted to 9.4, which was done with sodium hydroxide 3N and/or hydrochloric acid IN. The mixture was stirred for 30 minutes at 180 R.P.M. The pH was rechecked. If less than 9.3 or greater than 9.5 readjusted pH to 9.4 with sodium hydroxide 3N and/or hydrochloric acid 1N. The sodium fluorescein solution was brought to volume with additional water for injection, and stirred for 15 minutes. The pH was rechecked as noted above. Using a nitrogen tank, the solution was pressure filtered through a series of three membrane filters with pore size of 5 microns, 0.8 microns, and 0.45 microns into a sterile filling tank. The pH of the product was rechecked using procedure noted above. A sample was aseptically withdrawn for laboratory testing. Product was filled in ampoules previously sterilized. To each ampoule was added 2.15 to 2.25 mL. Immediately after filling, the samples were tip-sealed or pull-sealed by standard methods. Each ampoule seal was tested during sterilization. The ampoules were sterilized by autoclaving at 121° C. for 20 minutes or longer depending on batch size. Inspected carefully for leaks. Each ampoule was individually inspected for particulate matter under optimum lighted conditions.
EXAMPLE 8
Preparation of Fluorescein for Injection, or Fluorescite 10%
As an alternative procedure for preparing fluorescein for injection, into a suitable stainless steel tank was added approximately 70%-75% of batch quantity of cool water for injection (approximately 30° C.). Fluorescein was added with mixing until suspension was complete. The initial pH was recorded. A sufficient quantity (approximately 7.5% of the total volume) of 7N sodium hydroxide was added, then further amounts of 7 N sodium hydroxide were added, with rechecking of the pH value after waiting for approximately 15 minutes between additions, until the pH was between 9.3-9.5 with a target of pH 9.4. If the pH was greater than 9.5, the pH was adjusted by adding IN hydrochloric acid to obtain the pH range of 9.3-9.5. After the pH range is reached, mixing was continued for not less than 15 minutes. The batch was brought to final weight with water for injection, and mixed for not less than 30 minutes. The pH was tested and adjusted with sodium hydroxide or hydrochloric acid as needed. The product was filled aseptically into sterile vials, with further inspection and testing according to standard operating procedures.
The specific embodiments highlighted here are not intended to be a catalog of all the embodiments of the invention. Further, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the embodiments of the invention. Such equivalents are intended to be encompassed by the following claims.
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The present invention is directed to an improved process for producing substantially pure fluorescein, as well as to substantially pure fluorescein compositions prepared by the process. The invention is particularly directed to the provision of pharmaceutical compositions for use in angiography. The substantially pure fluorescein produced by the process of the present invention is low in color, low in sodium chloride content, and substantially free of pyridine.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application claims the benefit under 35 U.S.C. §119 of Swiss Patent Application No. 345/04, filed Mar. 2, 2004 and Swiss Patent Application No. 280/05, filed on Feb. 17, 2005 and is a continuation under 35 U.S.C. §120 of International Application No. PCT/CH2005/000115, the disclosures of which are incorporated herein in their entireties by reference.
BACKGROUND
A rope-like structure is disclosed.
U.S. Pat. No. 4,640,178 discloses a core rope which combines a host of core fiber bundles as a core and which is surrounded by an intermediate jacket. Around the intermediate jacket is a braided, outside jacket of monofilament yarn. The core, intermediate jacket and jacket are not connected among one another and therefore slip mutually.
U.S. Pat. No. 4,170,076 discloses a core rope having a braided core which is formed for its part by a host of core fiber bundles. The core is likewise surrounded by a braided jacket. The core and jacket are not connected between one another and thus are not slip-proof. In use, thickened and thinned areas form.
WO 03/027383 discloses a rope-like structure, especially core ropes, cords and ropes, in which the individual fibers, yarns or yarn strands are connected among one another such that they are mutually slip-proof. These rope-like structures have increased strength in stretching behavior and increased knot strength.
AT 358433 discloses a rope, especially a mountain-climbing rope, in a core-jacket construction in which the jacket threads are guided such that they lie as a braided pattern colored to the outside or lie on the core to the inside for better holding of the jacket. The core yarns are held by tubular braidings.
Furthermore, ropes with a core and a jacket or cords are known which are conventionally twisted or produced from different braided strands as hollow braiding without a core or from strands. In this way tubes can be formed with these cords on one end with so-called “splicing”. These properties are valued and used mainly in sailing. But splicing can be complex and expensive.
Strings or thin cords are known as strings in a tennis racket; they are plaited round as a core with a fine yarn in order to obtain greater friction and strength. Likewise strings and fine cores are known which have a ribbed surface (‘longitudinal-traverse’ pattern) or another special structure to increase friction.
All of the foregoing documents are incorporated herein by reference in their entireties.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are detailed below using the figures.
FIG. 1 shows a schematic structure of an exemplary core rope;
FIG. 2 shows the schematic structure of an exemplary cord as claimed in the invention;
FIG. 3 shows a cord with reversed, additional traverse fibers;
FIG. 4 shows cords with additional traverse fibers guided from the inside to the outside and from the outside to the inside;
FIG. 5 shows cords with at least one high-strength longitudinal fiber;
FIG. 6 shows a first exemplary embodiment of a core with several traverse melt fibers;
FIG. 7 shows a second exemplary embodiment of a core with several parallel fibers in longitudinal direction;
FIG. 8 shows a third exemplary embodiment of a cord with outside melt fibers;
FIG. 9 shows a first exemplary embodiment of a core rope with an intermediate jacket and traverse additional fibers;
FIG. 10 shows a second exemplary embodiment of a core rope of the same materials of differing thickness and strength;
FIG. 11 shows a schematic structure of a low-stretch rope;
FIG. 12 shows a first exemplary embodiment of a rope with good damping properties;
FIG. 13 shows a rope with lettering;
FIG. 14 shows a rope with continuous marking;
FIG. 15 the schematic structure of a climbing rope;
FIG. 16 shows a rope with a cavity;
FIG. 17 shows a rope with a change of cross section;
FIG. 18 shows a rope-like structure with openings;
FIG. 19 shows a rope-like structure with looped-back end;
FIG. 20 shows a part of a rope-like article with cross sections;
FIG. 21 shows a cord with openings arranged in a grid for low-slip stringing; and
FIG. 22 shows a cord with thickened areas arranged in a grid for low-slip strings.
DETAILED DESCRIPTION
A rope-like article or rope-like structure is disclosed in which the individual fibers, yarns or yarn strands are connected as longitudinal fibers among one another such that the fibers, yarns, or yarn strands are present mutually slip-proof.
FIG. 1 shows the schematic structure of an exemplary core rope. The core rope 10 has an inner core area 1 and a jacket area 2 which surrounds it. The core area 1 comprises (e.g., consists of) at least one core 3 which is for its part formed from a host of fibers, yarns, yarn strands and/or at least one cord, and which are all designated as a so-called core fiber structure 5 below. The jacket area 2 comprises (e.g., consists of) a jacket 4 , which for its part is formed from a host of fibers, yarns, yarn strands and/or at least one additional cord, and which are all designated as a so-called jacket fiber structure 6 below. In the core area 1 there can also be several cores, for example three or five, provided with core fibers and/or cores of the same or different type, with which the diversity of the core fiber structure 5 is shown. The similar also applies to the jacket fiber structure 6 .
Core fiber structures 5 and jacket fiber structures 6 comprise (e.g., consist of) longitudinal fibers and are combined below as longitudinal fiber structures 40 .
A portion of the core fiber structure 5 , called core fibers 5 ′, is present in the jacket area 2 and is connected in it to the jacket fibers of the jacket fiber structure 6 , while a portion of the jacket fiber structure 6 , called jacket fibers 6 ′, is present in the core area 1 and connected in it to the core fibers 3 . In this way the jacket is attached to at least one core mutually slip-proof. Several jackets with the most varied fibers can also be connected mutually slip-proof to at least one core. At least one other fiber 50 which lies essentially transversely to the longitudinal fiber structure 40 , or a fiber bundle holds the longitudinal fibers in the longitudinal fiber structure 40 unable to slip against one another, or mutually together. Furthermore the expression ‘fiber 50 ’ also always means a fiber bundle below.
The fiber 50 to the longitudinal fiber structure 40 is essentially transversely diagonal to the longitudinal fibers and runs at almost any angle to them, but generally however at an angle which is less than 45°. But it can also be an angle from 45° to 90° or exactly 90°. Special arrangements of the fiber 50 are described below.
Slipping of the jacket on the core is a known, but highly undesirable property in core ropes, as already described. The described structure, on the one hand with mixing of core and jacket fibers and on the other hand by binding to traverse fibers, can prevent any slippage and therefore can offer advantages.
Advantageously it runs uniformly when running over carabineers, rollers, and rope dispensers. Neither thickened sites nor thin sites occur, as is conventional in jacket slippage. These core ropes can be used in place of twisted ropes.
The fibers can be materials such as PBO, polyolefin, polyamide, polyester, Dyneema, Aramid, Vectran and Zylon for high-strength applications, Aramid, Nomex and monofil yarns for heat-resistant and flame-resistant applications, polypropylene, polyamide, polyester and monofil yarns for UV-resistant, polypropylene monofil yarns for floating applications, and polyamide, polyester and monofil yarns for cut- and shear-resistant applications.
Traverse fiber bundles comprise (e.g., consist of) monofil, multifil or staple fibers. They can be twined, twisted or processed as parallel fiber bundles. Mixed fibers of different fibers can also be used. Any combination of individual fibers is conceivable.
FIG. 2 shows the schematic structure of an exemplary cord. The cord 20 has a longitudinal fiber structure 40 made from fibers, yarns, and/or yarn strands. The individual yarn strands are surrounded or bound with at least one other fiber 50 or a fiber bundle. It lies roughly transversely to the longitudinal fibers. The connection of the longitudinal fibers by means of the other fibers 50 is made such that it runs in the traverse direction, diagonal direction or some other selected angle to the longitudinal fibers.
Under the longitudinal fibers there is at least one longitudinal thread, or a longitudinal fiber 41 which is surrounded or enclosed by the fiber 50 , the longitudinal thread or the longitudinal fiber 41 being held at a certain position within the longitudinal fiber structure 40 . The fiber 50 is routed back after this position such that it surrounds other individual longitudinal fibers of the longitudinal fiber structure 40 individually, partially or entirely, and holds them in position, or holds them essentially stationary among one another without the capacity to slip or move.
A primary function of the exemplary fibers 50 or of the fiber bundle lies in this binding process. Of course the same fibers after “binding” can be routed further to the next binding site, for which the fiber generally runs parallel to the longitudinal fibers; this is equivalent to “offset” of the binding points. This continued routing of the fibers 50 is a secondary function; for this reason the designation “essentially traverse” seems appropriate. With this one or several fibers 50 a surface which appears differently is formed or achieved. The individual yarn strands and fibers which are used for this purpose and which can be different in thickness, strength, and color are connected essentially immovably to the longitudinal fibers of the longitudinal fiber structure 40 .
A cord of this type looks similar to a conventional, twisted core, but can also have different materials and does not unravel or is resistant to unraveling; this can be a major advantage. Likewise it can be produced such that it looks similar to a braided cord. It can comprise (e.g., consist of) different fibers which are immovably connected against one another, but has higher strength with respect to a braided cord.
FIG. 3 shows a cord 20 with a further traverse fiber 50 placed around the longitudinal fibers of the longitudinal fiber structure 40 . The fiber 50 , lying outside, surrounds one of the longitudinal fibers 41 at at least two points, in order to then be guided away or back in the direction of the core center from the outer surface of the cord, and in order to later reach the surface again between two longitudinal fibers and to surround another longitudinal fiber 41 ′ or to be “wrapped” around it. The fibers 50 can be of different strength and extension. Some of the longitudinal fibers are made as so-called melt fibers which are melted with heat. Elastically made fibers can be likewise used.
FIG. 4 shows a core 20 with another traverse fiber 50 guided from the inside to the outside and from the outside to the inside. The fiber 50 runs over a larger part of the cord surface and is wrapped around the longitudinal fiber 41 . 1 of the longitudinal fiber structure 40 , routed to the inside, wrapped around the longitudinal fibers 41 . 2 and 41 . 3 and routed to the outside to the surface of the cord in order to be routed again around the longitudinal fibers 41 . 1 . The latter however takes place around the reverse direction. Each of the outside longitudinal fibers can assume the role of the longitudinal fibers 41 . 1 with respect to “wrapping”. The choice of the next longitudinal fibers can take place in a strict sequence as the next or according to any, even stochastic pattern. The same applies to the choice of one of the inside longitudinal fibers 41 . 2 or 41 . 3 , or one of the core fibers.
In this way the core fibers and the fibers and/or the yarn strands which form the jacket area are especially strongly bonded. A different stiffness or flexibility of the cords can be achieved in almost any way. Such a core is resistant to unraveling when cut.
FIG. 5 shows a cord with at least one high-strength longitudinal fiber. A cord 20 under the longitudinal fibers of the longitudinal fiber structure 40 has at least one other longitudinal fiber, or longitudinal thread 41 , 41 ′ which has much higher strength than the remaining longitudinal fibers. In this way extremely low stretching of the rope-like structure can be achieved. At the same time, the longitudinal threads 41 , 41 ′ form one or more sites 42 or areas within the longitudinal fiber structure 40 which have a much higher density and strength, by which also especially strong, reliable sewing 43 is enabled with low sewing loss. Moreover the sites 42 have less stretching.
FIG. 6 shows a first embodiment of a cord with several traverse fibers, or fiber bundles. A cord 20 has several traverse fibers 50 to the longitudinal fibers of the longitudinal fiber structure 40 or yarn strands. Under the longitudinal fibers of the longitudinal fiber structure 40 there is at least one longitudinal thread 41 , 41 ′ with much higher elasticity and/or extension at at least one location within the longitudinal fiber structure. For this reason such a cord acquires special elasticity and ease of bending. The longitudinal fibers comprise (e.g., consist of) polyester, the traverse fibers of polyamide. Each of the outside longitudinal fibers is surrounded every 0.3-1.5 mm by a fiber 50 or is bound by it.
Such a cord 20 can be characterized by higher stretching and/or elasticity. The damping properties of such a cord are especially high. This is the case especially when it is worked into a dynamic rope as one of the core cords. In this connection cords are processed as a “finished product” or as a longitudinal yarn, longitudinal cord or longitudinal fiber structure into a core rope.
FIG. 7 shows a second embodiment of a cord with several parallel fibers in the longitudinal direction. A cord 20 under the longitudinal fibers of the longitudinal fiber structure 40 has at least one other longitudinal fiber 44 which are present as so-called melt fibers in the core and/or in the jacket. The traverse fibers 50 are present here partially likewise as melt fibers 51 of polyamide. The longitudinal fiber structure comprises (e.g., consists of) polyester in addition to these melt fibers. In heat, i.e., during heat treatment in the course of the production process or after it, these fibers melt at several locations 45 with the longitudinal fibers, by which much higher abrasion resistance of the individual fibers or yarn strands among one another or in the jacket area is achieved. In this connection the melt fibers 44 and 51 fuse with the other longitudinal fibers at sites 45 . Moreover, the longitudinal fibers are present slip-proof after fusion. This results in much higher impregnation (for example with polyamide) and/or coating (polyamide).
FIG. 8 shows a third embodiment of a cord with outside melt fibers. A cord 20 under the longitudinal fibers of the longitudinal fiber structure 40 has other outside longitudinal fibers 46 which are made as melt fibers of polyamide PA 6 or polyamide PA 6.6 (Griion, Ems-Chemie, CH-7013 Domat/Ems). This yields an especially abrasion-resistant but flexible jacket after processing (among others, heat treatment). Other traverse fibers 50 are polyamide (melt fibers PA 6) which bind the longitudinal fibers every 2 mm in alternation.
The resulting cord properties are extremely high abrasion resistance and improved UV resistance. These cords can be used in rollers, winches, carabineers and clamps and have improved abrasion resistance.
One structure of a cord as described in FIG. 8 can also apply to a rope. In more general form the core and the jacket have the same or different longitudinal fibers of the longitudinal fiber structure 40 . The outside longitudinal fibers 46 can be made at least partially as melt fibers. One at least additional traverse fiber 50 surrounds the outside longitudinal fibers 46 or binds them. At the same time, at least one second additional traverse fiber 50 ′ is present as a melt fiber which surrounds the outside longitudinal fibers 46 , or binds them. Melting of the longitudinal fibers 46 with the second additional traverse fiber 50 ′ yields a fused jacket.
FIG. 9 shows a first embodiment of a core rope with an intermediate jacket and traverse additional fibers.
The core 3 has high-performance fibers in the core fiber structure 5 with fibers like polyamide (PA), polyester (PES), low-stretch polyester (PEN), Aramid, Dyneema, Vectran or Zylon. The intermediate jacket 8 comprises (e.g., consists of) so-called damping yarns such as monofil or elastic yarns which have a high compression property, while the jacket 4 comprises (e.g., consists of) jacket fibers in a jacket fiber structure 6 , such as polyester or polyamide, which have high abrasion resistance, cutting resistance or edge strength.
The high-performance fibers of the core fiber structure 5 and the jacket fibers of the jacket fiber structure 6 , also called longitudinal fibers of the longitudinal fiber structure 40 , are covered or looped by additional roughly traverse fibers 50 , some fibers 51 as entirely outside surrounding the longitudinal fibers, while other fibers 51 ′ surround the longitudinal fibers only in alternation, i.e., only every other outside longitudinal fiber is bound. Polyamide can be used as fibers 51 , 51 ′.
When at least one other fiber 50 has higher strength relative to the longitudinal fibers of the longitudinal fiber structure 40 and loops and binds the longitudinal fibers differently, a rope can be formed with higher bending strength and strength and thus higher stiffnes.
If the core comprises (e.g., consists of), for example, of high-strength Aramid fibers and one or in any case several jackets of heat-resistant Nomex fibers, the core rope is especially well suited for rescue applications as heat-resistant rope in firefighting and in the military.
Mixing or connection of the core fibers in at least one jacket area can be low, i.e. less than 3%. Here there need not be mixing of jacket fibers in the core area at the same time. But if this is the case, it is likewise considered low mixing, i.e. it is less than 3%. Core fibers are then in at least one jacket area, while jacket fibers are present connected in the core area. This applies to applications of currently used static and dynamic core ropes.
FIG. 10 shows a second embodiment of a core rope of the same materials of different thickness and strength. A core rope has longitudinal fibers 40 , the outside jacket fibers being thicker than the core fibers. The outside jacket fibers are bound with the other fibers 50 in alternation. This yields higher strength in the jacket area. The rope can also have a surface which is similar to a twisted rope. Core and jacket fibers consist of polyester and the traverse fibers comprises (e.g., consists of) polyamide.
The longitudinal fibers of the longitudinal fiber structure 40 are generally present mixed as core and jacket fibers, the jacket fibers forming part of the core and the core fibers forming part of the jacket. They are at the same time bound by at least one other fiber 50 with higher strength with respect to the longitudinal fibers, the other fibers having a different thickness, strength or extensibility.
FIG. 11 shows the schematic structure of a low-stretch rope. The rope comprises (e.g., consists of) individuals fibers, yarns or yarns strands as longitudinal fibers of the longitudinal fiber structure 40 , which are present or connected among one another such that the fibers, yarns or yarn strands are mutually slip-proof. At least one other traverse or crosswise running fiber 50 or fiber bundle binds the longitudinal fibers again and again, by which the longitudinal fibers are held mutually immovably, or stationary. In appearance it looks similar to a twisted or braided rope, but it has strength which is at least 10% higher in stretching behavior and knot strength at least 10% higher than conventional ropes. One positive property is that on the cut end it does not unravel or fringe. In this rope structure as many yarns as possible are present parallel or are additionally oriented or prestretched.
In these applications the fibers in the core area can be externally parallel and partially prestretched, while the fibers in the jacket area are arranged looping and thus are more flexible and resistant to abrasion and cutting and thus can also greatly increase UV resistance.
If at least one other fiber 50 has higher elasticity relative to the longitudinal fibers of the longitudinal fiber structure 40 and if it binds the longitudinal fibers, for a core of high-strength Aramid fibers and a jacket of heat-resistant Nomex fibers or abrasion-resistant, cut-proof and/or flame-proof, heat-resistant, acid-resistant or UV-resistant fibers and/or yarns, a typical firefighting rope results. Other typical applications can be found generally in rescue applications as a rope instead of steel cables, as a load rope with little alternate bending or as a replacement of twisted ropes.
But if the core has extremely high-strength fibers which are partially oriented or prestretched, and the jacket comprises (e.g., consists of) UV-resistant, abrasion-resistant and cut-resistant yarns and/or fibers, typical properties of a sailing sheet arise.
FIG. 12 shows a first embodiment of a cable with especially fall-damping properties.
A rope can also be produced claimed in the invention to be as fall-damping as possible from yarns which comprise (e.g., consist of) as many fibrils as possible and form a cord 20 , the core fiber structure being looped repeatedly with at least one other fiber 50 or a fiber bundle. Thus, for example a host of fibers 50 , different in material and properties, can be used to surround one or more of the cores according to any pattern.
These cords can be used in the core of a rope. Due to the good damping properties achieved, this structure can be suited for dynamic mountaineering ropes. Due to the good fall-damping properties here mainly yarns of polyamide, polyester or POY yarns are used.
FIG. 13 shows a rope with lettering. In a longitudinal fiber structure 40 by means of at least one additional fiber 50 or a fiber bundle lettering 52 has been worked into the outer surface of the structure continuously in the lengthwise direction of the rope. Good readability is greatly supported by a skillful choice of colors of the fibers 50 and/or individual longitudinal fibers.
In addition to lettering, there can be marking of any type and/or for example center marking of the rope. This working can also take place in the traverse direction or at any angle to the longitudinal direction of the rope.
FIG. 14 shows a rope with continuous marking. In the longitudinal fiber structure 40 , by means of at least one other fiber, continuous marking 53 has been worked into the outer surface of the structure of the rope. This is for example ring marking with continuous numbering. The surfaces of the intervals 54 ′, 54 ″ between the markings are identified like the markings 53 with a special choice of fibers 50 on the one hand and on the other by corresponding working into the structure of the surfaces. Thus, for example the surface of the interval 54 ′ appears crosshatched and that of the interval 54 ′ with broken lines lengthwise. This configuration of the rope surface can be advantageous and especially user-friendly.
FIG. 15 shows the schematic structure of a sailing sheet or an extremely static high-performance rope. Ropes which are similar in appearance to braided, twisted ropes or similar construction or design can be produced instead of conventional core-jacket constructions of static high-performance ropes with extremely low stretching so that the extremely high-strength, high-performance fibers in the core are very parallel and have much reduced extension and higher tearing resistance, and thus static properties can be improved even with the same or reduced diameters. These longitudinal fibers of the longitudinal fiber structure 40 can be prestretched or predrawn. The fibers of the jacket can yield considerably more abrasion-resistant, less moisture-sensitive and more cut-resistant properties, the core 3 and jacket 4 being connected to one another by one or more threads or other fibers 50 which run in the other direction, such that even with the most varied fiber properties there is no jacket slip or additional stretching.
FIG. 16 shows a rope with a cavity. A longitudinal fiber structure 40 in the core 3 has very high-strength, high-performance fibers with a much reduced stretching and higher tearing resistance which yield improved static properties even for the same or reduced diameters. These core fibers surround a cavity 55 which lies in the center of the core. The longitudinal fibers of the core, intermediate jacket and jacket are connected to one another by at least one other traverse fiber 50 such that jacket slip does not occur even with the most varied fiber properties. The intermediate jacket comprises (e.g., consists of) different or the same fibers as those of the core or jacket. This yields a soft-flexible structure which allows formation of a damping cushion or an air cushion under the jacket, and paired with abrasion-resistant, edge-strong, cut-proof fibers and fiber structures of the jacket has extremely improved edge strength. The fiber structure of the intermediate jacket has fine-structured, extremely small cavities or extremely small air bubbles. The cavity 55 is also called a “soft core middle point”. The construction is similar in appearance to braided ropes. Such a rope is especially cut-proof and is also especially well suited to rescue applications of any type.
FIG. 17 shows a rope with a change of cross section. A rope with an essentially round cross section 61 during the production process at at least one site 62 changes the cross section 63 to an oval or flat shape. At this point the rope can be for example better attached, sewn or clamped more easily. The cross section can change one time or repeatedly. Thus the oval shape can pass for example into a flat shape and later again into a round shape. The traverse fibers 50 , or fiber bundles repeatedly bind the longitudinal fibers so that the rope seems surrounded by them in the manner of a net.
Cords and ropes of this type can be sewn and need not be spliced; this is a great simplification in fabrication for end connections.
The disclosed ropes can also be produced which are similar in appearance to a turned rope and in the core area comprise (e.g., consist of) other extreme high-loading fibers such as high-strength Aramid fibers or Vectran, Zylon. The protective jacket can comprise (e.g., consist of) fibers and/or yarns which form UV protection or an especially abrasion-resistant jacket. At the cut site this rope can be sewn and therefore need not be spliced. Moreover this rope does not unravel at the cut site. The embodiments of these core ropes are extremely diverse and cannot be definitively enumerated here.
FIG. 18 shows a rope-like structure, a cord or a rope which have openings 64 , 64 ′, 64 ″ with slot lengths L in a predefined grid with spacing d. If the slot length L is roughly 3.5 times the diameter D of the undivided rope-like structure which is present braided as a ‘one-piece’, an especially advantageous arrangement arises. It becomes possible to loop back the one-piece through the openings 64 , by which one loop is formed on one end of the rope-like structure. Repeatedly looping back under tension yields compaction of the loop, the loop no longer be able to open, similarly to a spliced end. The grid can however also be selected arbitrarily, i.e., the distances d then follow one another irregularly.
FIG. 19 shows a rope-like structure with a looped-back end. The end 65 has been looped through the openings 64 , 64 ′ and 64 ″ and thus a loop has been formed which under tension has similar properties to those of spliced loops.
FIG. 20 shows a part of a rope-like structure with cross sections. The opening 64 and the undivided areas 66 ′ and 66 ″ of the rope-like structure which border it are apparent. The opening 64 and the areas 66 ′ and 66 ″ include the cross sections A-A, B′-B′ with cross section pictures A, B′ and B″. While the cross section pictures B′ and B″ indicate a round rope-like structure, for the cross section picture A a division and the resulting opening can be recognized.
FIG. 21 shows a cord as a rope-like structure with openings arranged in a grid for low-slip strings. The structure of the cord or string corresponds roughly to FIG. 18 . It is however designed for smaller diameters of 0.8-2.0 mm. The first sections 70 with the openings 64 , 64 ′ and 64 ″ are followed by second sections 71 in which the cord is present braided as an undivided, rope-like structure, or as a ‘one-piece’. The sections 70 and 71 follow one another in a certain given grid. A second cord 73 is located perpendicular to the first cord 72 horizontally and has been looped through the opening 64 of the first cord. The length L of the openings or slots has been selected such that the traverse cord in the tensioned state lies roughly in the middle. Likewise, the length of the sections 70 and 71 , i.e. the grid dimension, is matched primarily to the dimension of the slots and secondarily to the tension regions and the materials used. The grid fluctuates for example from 3-30 mm, i.e. the slots follow one another at these intervals.
The second core 73 is arranged essentially perpendicularly to the first cord 72 . It adjoins it and forms part of the strings. But strings can be used which allow the free spaces between the cords to appear as lozenges.
These arrangements of cores or strings are suited for stringing of any type, for example for games which use balls such as tennis, badminton, squash or golf. Due to this arrangement the cords or strings can hardly move even under extremely high frictional pressure or impact pressure. In this way improved tensioning of the racket surface can be achieved upon ball contact. The first and second cords can be, for example, generally of identical structure.
FIG. 22 shows a cord with thickened areas arranged in a grid for low-slip strings. The cord structure corresponds roughly to FIG. 21 . The sections 70 and 71 follow one another in the first and second cords 74 , 75 or strings. In the sections 71 the cord is made as an undivided rope-like structure, braided as a ‘one-piece’. In sections 70 the cords have thickened areas 76 which are up to twice the diameter of the cord diameter in section 71 . In this arrangement the lengths of the sections 70 and 71 and the grid size are matched to the tension ranges and the materials used. The grid fluctuates for example from 3-30 mm, i.e. the slots follow one another at these distances. The cords 74 , 75 are essentially perpendicular to one another, in the tensioned state the middle regions of the sections 71 adjoining one another and forming part of the stringing.
These arrangements of cords or strings are suited for strings of any type, for example for games which use balls such as tennis, badminton, squash or golf. The cords or strings can only move insignificantly due to this arrangement even under extremely high frictional pressure and impact pressure. In this way improved tensioning of the racket surface is achieved upon ball contact. The first and second cords can be, for example, generally of identical structure in this version.
Core ropes claimed in the invention are used in industrial safety, in water sports, sailing and mountain climbing, and also in the police, fire department and military.
The disclosed ropes and cords can be used for recreation and hobbies, primarily as a replacement of braided or turned ropes.
It will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.
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A rope-like structure, such as a core-spun rope, a cord or a rope, disclosed wherein the individual fibers, threads, strands and/or cords are provided in the form of longitudinal fibers of a longitudinal fiber structure which are joined to another fiber which extends in a substantially crosswise manner or at any particular angle in relation to the longitudinal fibers, such that the longitudinal fibers of the longitudinal fiber structure are mutually non-slip and essentially cannot move backwards in relation to each other, wherein the other fibers are untied, at least on one occasion, in relation to the longitudinal fibers and the latter are thus retained thereby.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/742,627, filed on Aug. 15, 2012, the entire teachings of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Pneumatic-actuated tools, sometimes referred to as “air” tools, are a type of power tool common at construction sites. Pneumatic tools are a category of power tools actuated by compressed air, usually supplied by a gas or electric compressor, delivered to the pneumatic tool by way of an air hose. Examples of pneumatic tools include nail guns, impact wrenches, and drills. Pneumatic fittings on both the air hose and the pneumatic tool enable connecting and disconnecting on demand. Typically, pneumatic tools are equipped with a male fitting component that mates with a female fitting on the end of the air hose. These pneumatic fittings can be attached and disconnected without the use of tools.
[0003] Pneumatic tools, because of their remote air supply, are easily carried by a worker to various locations around a job site, often switching to a new supply of compressed air at each location. It is also common for the worker with a pneumatic tool, such as a nail gun, to climb ladders or traverse joists while carrying the pneumatic tool in order to reach a location where the pneumatic tool is needed. For example, during the construction of a roof with asphalt tiles, a worker may climb one or more ladders to reach the roof and subsequently traverse various sections of the roof while placing asphalt tiles at the various sections and affixing the asphalt tiles with nails driven by a pneumatic nail gun.
[0004] A worker usually keeps a pneumatic tool in one or both hands while working on a jobsite, but must place the tool on a surface or otherwise suspend it from the worker's belt or a nearby fixture to use both hands freely or to change to a second pneumatic tool. Using a second pneumatic tool may also require detaching the pneumatic hose from the first tool and reattaching the pneumatic hose to the second tool. Workers commonly use pneumatic tools while at the top of a ladder to insert roofing nails on the roof of a building to secure roofing tiles or in other typically dangerous environments. In such dangerous situations, the worker is both safer and more efficient when able to easily stow the pneumatic tool and use both hands where necessary.
SUMMARY OF THE INVENTION
[0005] Embodiments of the present invention provide a universal quick-change hook designed to accept two (input and output) pneumatic fittings. With an attached pneumatic fitting, the universal quick-change hook is configured to attach to an existing pneumatic fitting on a pneumatic tool. When attached, the universal quick-change hook allows a worker to easily stow or support the pneumatic tool from a wide variety of shapes and objects with the universal quick-change hook while also protecting the pneumatic fitting from accidental disconnection. The universal quick-change hook also includes a hook stop to protect a quick-release mechanism of an attached pneumatic fitting from being accidently struck by an object when the universal quick-change hook is placed on that object to support the attached pneumatic device while also providing attachment and support functions, such as to fixtures or belts, for the pneumatic tool and pneumatic hose. The hook stop of the universal quick-change hook reduces that risk that a pneumatic tool will fall from an elevated support and cause an injury and/or damage to the tool.
[0006] An example embodiment of the present invention is a universal quick-change hook, comprising a main body having a first end and a second end, a fitting interface region at the first end of the main body, a fitting extension region adjacent to the fitting interface region in a direction of the second end of the main body, and a fitting bend located at an intersection of the fitting interface region and the fitting extension region. The fitting bend defines an inside surface of the main body and an outside surface of the main body. The universal quick-change hook also has a hook region, adjacent to the fitting extension region, and a hook stop, projecting from the inside surface of the main body, at an intersection of the fitting extension region, and the hook region.
[0007] Other embodiments may include a pneumatic fitting coupled to the main body in the fitting interface region in an orientation enabling a direction of airflow though the pneumatic fitting perpendicular to the main body at the fitting interface region, the pneumatic fitting having and inlet and an outlet with flow path therebetween.
[0008] In some embodiments, the outlet of the pneumatic fitting is a push-type coupler, and the hook stop is arranged to protect the push-type coupler. A pneumatic hose may be connected to the inlet of the pneumatic fitting or the outlet of the pneumatic fitting. In one embodiment, the hook stop extends to a location between the push-type coupler and a location of a hook-side end of a tool, employing a standard corresponding fitting, coupled to the push-type coupler. The tool may be pneumatic-actuated tool.
[0009] In some embodiments, the hook stop projects from the inside surface of the main body between −20 and 20 degrees off perpendicular from a planar surface of the fitting interface region.
[0010] In one embodiment, the hook stop has a proximal end at the main body and a distal end distal from the main body, and wherein the hook stop includes a barb at the distal end. In some embodiments, the hook stop is between 0.5 and 2 inches in length.
[0011] In another embodiment, the angle of the fitting bend is between 30 and 80 degrees with respect to a planar surface of the fitting interface region.
[0012] In some embodiments, the main body of the universal quick-change hook may include a taper at the second end of the main body. In one embodiment, the hook region includes a taper bend, the taper bend defined by an angle greater than 180 degrees with respect to the inside surface of the main body.
[0013] In another embodiment, the main body of the universal quick-change hook includes a hook bend, the hook bend located at an intersection of the fitting extension region and the hook region, the hook bend defined by an angle less than 180 degrees with respect to the inside surface of the main body.
[0014] In some embodiments, the fitting extension region includes a nail hanging hole defined by the main body and extending through the main body. The nail hanging hole may have a subhole smaller in diameter than a head of a nail from which the universal quick-change hook is to be suspended. The hook region may be configured to support the main body against a structure to which a nail is attached when the nail hanging hole of the main body is placed around the nail. The main body at the hook region may define a wrench hole, and the wrench hole may be a hex opening.
[0015] Another embodiment of the present invention is an anchor assembly with an anchor pneumatic fitting. The anchor pneumatic fitting has a mating port gender opposite from a mating port gender of a pneumatic fitting to be coupled thereto. The anchor assembly may be configured to be coupled to a utility belt.
[0016] In yet another embodiment, a utility belt comprises an attached anchor, where the attached anchor provides a fitting for attaching a device or hose having a corresponding mating fitting. The anchor may be a pneumatic fitting for attaching a pneumatic tool or a universal quick-change hook with the mating fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
[0018] FIG. 1 is a diagram showing an embodiment of the present invention in an example environment in which a pneumatic tool, such as a nail gun, is employed.
[0019] FIG. 2 is a diagram illustrating of an embodiment of the present invention supporting a pneumatic tool on a tool belt.
[0020] FIG. 3 is a profile view of an embodiment of the present invention.
[0021] FIGS. 4A-C are angular views of an embodiment of the present invention.
[0022] FIG. 5 is diagram illustrating of an embodiment of the present invention supported by a nail protruding from a surface.
[0023] FIG. 6 is a mechanical schematic diagram illustrating an embodiment of the present invention attached to a utility belt using an anchor fitting.
[0024] FIGS. 7A and 7B are illustrations of the utility belt and pneumatic fitting anchor used with embodiment of the present invention.
[0025] FIG. 8A is a diagram illustrating the operation of an embodiment of the present invention being connected to a pneumatic hose and the pneumatic tool of FIG. 3 .
[0026] FIG. 8B is a diagram illustrating the operation of an embodiment of the present invention being connected to the pneumatic fitting anchor and utility belt of FIG. 6 .
[0027] FIGS. 9A and B are diagrams illustrating an embodiment of the present invention supporting a pneumatic tool from various objects.
DETAILED DESCRIPTION OF THE INVENTION
[0028] A description of example embodiments of the invention follows.
[0029] Traditionally, pneumatic tools do not include any shape or structure designed to support the pneumatic tool from a utility belt or common features found in environments where pneumatic tools are typically used. To a limited degree, a pneumatic tool can be suspended from an attached air hose, or the handle can be balanced on a wall, but such positions are potentially dangerous and require careful balance to ensure equipment does not fall and strike a person working below. After-market hooks provide additional ways for pneumatic tools to be supported, and typical after-market hooks are connected between the tool and the male pneumatic fitting used for connecting the pneumatic tool to an air supply. However, changing after-market hooks of the typical design is an impractically long process in the typical, fast-paced, construction environment. For example, today's after-market hooks require a tool's pneumatic fitting to be unscrewed from a threaded connecting to the tool and, in doing so, require a reapplication of a sealing tape, e.g., Teflon tape, to maintain an air-tight connection.
[0030] FIG. 1 is a diagram showing an embodiment of the present intention in an example environment, such as a roofing worksite environment. In the environment, a worker 10 is positioned on an extension ladder 20 with rail guides 21 a - b . The ladder is positioned to reach a roof 30 of a house 40 and the worker 10 is using two hands to support himself against the ladder 20 . A nail gun 120 is suspended from a rail guide 21 a within reach of the worker 10 by way of a universal quick-change hook 100 , which has features of an embodiment of the present invention. The universal quick-change hook 100 is attached to the nail gun's 120 pneumatic fitting 121 by way of a corresponding pneumatic fitting 130 b attached to the universal quick-change hook 100 .
[0031] During use of the nail gun 120 , an air hose 150 delivers compressed air to the nail gun 120 , allowing the worker 10 to drive nails (not shown) into roofing tiles (not shown), for example. The universal quick-change hook 100 is attached to a pneumatic fitting 151 on the end of the air hose 150 by way of a corresponding pneumatic fitting 130 a attached to the universal quick-change hook 100 . The corresponding pneumatic fitting 130 b attached to the nail gun 120 is positioned opposite the corresponding pneumatic fitting 130 a attached to the air hose 150 , such that both fittings 130 a and 130 b are connected to each other through the universal quick-change hook 100 and provide a flow path (not shown) for compressed air to power the nail gun 120 .
[0032] The universal quick-change hook includes a hook stop 104 to prevent the rail guide 21 a from reaching the connected pneumatic fittings 130 b and 121 . The hook stop 104 enables the universal quick-change hook 100 to support the nail gun 120 from the rail guide 21 a without the rail guide's 21 a affecting a quick-release mechanism on the pneumatic fitting 130 b or otherwise influencing the connection between the universal quick-change hook 100 and the nail gun 120 . Additionally, the hook stop 104 positions the universal quick-change hook 100 and attached nail gun 120 at a given position with respect to the rail guide 21 a . In this example, the universal quick-change hook 100 provides the worker 10 the ability to use a common feature found in environments where pneumatic tools are typically used, i.e., a rail guide 21 a of an extension ladder 20 , to support a nail gun 120 whenever the worker needs to have both hands free. In other example environments, a worker 10 can hang a nail gun 120 with an attached universal quick-change hook 100 from a loop on a utility belt (shown in FIG. 2 ), a beam or joist, or an edge of a surface.
[0033] The universal quick-change hook 100 can be disconnected from the pneumatic tool 120 and pneumatic hose 150 and used with different pneumatic tools and hoses or enabling the universal quick-change hook 100 to stay with the same pneumatic tool or hose. The flexibility of association is used for most jobsites and for the individual worker.
[0034] FIG. 2 is a diagram illustrating of an embodiment of the present invention supporting a pneumatic tool 204 on a tool (or utility) belt 260 . A nail gun 220 is suspended from a metal loop 261 on the utility belt 260 with a universal quick-change hook 200 . Utility belts 260 are commonly used to carry tools and often have metal loops 211 to support hammers or other tools too large to fit in pouches attached to the belt 260 . To attach to pneumatic tools, the universal quick-change hook 200 has a fitting interface region 201 with a male pneumatic fitting 230 a and a female pneumatic fitting 230 b . The female pneumatic fitting 230 b has a push-type quick release collar. The pneumatic fittings 230 a - b are connected through the fitting interface region 201 via a common flow path axially through the pneumatic fittings 230 a - b to allow compressed to be supplied to the pneumatic tool 220 with the universal quick-change hook 200 attached.
[0035] The nail gun 220 is powered by compressed gas provided through a male pneumatic fitting 221 . Using this existing male attachment fitting 221 , the universal quick-change hook 200 is attached to the nail gun 220 with the corresponding female pneumatic fitting 230 b . The universal quick-change hook 200 supports the nail gun 220 on the metal loop 211 with a hook region 203 and a hook stop 204 .
[0036] The hook stop 204 prevents the metal loop 261 of the utility belt 260 from reaching the female pneumatic fitting 230 b . This prevents accidental release of the female pneumatic fitting 230 b from the nail gun's 220 pneumatic fitting 221 from the metal loop's 211 striking the release collar 231 of the female pneumatic fitting 230 b . To ensure that the metal loop 261 cannot reach the female pneumatic fitting 230 b and to keep the universal quick-change hook 200 on the metal loop 261 , a barb 205 is provided on the end of the hook stop 204 to prevent the metal loop 261 from sliding off the edge of the hook stop 204 . The hook region 203 is separated from the fitting interface region 201 by a fitting extension region 202 . The fitting extension region 202 positions the hook region 203 away from the pneumatic fittings 203 a - b and any attached pneumatic tool 220 .
[0037] The hook region 203 in combination with the hook stop 204 allows the universal quick-change hook 200 to be suspended from a wide variety of support members. For example, the universal quick-change hook 200 with attached nail gun 220 can be supported by a beam of wood, such as the short side of a typical 2×4 beam, or the hook region 203 can rest against a flat board while the nail gun 220 leans over the edge. Generally, any support member with a width less than the distance between the nail gun 220 and the hook region 203 can support the universal quick-change hook 200 . If the support member is of a width less than the distance of the hook region 203 to the nail gun 220 , the weight of the attached nail gun 220 is entirely supported by the universal quick-change hook 200 .
[0038] In this example embodiment, the universal quick-change hook 200 enables a worker (not shown) wearing a typical utility belt 260 with a metal loop 261 to easily support a nail gun 220 attached to the universal quick-change hook 200 from the metal loop 261 of the worker's utility belt 260 . In operation, the hook region 203 of the universal quick-change hook 200 is placed inside the metal loop 261 , and the weight of the universal quick-change hook 200 and attached nail gun 220 rests against the hook region 203 , the hook stop 204 , or both.
[0039] FIG. 3 is a profile view of an embodiment of the present invention. A universal quick-change hook 300 , with an outside surface 310 a and an inside surface 310 b , is shown with pneumatic fittings 330 a - b connected to a fitting interface region 301 . Washers 331 a - b allow the pneumatic fittings 330 a - b with threaded fasteners to be screwed together against the fitting interface region 301 . The universal quick-change hook 300 has a fitting bend 311 at the intersection of the fitting interface region 301 and the fitting extension region 302 . A hook bend 312 is provided at the interface of the fitting extension region 302 and the hook region 303 . The hook region 303 terminates with a tapered region 306 and a tapered bend 313 . The tapered bend 313 is defined by an angle greater than 180 degrees with respect to the inside surface 310 b of the universal quick-change hook 300 . In this illustration, the hook stop 304 protrudes from a point on the universal quick-change hook 300 near the hook bend 312 .
[0040] For a typical sized embodiment, the hook stop 304 can range between 0.5 and 2 inches in length, depending on the angle of the fitting bend 311 and length of the fitting extension region 302 . The dimensions can be modified for different sized embodiments or different angles of the hook stop 305 . The hook stop 304 is positioned to terminate between the female pneumatic fitting 330 b and an attached pneumatic tool (not shown). The hook stop 304 has a barb 305 at the free end to prevent a support means (not shown) from sliding between the hook stop 304 and the attached pneumatic tool. The universal quick-change hook 300 can be made out of steel, plastic, or any other material sufficiently strong to support the weight of an attached pneumatic tool.
[0041] FIGS. 4A-C are angular views of an embodiment of the present invention. A universal quick-change hook 400 is shown with a nail hole 407 in the fitting extension region 402 and a wrench tool 407 in the hook region 403 . In other embodiments, the nail hole 408 can be any through-hole in the universal quick-change hook 400 that allows the universal quick-change hook 400 to be suspended against a surface having a protruding nail (not shown), as shown in FIG. 5 .
[0042] The nail hole 408 may have a smaller subhole (not shown) having a diameter smaller than a nail of the nail head from which the universal quick-change hook 400 is to be suspended to prevent the universal quick-change hook 400 from accidentally sliding off the nail. The wrench tool 407 is shown in FIG. 4 as a protrusion from the hook region 403 having a hex socket indentation; in other embodiments, the wrench tool 407 is out of the hook region 403 as an opening having a hex socket profile or other wrench profile.
[0043] FIG. 5 is diagram illustrating of an embodiment of the present invention attached to a surface 550 having a protruding nail 551 . The universal quick-change hook 500 has a nail hole 508 through the fitting extension region 502 . The universal quick-change hook 500 is suspended from the nail 551 by way of the nail hole 508 . The weight of the universal quick-change hook 500 and any device coupled to a fitting 530 attached to a fitting interface region 501 of the universal quick-change hook 500 is supported by the nail 551 through the nail hole 508 and the hook region 503 where the universal quick-change hook 500 makes contact with the surface 550 . FIG. 5 shows the hook region 503 of the universal quick-change hook 500 having a tapered region 506 making contact with the surface 550 .
[0044] As described above in reference to FIGS. 4A-C , the nail hole 508 may have a subhole to allow the nail 551 to slide upward relative to the nail hole 508 after the head of the nail 551 has passed through the nail hole 508 .
[0045] FIG. 6 is a mechanical schematic diagram illustrating an embodiment of the present invention attached to a utility belt using a pneumatic fitting anchor. A pneumatic fitting anchor 640 is provided on a utility belt 660 . The pneumatic fitting anchor 640 connects a fitting 641 to the utility belt 660 . A universal quick-change hook 600 is shown having a male pneumatic fitting 630 a and a female push-type pneumatic fitting 630 b , where the male fitting 630 a is attached to the fitting interface region 601 of the universal quick-change hook 600 with a single washer 631 . The female push-type pneumatic fitting 630 b is connected to the male pneumatic fitting 641 of the pneumatic fitting anchor 640 on the utility belt 660 . In this configuration, the universal quick-change hook 600 is a support device enabling a utility belt 660 to support objects (not shown) hung from the universal quick-change hook 600 . FIG. 6 also shows the universal quick-change hook 600 having an integrated socket wrench 607 .
[0046] It should be understood that tools or hoses having mating fittings corresponding to the fitting 641 of the utility belt 660 can be connected directly to the utility belt 660 without need for the universal quick-change hook 600 .
[0047] FIGS. 7A and 7B are illustrations of the utility belt and pneumatic fitting anchor used with embodiments of the present invention. FIG. 7A shows a pneumatic fitting anchor 740 having a fitting 741 connected to a belt anchor 742 by a support member 743 . FIG. 7B shows the pneumatic fitting anchor 740 of FIG. 7A connected to a utility belt 710 . The belt anchor 742 secures the pneumatic fitting anchor 740 to the material of the utility belt 710 and fitting 741 .
[0048] FIG. 8A is a diagram illustrating the operation of an embodiment of the present invention being connected to a pneumatic hose and a pneumatic tool. In operation of one embodiment of the present invention, a universal quick-change hook 800 is connected to both a pneumatic tool 820 and an air hose 850 . The universal quick-change hook 800 has attached pneumatic fittings 830 a - b for connecting to both the pneumatic tool 820 and the air hose 850 . Typically, pneumatic tools have a male pneumatic fitting 821 protruding from an end of a main handle 825 . This male pneumatic fitting 821 is coupled to a corresponding female pneumatic fitting 830 b on the universal quick-change hook 800 by pushing the fittings together along a concentric path 891 . When coupled, the hook region 803 of the universal quick-change hook 800 is positioned adjacent and offset from the handle 825 of the pneumatic tool 820 . A hook stop 804 provides a third surface between the hook region 804 and the handle 825 and prevents an object (not shown) placed against the hook region 804 or between the hook region 804 and the handle 825 , such as a belt loop (as shown in FIG. 2 ), from reaching the female pneumatic fitting 830 b and causing an accidental disconnect of a quick release mechanism on the pneumatic fitting 830 b.
[0049] Additionally, the male pneumatic fitting 830 a of the hook universal quick-change hook 800 is connected with the female pneumatic fitting 830 b such that the universal quick-change hook 800 does not restrict airflow between them, allowing for compressed air to be delivered from the air hose 850 to the pneumatic tool 820 when both are connected to the corresponding fittings 830 a - b of the universal quick-change hook 800 . To connect to the male pneumatic fitting 830 a of the universal quick-change hook 800 , the air hose is fitted with a female pneumatic fitting 851 at one end. The female pneumatic fitting 851 is coupled to the corresponding male pneumatic fitting 830 a on the universal quick-change hook 800 by pressing both fittings together along a concentric path 892 . Once the air hose 850 is connected to the universal quick-change hook and the universal quick-change hook 800 is connected to the pneumatic tool 820 , the pneumatic tool 820 and the air hose 850 can be individually disconnected from the universal quick-change hook 800 by disconnecting only pneumatic fitting 851 or 830 b , respectively.
[0050] FIG. 8B is a diagram illustrating the operation of an embodiment of the present invention being connected to the pneumatic fitting anchor and utility belt of FIG. 6 . In operation of one embodiment of the present invention, the universal quick-change hook 800 is connected to a pneumatic anchor 840 on a utility belt 860 having a male pneumatic fitting 841 . The universal quick-change hook 800 has an attached female pneumatic fitting 830 b for connecting the corresponding male pneumatic fitting 841 of the pneumatic anchor 840 . The female pneumatic fitting 830 b of the universal quick-change hook 800 is coupled to the corresponding male pneumatic fitting 841 on the pneumatic anchor 840 by pressing both fittings together along a concentric path 893 . Once connected, the universal quick-change hook 800 is stowed on the utility belt 860 , and the hook region 803 and hook stop 804 may be used together as a versatile support means for objects able to fit between the hook region 803 and the pneumatic anchor 840 .
[0051] FIGS. 9A and B are diagrams illustrating an embodiment of the present invention supporting a pneumatic tool from a wooden beam ( FIG. 9A ) and a metal rod ( FIG. 9B ). FIG. 9A shows a nail gun 920 with a pneumatic fitting 921 connected to of a corresponding female pneumatic fitting 930 b on a universal quick-change hook 900 . The universal quick-change hook 900 has a male pneumatic fitting 930 a connected to the female pneumatic fitting 930 b that is supporting the nail gun 920 . The nail gun 920 can be delivered compressed air though fittings 930 a - b . The universal quick-change hook 900 is supporting the nail gun 920 against a wooden beam 991 , which could be a common 2×4. The hook stop 904 of the universal quick-change hook 900 is resting against the wooden beam 991 and the universal quick-change hook is further held in place by the hook region 903 of the universal quick-change hook 900 The hook region 903 prevents the universal quick-change hook 900 from sliding off the wooden beam 991 .
[0052] FIG. 9B shows a nail gun 920 with a pneumatic fitting 921 attached to a universal quick-change hook 900 by way of a corresponding female pneumatic fitting 930 b . The universal quick-change hook 900 has a male pneumatic fitting 930 a connected to the female pneumatic fitting 930 b that is supporting the nail gun 920 such that the nail gun 920 can be delivered compressed air though fittings 930 a - b . The universal quick-change hook 900 is supporting nail gun 920 against a metal rod 992 . The hook stop 904 of the universal quick-change hook 900 and hook region 903 of the universal quick-change hook 900 are resting against the metal rod 992 .
[0053] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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Pneumatic tools are staple elements of constructions sites. Pneumatic tools are often hand-carried to specific locations and balanced on an available surface or between the knees of a worker while the worker uses two hands for related activities. A universal quick-change hook according to an embodiment of the invention can be coupled between fittings of a pneumatic tool and pneumatic hose without obstructing airflow though the fittings and provides a hook stop to protect fittings attached to the universal quick-change hook, preventing accidental activation of a connection release. The universal quick-change hook is configured to support the weight of an attached tool from a wide variety of different support means, such as a ladder, lumber stock, nail, or utility belt. The universal quick-change hook provides a worker with a convenient way to secure a hook to pneumatic tools in rapid fashion to be more efficient and competitive on a jobsite.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of copending application Ser. No. 09/298,433, filed Apr. 23, 1999.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH & DEVELOPMENT
[0002] The U.S. Government may have certain rights in this invention pursuant to Contract No. DEAC05-96-OR-22459, awarded by the U.S. Department of Energy.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to a method for treating contaminated soils and ground waters. In particular, the invention relates to treating soil that is contaminated with halogenated hydrocarbons, such as halogenated hydrocarbons in aqueous compositions.
[0004] Halogenated hydrocarbons, such as chlorinated hydrocarbons, are also known as chlorinated solvents (hereinafter collectively referred to as “chlorinated solvents”). Halogenated hydrocarbons have low flammability and are fairly stable, both chemically and biologically. They are commonly used in industry as chemical carriers and solvents, paint removers, and cleaners. The cleaning applications typically include metal degreasing, circuit board cleaning, metal parts cleaning, and dry cleaning. Chlorinated solvents are also used as intermediates in chemical manufacturing and as carrier solvents for pesticides and herbicides.
[0005] Chlorinated solvents are stable compounds, are relatively toxic at low levels, and many chlorinated solvents have been classified as suspected or confirmed carcinogens. Chlorinated solvents are among prevalent contaminants in ground water and soil because of their widespread use and stability. Ground waters and soils have become contaminated by chlorinated solvents from various sources. These sources include, but are not limited to, disposal facilities, chemical spills, and leaking underground storage tanks. Chlorinated solvents also may be released to the environment through the use, loss, or disposal of a neat liquid, and alternatively through the use or disposal of wash and rinse waters containing residual solvents.
[0006] Movement and dispersion of chlorinated solvents in the subsurface soils and ground waters vary depending on whether the solvents are released as a neat liquid or in a dissolved form. If released in a dissolved form, chlorinated solvent migration is governed largely by hydro-geological conditions and processes. The presence of solubilizing agents, such as soaps from wash waters, counteracts natural soil sorption-retardation mechanisms for chlorinated solvents, and enhances migration of the chlorinated solvents.
[0007] If chlorinated solvent is released as a neat liquid, the chlorinated solvent migrates through soil under the force of gravity. A portion of the chlorinated solvent is typically retained in soil pores. If sufficient chlorinated solvent is present in the soil, the soil pores become saturated. Additional chlorinated solvent continues to migrate in the soil until it encounters a physical barrier or a water table. If the chlorinated solvent encounters a water table, the chlorinated solvent disperses until it encounters, accumulates, and overcomes the water table's capillary forces. At this point, the chlorinated solvent, which has a greater density than water, penetrates the water table's surface. The chlorinated solvent migrates under the force of gravity until its amount has been diminished through sorption, or until the chlorinated solvent encounters an aquitard.
[0008] In recent years, soil and ground water contamination by chlorinated solvents has become an environmental problem. Chlorinated ethylenes, such as trichloroethylene (TCE), tetrachloroethylene (commonly known as perchloroethylene (PCE)), and chlorinated ethanes, such as 1,1,1-trichloroethane (TCA), which have been used as degreasing agents in a variety of industrial applications, pose environmental problems. Even though chlorinated degreasing agent use was curtailed in 1976, improper storage and uncontrolled disposal practices have resulted in contamination. Due to the high water solubility of chlorinated solvents, for example about 1100 mg/L TCE at 25° C., chlorinated solvents are highly mobile in soils and aquifers, and should be removed before dispersing too far. Therefore, a treatment to remove chlorinated solvents from contaminated soil and ground water is needed.
[0009] A pump-and-treat method is a proposed treatment method removing contaminants from contaminated ground water. The treatment usually involves withdrawing contaminated water from a well, volatilizing the contaminants in an air stripping tower, and adsorbing vapor-phase contaminants into granular-activated-carbon (GAC). There are limitations to this pump-and-treat method. The method is relatively inefficient, and some sites can require treatment for extended periods of time.
[0010] Chlorinated solvents can be degraded into less harmful materials by a method commonly referred to as “reductive dechlorination,” in which chlorine is replaced by hydrogen. The reductive dechlorination uses metallic, solid reaction elements, such as iron and zinc, to degrade chlorinated solvents and other organic compounds. For example, Gillham, U.S. Pat. No. 5,266,213, discloses feeding contaminated ground water through a trench containing iron to degrade contaminants. The Gillham process is conducted under strict exclusion of oxygen and occurs over a long time period. The Gillham process often requires large amounts of iron for complete reaction. Furthermore, it is difficult to introduce large volumes of solid reaction material, such as iron, using the Gillham process at effective depths for in situ remediation.
[0011] Clarke et al., U.S. Pat. No. 5,861,090, discloses a method that electrochemically remediates soil, clay, or other organic-polluted, contaminated media. The Clarke process remediates contaminated media using Fenton's Reagent. In Clarke, anodes and cathodes are provided in wells, which are disposed in the contaminated media. Anolyte and catholyte solutions are circulated in the contaminated media to deliver ions, such as iron ions, to anodes and to deliver ions, such as peroxide ions, to cathodes. A potential difference is applied across the contaminated media and causes the peroxide and iron ions to migrate toward each other through the contaminated media. The organic pollutants are destroyed by reactions with the ions. While Clarke teaches possible contaminated content monitoring and adjusting steps, Clarke does not disclose control of potential difference in response to contaminant content monitoring.
[0012] Therefore, a controllable process that effectively treats contaminated soils and ground waters compositions is needed, particularly for controlling a potential difference applied to the contaminated media. Further, the process should enable control of potential difference in response to contaminant content monitoring.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method for treating contaminated media. The method comprises introducing remediating ions consisting essentially of ferrous ions, and being peroxide-free, in the contaminated media; applying a potential difference across the contaminated media to cause the remediating ions to migrate into contact with contaminants in the contaminated media; chemically degrading contaminants in the contaminated media by contact with the remediating ions; monitoring the contaminated media for degradation products of the contaminants; and controlling the step of applying the potential difference across the contaminated media in response to the step of monitoring.
[0014] In another embodiment of the present invention, a method for treating contaminated media comprises determining a chlorinated hydrocarbon content of the contaminated media by sampling and analysis; introducing remediating ions being peroxide free, at an electrode disposed proximate the contaminated media; applying a potential difference across the contaminated media between electrodes to cause the remediating ions to migrate into contact with chlorinated hydrocarbons in the contaminated soil region; chemically degrading contaminants in the contaminated media by contact with the remediating ions to produce chloride ions; determining a chloride ion content; and controlling the step of applying the potential difference, the step of controlling being in response to the chloride ion content.
[0015] In a further embodiment of the present invention, a method for treating a contaminated media includes the steps of introducing ferrous ions, said ions being peroxide-free, at an iron-containing anode disposed proximate the contaminated media; applying a potential difference across the contaminated media between at least one cathode and the iron-containing anode that are disposed proximate the contaminated media to cause the remediating ions to migrate into contact with contaminants in the contaminated media.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a flow chart of a method for controllably treating contaminated media;
[0017] [0017]FIG. 2 is a schematic representation of a system for migrating a remediating salt into at least a portion of a zone; and
[0018] [0018]FIG. 3 is a graph of accumulated mass of trichloroethylene (TCE) input and collected chloride (chloride out) versus time according to a method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention comprises a method for controllably treating contaminated media, such as, but not limited to, at least one of contaminated soil and contaminated ground water. The following description will refer to “contaminated media,” and includes contaminated soil, contaminated ground water, and combinations, mixtures and suspensions thereof. The description of the present invention refers to chlorinated solvents. The scope of the present invention includes contaminants comprising, but not limited to, chlorinated solvents, chlorinated hydrocarbons; halogenated hydrocarbons; chlorinated ethylenes, such as trichloroethylene (TCE), tetrachloroethylene, commonly known as perchloroethylene (PCE); chlorinated ethanes, such as 1,1,1-trichloroethane (TCA); combinations and mixtures thereof.
[0020] The method for controllably treating contaminated media, as embodied by the present invention, will be described with reference to the flow chart of FIG. 1. The method comprises disposing (also known in the art as “emplacing”) electrodes in the contaminated media in step S 1 . The electrodes comprise at least one anode and at least one cathode. Alternatively, the electrodes are disposed around the contaminated media. In the following description of the present invention, the electrodes are described as “proximate” the contaminated media, which means that the electrodes are disposed in the contaminated media, are disposed around the contaminated media, or are disposed in and around the contaminated media.
[0021] In an exemplary method, electrodes are disposed in the contaminated media by disposing a cathode at a first location, such as an end of the contaminated soil region. An anode is located at an opposite end of the of the contaminated soil region. Therefore, ion flow can be created between the cathode to the anode across the contaminated soil region.
[0022] At least one of the anodes and cathodes comprise an iron-containing material. For example, an anode is formed as an iron anode. As used herein, the term “cathode” and the term “anode” are used in the singular, however the terms can mean a single electrode or a plurality of electrodes. The electrodes are disposed at approximately the same plane or level, for example, the same horizontal, vertical, or diagonal level. The levels depend on whether the contaminated-media treatment zone is disposed vertically, horizontally, or diagonally with respect to a contaminated media surface. Electrical connections, electrode sizes, and electrode materials for the electrodes include varying specifications depending on each treatment. For example, the electrodes may comprise carbon, in addition to iron, since carbon is a corrosion resistant material, in which carbon aids in pH buffering of the treatment method.
[0023] The electrodes may also comprise at least one of porous and perforated structures, each of which permits ingress and egress of liquid, for example ground water. Alternatively, the electrodes are located within a perforated container, which is disposed in the contaminated media. A further alternative comprises electrodes that are disposed behind a liquid permeable barrier in the contaminated media.
[0024] A potential difference is applied across the contaminated media in step S 2 . The potential difference is activated by applying a direct current (DC) electrical field in the contaminated media. The DC electrical field is applied between the electrodes to create the potential difference across the contaminated media.
[0025] The application of the potential difference in step S 2 causes the ions to migrate and contact contaminants in the contaminated media. This migration is an electrokinetic process called “electromigration.” Electromigration means the movement of ionic contaminants in a matrix toward an electrode of opposite charge when a constant, low DC electrical current is applied to electrodes. Comparatively, electroosmosis is the movement of water in a soil matrix resulting from an electric field. Electroosmosis and electromigration are known processes to those of ordinary skill in the art.
[0026] Remediating ions are then introduced at the anode in step S 3 with the proviso that the remediating ions are peroxide-free. For example, the remediating ions comprise ferrous ions (peroxide-free), if the anode comprises an iron-containing material. The introduction of iron ions at an iron-containing anode will dissolve the iron-containing anode. While the iron ions are adsorbed, to a limited degree, in the contaminated media, ion migration will occur once an equilibrium is attained between adsorbed and dissolved iron ions.
[0027] The introduction of the ions in step S 3 comprises direct treatment, such as chemical degradation by reductive dechlorination, of contaminated material with ferrous ions, for example ferrous ions, in an aqueous solution. Alternatively, the introduction of the ions in step S 3 comprises dissolution of ferrous ions that are provided by an interaction of iron-bearing minerals with organic and inorganic reducing agents. A further alternative for the introduction of the ions in step S 3 comprises dissolution of ferrous ions that result from iron metal corrosion. Another alternative of introduction of the ions in step S 3 , within the scope of the invention, comprises dissolution of ferrous ions that are formed by electrolytic processes at iron electrodes. Furthermore, another alternative of the introduction of the ions in step S 3 comprises dissolution of ferrous ions produced by stimulation and growth of iron-reducing bacteria in iron-containing substrates such as, but not limited to, soil sediment.
[0028] The DC electrical field, which is applied to the contaminated media, causes the formed remediating ions to migrate in and through the contaminated media, in step S 4 . The migration typically is from the anode, where the remediating ions are generated, to the cathode. The migration permits the remediating ions to reach contaminated-media regions, where conventional pump-and-treat methods and other known hydraulic pumping treatment processes cannot reach. For example, but in no way limiting of the present invention, the migration permits remediating ions to reach low-permeability contaminated media, where prior pumping treatments could not reach.
[0029] The remediating ions react with the contaminated media and produce reducing agents, in step S 5 . The reducing agents react with contaminants and effectively treat the contaminates in the contaminated media, for example by chemical degradation by reductive dechlorination, so any harmful effects are lessened. The reducing agents, including but not limited to, ionized reducing agents, provide in situ reductive dechlorination of the contaminated media. The process, as embodied by the present invention, can be applied to treat and remove the chlorinated solvent from contaminated media.
[0030] The method, as embodied by the present invention, is monitored and controlled in step S 6 . The monitoring and control of the method occur in response to a contaminant content in the contaminated media. The monitoring step can comprise an initial sampling of the contaminated soil region to determine a baseline contaminant level, including chlorine amounts, followed by periodic monitoring of the contaminate level during the process to determine the progress of the process. In step S 6 , the contaminant content of a contaminated-media region is monitored as to the contaminant level. The monitored-contaminant level is compared to the baseline contaminant level and is used to control the potential difference in the method. The control of the potential difference comprises at least one of increasing, redirecting, and terminating the application of the DC electrical field, and thus its potential difference. Therefore, progress of the treatment can be determined through the monitoring step S 6 .
[0031] One method of controlling the process comprises determining and monitoring contaminant content. The monitoring of contaminant content comprises initially determining the initial contaminant content by initial sampling and analysis, as above. Chloride ion content is then monitored during the treating of the contaminated soil region treatment, for example by chemical degradation by reductive dechlorination, and compared to the initial contaminant content. Thus, progress of the treatment can be determined. The electrode potential difference, applied in step S 2 , can be controlled for example by increasing, redirecting, or terminating according to the treatment progress and the monitored-contaminant content. A processor, such as, but not limited to a computer, can analyze contaminant content, and adjusts the electrode potential difference in response to the contaminant content level.
[0032] The scope of the present invention comprises any use of a remediating ion with the proviso that the remediating ion is peroxide-free, which is effective to reduce chlorinated solvents in the contaminated media, for example by reductive chlorination. Therefore, the remediating ions can comprise known remediating ions, such as those disclosed in Sivavec, U.S. Pat. No. 5,750,036.
[0033] These and other features will become apparent from the following example, which describes exemplary embodiments of the present invention. The example is in no way limiting of the present invention. This example demonstrates the feasibility of creating a treatment system for reactive soil and water that reductively dechlorinates TCE. The experiment was conducted in the apparatus 1 , illustrated in FIG. 2. A contaminated media sample 2 , in the example a clay-soil specimen, was loaded into a glass cylindrical cell 3 . The diameter of the glass cylindrical cell 3 is about 5 centimeters (cm) and its length and the length of the contaminated media sample 2 is about 15 cm. These dimensions are merely exemplary of the apparatus 1 . Other dimensions and apparatuses are within the scope of the present invention.
[0034] Receptacles 4 and 5 house electrodes 6 and 7 , respectively. The receptacles 4 and 5 are disposed at ends of the glass cylindrical cell 3 . Electrode 6 comprises an anode and electrode 7 comprises a cathode. The receptacle 5 is connected through a conduit 8 to a graduated receptacle (vessel) 9 . The vessel 9 measures electroosmotic flow rate.
[0035] The anode 6 comprises an iron-containing material. The anode 6 can be submerged in anolyte at the start of the experiment. For example, an anolyte that comprises about 1 mM Na 2 SO 4 , can be supplied from the anolyte reservoir 10 through conduit 16 .
[0036] The anode 6 is separated from a feed chamber 11 by a cation exchange membrane 12 . The cation exchange membrane 12 allows cations, such as ferrous ions, to migrate and pass through toward the cathode 7 . Anions, such as, but not limited to, chloride ions, however do not migrate therethrough and are rejected by cation exchange membrane 12 . These anions accumulate in the feed chamber 11 .
[0037] A solution, for example a feed solution that comprises about 100 ppm TCE, is feed through conduit 13 into a bottom portion of the feed chamber 11 . The flow rate of the TCE through the conduit 13 is typically higher than its electroosmotic flow through the contaminated media sample 2 . Any feed solution that does not pass through the contaminated media sample 2 by electroosmosis, overflows the chamber 11 . The overflow feed solution is passed through line 14 and is then collected in receptacle 15 . Feed solution that is collected in the receptacle 15 is then analyzed for chlorides by an appropriate device (not illustrated). The results are used for controlling the process, and the application of the potential difference between the electrodes.
[0038] One exemplary analyzing process comprises comparing the rate of chloride removal to the rate of TCE input into the contaminated media sample 2 as the apparatus 1 reaches a steady state. The comparison indicates a soil effectiveness for dechlorinating TCE. Additionally, effluent at the cathode 7 is analyzed and measured for unreacted TCE to purge solution analysis.
[0039] Results of the example are graphed in FIG. 3. In FIG. 3, the cumulative mass of TCE input through the conduit 13 into the glass cylindrical cell 3 (“TCE input”) and the cumulative mass of chloride that is collected in the feed chamber overflow receptacle 15 (“Chloride out”) are graphed versus time. In the example, a ratio of chloride moles removed from the glass cylindrical cell 3 (7.3 μmoles/day) to TCE input to the glass cylindrical cell 3 (2.9 μmoles/day) is 0.84. If the exemplary treatment process were 100 percent effective, three moles of chloride would be produced for every mole of TCE fed into the system 1 . The example illustrates that about 84% of TCE fed into the glass cylindrical cell 3 by electroosmosis is dechlorinated.
[0040] While embodiments of the present invention have been described, the present invention is capable of variation and modification, and therefore should not be limited to the description herein. The present invention includes changes and alterations that fall within the purview of the following claims.
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The present invention provides a method for treating contaminated media. The method comprises introducing remediating ions consisting essentially of ferrousions, and being peroxide-free, in the contaminated media; applying a potential difference across the contaminated media to cause the remediating ions to migrate into contact with contaminants in the contaminated media; chemically degrading contaminants in the contaminated media by contact with the remediating ions; monitoring the contaminated media for degradation products of the contaminants; and controlling the step of applying the potential difference across the contaminated media in response to the step of monitoring.
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RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of copending application Ser. No. 09/632,187, entitled Device For Improving The Fit Between A Limb Prosthesis And A Limb Liner, which was filed on Aug. 03, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] In general, the present invention relates to methods of manufacturing liner socks that are used to improve the fit of a limb prosthesis with the human body. More particularly, the present invention relates to the manufacture of liner socks that are worn between a limb liner and a limb prosthesis.
[0004] 2. Prior Art Statement
[0005] Many people who have amputated limbs or partially amputated limbs rely upon prosthetic limbs to better live a more normal life. When a person is fitted for a limb prosthesis, a limb liner is typically placed over the portion of the limb stump that remains on the body. A limb liner is an elastomeric device that is pulled over the limb stump. The liner conforms to the shape of the limb stump and creates a strong frictional attachment to the skin of the limb stump. In many instances, a metal locking pin extends from the tip of the limb liner. The locking pin is used to engage a prosthetic limb, when a prosthetic limb is mated with the limb liner. As such, the limb liner acts as the anchor for retaining the limb prosthesis onto the limb stump.
[0006] When a limb prosthesis, that utilizes a limb liner, is manufactured, a cast is taken of the limb liner while the limb liner worn in place on the limb stump. The cast is used to produce a socket. The socket is then attached to the limb prosthesis. The socket of the limb prosthesis is the portion of the limb prosthesis that mates with the limb liner and conforms to the shape of the stump. In this manner, the limb prosthesis manufactured will theoretically mate perfectly with the limb liner and the limb prosthesis will be properly fitted onto the limb stump.
[0007] Amputees commonly retain their prosthetic limbs for many years. However, during this time, the amputee may gain weight, lose weight, lose muscle mass in the stump or otherwise undergo physiological changes in their bodies that effect the size and contour of the limb stump. As the stump changes in size and/or contour, the configuration of the limb liner also changes. As a result, the configuration of the limb liner is no longer matched by configuration of the socket in the prosthetic limb. This causes gaps to occur between the limb liner and the limb prosthesis when the limb prosthesis is worn. The gaps can cause the limb prosthesis to feel loose. Furthermore, the gaps can cause physical discomfort by causing chafing against the limb stump.
[0008] In the prior art, fabric-based liner socks have been used to compensate for any inconsistencies between the configuration of the limb liner and the configuration of the limb prosthesis. Prior art liner socks are basically knitted or woven socks that are worn over the limb liner. The liner sock is compressed between the limb liner and the limb prosthesis when the limb prosthesis is worn. The liner sock becomes highly compressed at points of contact between the limb liner and the limb prosthesis and less compressed in areas of gaps. Accordingly, the liner sock helps to fill the gaps between the limb liner and the limb prosthesis and makes for a better fit.
[0009] A problem associated with prior art liner socks is that as they are unevenly compressed between the limb liner and the limb prosthesis, uneven pressure points are exerted against the limb liner and the underlying skin. The uneven pressure points may cause discomfort or more serious problems such as chafing or blistering.
[0010] A need therefore exists for a new type of liner sock that can compensate for irregularities between a limb liner and a limb prosthesis without causing pressure points against the limb stump. This need is met by the present invention as described and claimed below.
SUMMARY OF THE INVENTION
[0011] The present invention is a method of manufacturing a liner sock device for placement between a limb liner and a limb prosthesis. The liner sock contains an elastomeric material, such as a tri-block copolymer gel. The elastomeric material is preferably a gel that uniformly distributes stresses between the limb liner and the limb prosthesis when the liner sock is worn between the limb liner and the limb prosthesis. The entire liner sock is fabricated from elastomeric material that is bonded to either one or two fabric sock elements. Regardless to the construction, the liner sock has a first end and a second end. The second end of the liner sock is open to allow the liner sock to be pulled over a limb liner. The first end of the liner sock defines an aperture that enables a locking pin from the limb liner to protrude through the liner sock and engage the prosthetic limb.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a better understanding of the present invention, reference is made to the following description of exemplary embodiments thereof, considered in conjunction with the accompanying drawings, in which:
[0013] [0013]FIG. 1 is a perspective view of a liner sock device in accordance with the present invention. The liner sock is shown in conjunction with a limb stump, a limb liner and a limb prosthesis.
[0014] [0014]FIG. 2 is a cross-sectional view of the liner sock device shown in FIG. 1.
[0015] [0015]FIG. 3 is a cross-sectional view of a second exemplary embodiment of the present invention liner sock;
[0016] [0016]FIG. 4 is a cross-sectional view of a third exemplary embodiment of the present invention liner sock;
[0017] [0017]FIG. 5A illustrates the first set of method steps used to manufacture the liner sock device of FIG. 2;
[0018] [0018]FIG. 5B illustrates the second set of method steps used to manufacture the liner sock device of FIG. 2;
[0019] [0019]FIG. 5C illustrates the third set of method steps used to manufacture the liner sock device of FIG. 2;
[0020] [0020]FIG. 6 is a method flow schematic illustrating an exemplary method of manufacture for the liner sock device of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Although the present invention device can be used in conjunction with either an arm prosthesis or a leg prosthesis, an application with a leg prosthesis is shown and described merely by way of example.
[0022] Referring to FIG. 1, an exemplary embodiment of the present invention device 10 is shown in conjunction with a traditional limb liner 12 and a segment of a limb prosthesis 14 . The limb liner 12 has an elastomeric body 15 that can be pulled over the limb stump 16 of an amputee. Once in place over the limb stump 16 , the elastomeric body 15 of the limb liner 12 conforms to the configuration of the limb stump 16 . A metal locking pin 18 extends forwardly from the apex of the limb liner 12 . It is the metal locking pin 18 that is physically engaged by the limb prosthesis 14 .
[0023] The limb prosthesis 14 contains a socket 20 that is shaped to mate with the limb liner 12 when the limb liner 12 is present over the limb stump 16 .
[0024] The present invention liner sock 10 is a generally tubular structure having a first end 22 and a second end 24 . The first end 22 of the liner sock 10 defines a small aperture 26 . The aperture 26 is reinforced by at least one reinforcement patch 28 which will later be explained. The second end 24 of the liner sock 10 is fully open. The second end 24 of the liner sock 10 is sized to fit over the limb liner 12 so that the liner sock 10 can be pulled over the limb liner 12 . The aperture 26 at the first end 22 of the liner sock 10 is sized to enable the locking pin 18 of the limb liner 12 to pass therethrough.
[0025] Referring to FIG. 2, in conjunction with FIG. 1, it can be seen that the illustrated liner sock 10 has a laminated construction. The inner most layer 30 of the liner sock 10 is fabric, wherein fabric refers to either woven or knitted threads. The inner layer of fabric 30 extends from the first end 22 of the liner sock 10 to the second end 24 of the liner sock 10 . The outer most layer 32 of the liner sock 10 is also fabric. The outer most layer of fabric 32 also extends the full length of the liner sock 10 from the first end 22 of the liner sock 10 to the second end 24 of the liner sock 10 . The inner layer of fabric 30 and the outer layer of fabric 32 are coupled together at the second end 24 of the liner sock 10 with a joining stitch, adhesive or some other coupling means.
[0026] An elastomeric material 34 is interposed between the inner layer of fabric 30 and the outer layer of fabric 32 . The elastomeric material 34 is bonded to both the outer layer of fabric 32 and the inner layer of fabric 30 . Referring now solely to FIG. 2, it can be seen that the elastomeric material 34 extends from the first end 22 of the liner sock 22 a predetermined distance D toward the second end 24 of the liner sock 10 . The predetermined distance D can be any length. For example, the elastomeric material 34 may just coat the closed end of the liner sock. However, in a preferred embodiment, the elastomeric material 34 extends between the middle of the liner sock 10 and the full length of the liner sock 10 . By way of example, the shown embodiment shows the elastomeric material 34 extending approximately 3 / 4 the total length of the liner sock 10 .
[0027] Although the elastomeric material 34 can be any material with elastomeric properties, such as foam rubber, silicon impregnated foam, and the like. The preferred embodiment uses a tri-block copolymer mixed with an oil to form an elastomeric gel. Suitable tri-block copolymers would include poly(styrene-ethylene-butylene-styrene and poly(styrene-ethylene-propylene-styrene).
[0028] The elastomeric material 34 spreads when it is compressed. As a result, when the liner sock 10 is compressed between the limb liner 12 (FIG. 1) and the limb prosthesis 14 (FIG. 1) the elastomeric material 34 inside the liner sock 10 spreads from points of high compression into points of low compression. The result is a much more even pressure across the entire limb liner/limb prosthesis interface. Additionally, the elastomeric material 34 spreads to fill any voids at the limb liner/limb prosthesis interface. Accordingly, the elastomeric material 34 in the liner sock 10 compensates for any irregularities that exist between the limb liner 12 (FIG. 1) and the limb prosthesis 14 (FIG. 1). The limb prosthesis therefore fits better and can be worn in a more conformable manner despite any physiological changes that may occur in the limb stump over time.
[0029] Referring to FIG. 3, a second embodiment of a liner sock 50 is shown. In this embodiment, a first fabric sock element 52 is provided. The fabric sock element 52 is then coated with an elastomeric material 54 in the same manner as the embodiment of FIG. 2. However, in the shown embodiment of FIG. 3, the elastomeric material 54 is allowed to cure without the application of a second sock element. As a result, the liner sock 50 has one surface that is fabric and another surface that is comprised of the elastomeric material. The liner sock 50 can be worn either with the fabric contacting the limb liner and the elastomeric material contacting the limb prosthesis or vise versa.
[0030] An aperture 56 is disposed through the first end of the liner sock 50 . The aperture 56 is sized so that a metal locking pin of a limb liner can pass through the aperture 56 . An optional reinforcement patch 58 can be attached to the fabric sock element 52 in the area surrounding the aperture 56 . The benefits of the reinforcement patch are later explained.
[0031] Referring to FIG. 4, a third embodiment of a liner sock 60 is shown. In this embodiment, an first fabric sock element 62 is provided. The fabric sock element 62 is then coated with an elastomeric material 64 on both its internal surface and its external surface. As a result, the liner sock 60 has a laminated construction wherein both elastomeric material 64 is present on both sides of a fabric sock element 62 . The elastomeric material 64 on one side of the fabric sock element 62 will contact the limb liner, while the elastomeric material 64 on the opposite side of the fabric sock element 62 will contact the limb prosthesis.
[0032] An aperture 66 is disposed through the first end of the liner sock 60 . The aperture 66 is sized so that a metal locking pin of a limb liner can pass through the aperture 66 .
[0033] Referring to FIG. 5A, the first three steps used in the manufacturing the liner sock of FIG. 2 are illustrated. The first step used to manufacture the liner sock is to manufacture an initial interior sock element 30 in a traditional manner. As such, this would be typically done on a programmable knitting machine. The interior sock element 30 has a first end 82 that is closed and a second end 84 that is open, as is traditional for socks. In Step 2 , the interior sock element 30 is placed on a dipping blank 85 that retains the interior sock element in a preferred shape for dipping. In Step 3 , the interior sock element 30 , while supported by the dipping blank 85 , is then dipped in a volume of molten elastomeric material 86 . The molten elastomeric material can be any non-thermoset elastic material. However, the preferred elastomeric material is a triblock copolymer mixed with a plasticizing oil. The depth of the dip, the number of dips and the temperature of the molten material determines the length and the thickness of the elastomeric layer 34 coating the interior sock element 30 . Accordingly, the thickness of the elastomeric layer 34 can be selectively controlled in the process.
[0034] After a desired length and thickness of elastomeric layer 34 is obtained, the elastomeric layer 34 is allowed to cool or otherwise cure. Referring to FIG. 5C, it can be seen by Step 4 that an exterior sock element 32 is then produced in a traditional manner. The exterior sock element 32 has a closed first end 87 , an open second end 88 and is sized to receive the interior sock element 32 coated with the elastomeric layer 34 . The external sock element 32 is then pulled over both the elastomeric layer 34 and the internal sock element 30 to produce an unattached assembly. As is indicated by Step 5 , the unattached assembly 89 is then heated, whereby the outermost parts of the elastomeric layer 34 melts and bonds to the external sock element 32 , thereby creating an attached assembly.
[0035] In Step 6 , the attached assembly 90 is allowed to cool and is then finished. To finish the attached assembly the open end of the internal sock element 30 and the open end of the external sock element 32 are then joined together. This is done be either running the open end of the attached assembly through a sewing machine 91 (shown) or another binding machine, such as a knitting machine.
[0036] Referring now to FIG. 5C, it can be seen from Step 7 that the attached assembly 90 is placed on a form 92 . A reinforcement patch 28 is then affixed to the first end of the external sock element 32 . The reinforcement patch 28 is a segment of tear resistant material that is coated on one side with an adhesive. The adhesive is preferably a heat activated adhesive. The reinforcement patch 28 is then placed against the attached assembly 90 and heated with an application iron.
[0037] A reinforcement patch 28 can be placed on only the external sock element 32 . However, in a preferred embodiment a reinforcement patch 28 is placed against both the internal sock element 30 and the external sock element 32 . To do this, the attached assembly 92 is removed from the blank 92 , inverted and replaced on the blank 32 , as is indicated by Step 8 . The internal sock element 30 is now exposed. A second reinforcement patch is then applied to the internal sock element 30 . The reinforcement patch on the interior sock element and the exterior sock element are concentrically oriented.
[0038] As is indicated by Step 9 , a punch 94 is used to punch the aperture 26 through both reinforcement patches 28 , the internal sock element, the external sock element and the elastomeric layer. The reinforcement patches 28 prevent the threads of the external sock element and the internal sock element from unraveling once the aperture 26 is created. The reinforcement patches 28 also help reinforce the elastomeric layer by stabilizing the edge of the elastomeric layer that is exposed to the aperture 28 . At is last shown by Step 10 , the finished liner sock 10 is removed from the manufacturing equipment and is ready for use.
[0039] The manufacturing process used to create the liner sock 50 illustrated in FIG. 3 is similar to that of liner sock 10 illustrated in FIG. 2. The step shown in FIG. 5A are used and the steps shown in FIG. 5C are shown. However, the steps shown in FIG. 5B are not used. A traditional sock is made and dipped in elastomeric material. However, no external sock element is used. Rather the reinforcement patches are applied directly to the interior sock element and the elastomeric material.
[0040] Referring To FIG. 6, an exemplary method of manufacturing the liner sock of FIG. 4 is illustrated. The first step used to manufacture the liner sock 60 is to manufacture an initial sock element 62 in a traditional manner. The sock element 62 has a first end 95 that is closed and a second end 96 that is open, as is traditional for socks. In step 2 , the sock element 62 is then dipped in a volume of molten elastomeric material 97 . The depth of the dip, the temperature of the molten elastomeric material 97 and the number of dips determines the length and the thickness of the elastomeric layer 64 coating the sock element 62 .
[0041] After a desired length and thickness of elastomeric layer 64 is obtained, the elastomeric layer 64 is allowed to cool or otherwise cure.
[0042] In Step 3 , the sock assembly is temporarily inverted. So that the fabric is again exposed. The sock element 62 is again dipped in a volume of molten elastomeric material 97 . The depth of the dip, the temperature of the molten elastomeric material and the number of dips determines the length and the thickness of the second elastomeric layer 64 coating the sock element 62 . The second dipping of elastomeric material is then allowed to cure.
[0043] Finally, in Step 4 , an aperture 66 is punched through the first elastomeric layer, the sock element, and the second elastomeric layer. The presence of the elastomeric material on either side of the sock element prevents the thread of the sock element from unraveling once the aperture is created. The sock element also acts as a reinforcement to the elastomeric material, wherein the sock element stabilizes the exposed edges of the elastomeric material.
[0044] It will be understood that the embodiments of the present invention described and illustrated herein are merely exemplary and a person skilled in the art can make many variations to the embodiment shown without departing from the scope of the present invention. For example, many different types of fabrics and elastomeric materials can be used in the construction of the device. Additionally, the length and the width of the device can be altered depending upon whether or not the device is to be used above the knee, below the knee, above the elbow or below the elbow. All such variations, modifications and alternate embodiments are intended to be included within the scope of the present invention as defined by the appended claims.
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A method of manufacturing a liner sock device for placement between a limb liner and a limb prosthesis. The liner sock contains an elastomeric material, such as a tri-block copolymer gel. The elastomeric material is preferably a gel that uniformly distributes stresses between the limb liner and the limb prosthesis when the liner sock is worn between the limb liner and the limb prosthesis. The liner is fabricated from elastomeric material that is bonded to either one or two fabric sock elements. Regardless to the construction, the liner sock has a first end and a second end. The second end of the liner sock is open to allow the liner sock to be pulled over a limb liner. The first end of the liner sock defines an aperture that enables a locking pin from the limb liner to protrude through the liner sock and engage the prosthetic limb.
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REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of my prior application of the same title which was assigned U.S. Ser. No. 364,985 and was filed on Apr. 2, 1982. This application is now Pat. No. 4,406,820.
BACKGROUND OF THE INVENTION
This invention relates to a method for improving the selectivity of supported silver catalysts for the production of ethylene oxide. Specifically, the invention relates to an improvement in the known process for incorporating promoters into such catalysts.
Supported silver-based catalysts have been industrially for many years for the oxidation of ethylene to ethylene oxide with oxygen or air. Most of the ethylene which is reacted is converted into ethylene oxide on the silver-impregnated catalyst support material and the remainder of the ethylene is converted almost exclusively to carbon dioxide and water. The goal is to react as much ethylene as possible, i.e., high productivity, such that the greater amount of the ethylene is converted to ethylene oxide, i.e., high selectivity.
It is well known in the art that the incorporation of promoters, such a rubidium or cesium, into these catalysts will increase the selectivity thereof. U.S. Pat. No. 4,012,425, issued Mar. 15, 1977, discloses one such process which comprises treating the catalyst with a solution of cesium or rubidium. There are many similar disclosures in the art, both for the manufacture of new catalyst and for the regeneration of spent catalyst. However, nowhere in the prior art is there any disclosure that any particular anion should be used with the promoters, other than that the anion should not be a catalyst poison such as sulfur-containing compounds. The above patent states that no unusual effectiveness is observed with the use of any particular anion and goes on to say that nitrates, nitrites, chlorides, iodides, bromates, bicarbonates, oxalates, acetates, tartrates, lactates, and isopropoxides may be used.
SUMMARY OF THE INVENTION
The present invention relates to an improvement in the known method for improving the selectivity of supported silver catalysts by incorporating a promoter therein. The improvement comprises forming a solution of a compound of the promoter and an anion which is not a catalyst poison and is selected from the group consisting of unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids in the solvent and then contacting the catalyst with the solution. The solution is drained from the catalyst and the catalyst is dried.
DETAILED DESCRIPTION OF THE INVENTION
The addition of promoters to silver-based ethylene oxide catalysts is an established part of the art catalyst manufacture. Promoters have been added to both new and used catalysts to provide increased selectivity and activity. A large array of anions have been listed as suitable for use with promoters. The chief restriction on the anion is the lack of harmful effect on catalyst performance.
It has been found that certain promoter-anion combinations are superior to those routinely employed in catalyst manufacture or regeneration today. The anion employed must have three general characteristics: (1) formation of a compound with a promoter which is soluble in a suitable solvent, (2) it must have one or more functional groups which have an affinity for the promoter ion and one or more groups which have an affinity for the silver surface of the catalyst, and (3) it must not contain a catalyst poison or act as a catalyst poison. The solubility of the promoter-anion combination is not restricted to water or aqueous systems, but encompasses all non-aqueous solvents that of themselves or in combination are not deleterious to catalyst performance. Suitable solvents are methanol, water, aliphatic, alicyclic, or aromatic ethers, alcohols, hydrocarbons, and ketones, and aliphatic or aromatic esters, amines, amides, aldehydes, and nitriles.
The polyfunctionality of the anion provides for site specific application of the promoter, optimum promoter utilization, and superior catalyst performance. The method provides a more homogeneous application of the promoter to the catalyst and minimizes the macro and microscopic concentration variations which adversely effect catalyst performance. The homogeneity is provided by the affinity of the functional groups for the silver surface of the catalyst. For the purpose of this invention, the anion preferably should not be solely of a chelating type in which all of the functional groups are tied up by the promoter cation. One or more of the functional groups should remain relatively free for complexation with the silver surface.
The anions which provide the above advantages and which are claimed herein are those derived fromm unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids. Examples of suitable unsaturated carboxylic acids are acrylic acid, vinylacetic acid, and 5-hexenoic acid. Examples of suitable aminoorganic acids are m-aminobenzoic acid, p-aminobenzoic acid, alpha-aminobutyric acid, 6-aminocaproic acid, o-aminophenol, m-aminophenol, p-aminophenol, 2-amino-p-cresol, 4-amino-o-cresol, aminomethanesulfonic acid, aniline-2-sulfonic acid, 2,5-diaminobenzenesulfonic acid, 3-pyridylhydroxymethanesulfonic acid, m-aminiphenylboronic acid, and 4-aminophenylphosphonic acid. Examples of the hydroxybenzoic acids are m-hydroxybenzoic acid and p-hydroxybenzoic acid.
The method by which the above advantages are achieved comprises forming a compound of the promoter ion which is to be incorporated into the catalyst and one of the above anions, forming a solution of said compound in a suitable solvent, and then contacting the catalyst with the solution. The concentration of promoter in this solution should be in the range of 1 to 10,000 parts per million. This method can be used in the production of new catalyst by simply applying the above solution at the end of the normal catalyst manufacturing process. The method can be used in the regeneration of used catalyst by merely contacting the used catalyst with the solution.
EXAMPLE I
A single sample of aged silver-based ethylene oxide catalyst was used in all of the following experiments. The sample was split into several 60-gram portions for identical treatment with cesium salts of the different anions. The treatment procedure consisted of contacting the catalyst sample with 70 milliliters of a 100 part per million cesium in methanol solution for two hours, draining, and then drying at 60° C. for 20 hours. The 100 parts per million cesium solution was prepared by mixing a 100 parts per million cesium hydroxide solution with an equivalent quantity of the acid according to the equation
CsOH+HOA→CsOA+H.sub.2 O
where OA represent the anion of the acid.
For this evaluation, acetate provided the base line for a monofunctional anion. The dried treated catalysts were evaluated by manufacturing ethylene oxide in a reactor at a temperature of 400°-500° F. at a flow rate of 200 milliliters per minute of inlet gas with a composition of 7 percent oxygen, 8 percent carbon dioxide, 18 percent ethylene, and nitrogen ballast with 1 part per million ethylene dichloride added as an inhibitor.
The results of these experiments, shown in the following table, prove that the catalysts which were treated with the polyfunctional anions were superior catalysts to the catalyst which was treated with the monofunctional acetate ion.
TABLE 1______________________________________ % Selec- tivity at 1.5% Temp.Acid Anion Δ EO* °F.______________________________________Acetic Acetate 70.4 452Acrylic Acrylate 72.0 447m-Aminobenzoic m-Aminobenzoate 72.6 458p-Aminobenzoic p-Aminobenzoate 74.0 443gamma-Aminobutyric gamma-Aminobutyrate 72.5 4396-Aminocaproic 6-Aminocaproate 70.8 480m-Hydroxybenzoic m-Hydroxybenzoate 71.9 451p-Hydroxybenzoic p-Hydroxybenzoate 72.8 476______________________________________ *The term Selectivity at 1.5% Δ EO means the selectivity at a productivity of 1.5%.
EXAMPLE II
A different sample of an aged silver-based ethylene oxide catalyst was split into several 60-gram portions for identical treatment with cesium salts of different aminoorganic acid anions. The treatment procedure was the same as the procedure in Example I. As in Example I, acetate provided the base line for a monofunctional anion. The dried treated catalysts were evaluated according to the procedure of Example I except that the temperature range was from 350°-500° F.
TABLE 2______________________________________ % SelectivityAcid at 1.5% Δ EO______________________________________Acetic acid 72.3o-Aminophenol 73.3m-Aminophenol 73.1p-Aminophenol 74.42-Amino-p-cresol 72.84-Amino-o-cresol 72.5Aminomethanesulfonic acid 72.5Aniline-2-sulfonic acid 73.02,5-Diaminobenzenesulfonic acid 74.8m-Aminophenylboronic acid 74.64-Aminophenylphosphonic acid 73.2o-Arsanilic acid 60.5p-Arsanilic acid 52.9______________________________________
The results of the experiments, shown in the above table, prove that the catalysts which were treated with the polyfunctional aminoorganic acid anions of the present invention were superior catalysts to the catalysts which were treated with the monofunctional acetate ion. The arsanilic samples were evaluated at 1% ΔEO. These samples acted as though they were poisoned and thus the arsanilic acid anions are not effective in the present invention.
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An improved method is disclosed for improving the selectivity of supported silver catalysts by incorporating a promoter therein. The improvement comprises forming a solution of a compound of the promoter and an anion which is not a catalyst poison and is selected from the group consisting of unsaturated carboxylic acids, aminoorganic acids, and hydroxybenzoic acids in a solvent and contacting the catalyst with the solution.
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FIELD OF THE INVENTION
[0001] The present invention relates to flotation devices used by swimmers and bathers in pools, lakes and oceans. More particularly, the present invention relates to devices which are formed as integral bodies from a suitable low-density synthetic resin material so that the bodies will float.
BACKGROUND
[0002] There are several types of flotation devices for the pool and other various types of bodies of water. These devices typically include floating chairs, inflatable rafts, inner-tubes and large rigid foam pieces.
[0003] These flotation devices are cumbersome, rigid and limit one's movement in the water. For instance, devices requiring inflation necessitate the need for either an external air pump or a person to manually inflate the device with air from their lungs. This proves to be cumbersome and in the latter case, exhausting. Once the device is inflated, pin hole leaks can develop which allow air to escape causing them to deflate and gradually become less effective in their continued use, at which point the flotation device must either be re-inflated or the hole must be patched. Other drawbacks to existing flotation devices are that they hold the majority of one's body above the surface of the water which reduces the effect of the water on the body. This would allow one's body to become very hot while also greatly reducing the movement of the body for propulsion and/or exercise purposes.
[0004] U.S. Pat. No. 5,520,561, issued to Langenohl on May 28, 1996, discloses making a pool float from a generally rectangular sheet of netting which is deformed to form sleeve segments in which a foam tube can be inserted. The shape of the flotation device that is obtained is limited.
[0005] Swim Ways Corp. of Virginia Beach, Va. markets a chair-like flotation device known as the FANNY FLOATER. In this design, permanently U-shaped foam block having a rectangular-shaped cross-section is fitted with three indentations which serve to hold in position three sleeves that are positioned around the foam block. A seat is provided by having a section of material extend from the left arm to the right arm and one section from the rear of the U-shaped block extending forward, thus forming a T-shaped seat. This design is limited to this particular shape. Further, the foam block is permanently shaped so that the device cannot be stored easily.
[0006] U.S. Pat. No. 5,571,036, issued to Hannigan on Nov. 5, 1996, discloses a flexible tube floating sling. In this design, a very long single foam tube is folded about itself in a U-shape and inserted in a pair of sleeves that support a sling-like structure. Again, this method of manufacture limits the shape that can be obtained.
[0007] U.S. Pat. No. 5,307,527, issued to Schober on May 3, 1994, discloses a pool chair adapted to be partially submerged in a swimming pool. The chair is designed to rest along the perimeter of the pool so that it is held in an upright, stationary position in order to allow a user to sit on the seat with the user's lower torso and legs submerged in the water while the user's head is above the water. Not withstanding the fact that the pool chair overcomes the limitation of holding the majority of one's body above the surface of the water, nonetheless, it is accomplished with a cumbersome and rigid construction which limits one's mobility throughout the pool due to the chair's dependency on the edge of the pool.
[0008] With respect to inner-tube type recreational devices, U.S. Pat. No. 5,295,885, issued to Karl on Mar. 22, 1994, discloses an attachable/detachable hammock-like seat designed to engage the central opening of the inner-tube to support users as they sit across the inner-tube's central opening. A user's head, arms and shoulders are over one end of the tube, with the feet over the other end. Unlike the Schober patent, this invention holds the majority of one's body above the surface of the water. In addition, the inflatable inner-tube device is subject to pin hole leaks which would allow air to escape, thus presenting a problem to the user; either re-inflate the inner-tube or patch the hole for continued use.
[0009] It would be an improvement on the current art to create a flotation device that is not cumbersome, rigid or limits one's movement in the water while holding the majority of one's body below the surface of the water. A benefit of holding one's body below the surface of the water would be to increase the effect of the water on the body such as preventing one's body from becoming very hot and to also increase the movement of the body for propulsion and/or exercise purposes. Furthermore, a device is desired that may provide entertainment when using the device. A device that overcomes the shortcomings as just described for a flotation device is not disclosed in the prior art.
SUMMARY
[0010] A flotation device for supporting a user may include a flotation body,
[0011] a connecting sleeve to detachably connect to the flotation body and
[0012] a decorative member including a base portion to detachably connect to the connecting sleeve.
[0013] The flotation body may include a noodle.
[0014] The decorative member may include a Mickey Mouse head.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which:
[0016] FIG. 1 illustrates a perspective view the flotation device of the present invention being used by a user;
[0017] FIG. 2 illustrates a perspective view of the flotation device of the present invention;
[0018] FIG. 3 illustrates a front view of a portion of the flotation device of the present invention;
[0019] FIG. 4 illustrates a sectional view of the flotation device of the present invention;
[0020] FIG. 5 illustrates an end view of the connecting sleeve of the present invention;
[0021] FIG. 6 illustrates an end view of the flotation body of the present invention.
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates the flotation device 100 of the present invention, and the flotation device 100 may include a flotation body 105 which may have any cross-sectional geometric shape, such as, circular, square, rectangle, or scalloped or other shape and which may have a first butt end 111 and a second butt end 113 .
[0023] The flotation body 105 may be configured to support the user or swimmer 107 at least partially above the water line as shown straddling the floatation body 105 . The flotation body 105 may be referred to as a noodle because of the thin and elongated shape. The flotation body 105 may be preferably fabricated from a suitable synthetic resin material, such as extruded cellular polyethylene, having a density such that the flotation body will float in water. The material from which the flotation body 105 is fabricated may be preferably both yieldable and shape-retaining. The flotation body 105 may be substantially straight or gently arcuate as shown in FIG. 2 , or may be yielded to have a more pronounced arcuate shape as shown in FIG. 1 .
[0024] In addition, the floatation body 105 might also include air bladders or other means to further enhance its buoyancy.
[0025] The flotation device 100 may include a connection sleeve 103 to connect to the flotation body 105 , and the connection sleeve 103 may connect to a decorative member 109 which may be a head or other object representing a horse, a unicorn, Mickey Mouse, Donald Duck or other such interesting object. The connecting sleeve 103 may be adapted to form a friction fit with the flotation body 105 and may form a detachable connection with the flotation body 105 . Furthermore, the connecting sleeve 103 may include a connecting aperture 115 and the decorative member 109 may include a base portion 117 which may include a base aperture 119 which may cooperate with the connecting aperture 115 to form a detachable connection when a fastening device 121 which may be a pin, screw, nail, bolt or other appropriate device extends through the base aperture 119 and the connecting aperture 115 .
[0026] FIG. 2 illustrates an exploded view of the decorative member 109 which may include the base portion 117 which may be connected to the connecting sleeve 103 and illustrates the connecting aperture 115 and the base aperture 119 . FIG. 2 additionally illustrates the flotation body 105 and the first butt end 111 .
[0027] FIG. 3 illustrates the decorative member 109 mounted on the flotation body 105 and illustrates the connecting sleeve 103 , the connecting aperture 115 , the base portion 117 , the base aperture 119 and the fastening device 121 .
[0028] FIG. 4 illustrates the connecting sleeve 103 , the connecting aperture 115 , the base portion 117 , the base aperture 119 and the fastening device 121 .
[0029] FIG. 5 illustrates an end view of the connecting sleeve 103 .
[0030] FIG. 6 illustrates an end view of the flotation body 105 .
[0031] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.
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A flotation device for supporting a user may include a flotation body, a connecting sleeve to detachably connect to the flotation body and a decorative member including a base portion to detachably connect to the connecting sleeve.
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[0001] This application claims the benefit from the priority of Taiwan Patent Application No. 097100686 filed on Jan. 8, 2008 and Taiwan Patent Application No. 097145344 filed on Nov. 24, 2008, the disclosures of which are incorporated by the later reference herein in their entirety.
CROSS-REFERENCES TO RELATED APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a starting apparatus for a direct current (DC) brushless motor and a method thereof. More particularly, this invention relates to a starting apparatus and a method thereof that can start a DC brushless motor without need of a sensor.
[0005] 2. Descriptions of the Related Art
[0006] To detect the correct position of a rotor in a DC brushless motor during the start-up period, the conventional technology is to place a sensor (e.g., a Hall sensor) within the motor. The sensor is configured to sense the variations of a magnetic field between the rotor and the sensor when the motor is running to obtain information of the rotor position. However, the Hall sensor has to be located inside the motor module and placed at the proper position, which appears to increase difficulties in assembly and add production costs to small motors.
[0007] DC brushless motors that do not use sensors have been widely adopted in various products requiring a drive force. Generally, for most motors, the speed thereof can be well controlled when running at a medium or high rotational speed. However, when stationary, it is difficult to determine the rotor position, and a particular starting procedure must be implemented to ensure the successful start-up of the motor before entering into the normal driving mode.
[0008] Conventional technologies aimed to start a DC brushless motor without the need of a sensor have also been proposed, for example, in U.S. Pat. No. 5,343,127 and U.S. Pat. No. 7,202,623. According to both U.S. patents, a back electromotive force (BEMF) generated across the rotor winding in response to the rotational movement thereof is detected as reference information for determining the rotor position to start the motor. Unfortunately, these technologies require complex operations to start the motor, causing increased difficulties in controlling the motor.
[0009] Accordingly, it is important to provide a control method and a circuit thereof that eliminates the need of a sensor while still properly starting a DC brushless motor.
SUMMARY OF THE INVENTION
[0010] One objective of this invention is to provide a method for starting a direct current (DC) brushless motor. The DC brushless motor comprises a plurality of windings jointly connected to each other through a joint juncture. The method comprises the following steps: exciting a first phase by supplying a current to a first winding and a second winding of the windings; measuring a first back electromotive force (BEMF) of a third winding which the current does not flow therethrough; switching to a second phase by switching the current to flow sequentially through the second winding and the third winding according to a start-time period or the determination that the first BEMF exceeds a reference value during the start-time period when a second BEMF of the first winding does not have a current that flows therethrough and crosses a negative zero-crossing point during the second phase. The apparatus then switches to a third phase by switching the current to flow sequentially through the second winding and the first winding.
[0011] Another objective of this invention is to provide a starting apparatus of a DC brushless motor. The DC brushless motor comprises a plurality of windings. By supplying a current to two of the windings, the DC brushless motor is rotated to excite a BEMF in the other winding. Then, according to the BEMF variation induced by the swing of the motor when the motor rotates to a static equilibrium point, the current is switched to another two-winding combination, thereby ensuring successful running of the motor.
[0012] To achieve the aforementioned objective, this invention provides a starting apparatus of a DC brushless motor. The starting apparatus comprises a control circuit and a detection circuit. The control circuit is configured to excite a first phase by supplying a current to a first winding and a second winding of the windings, and to switch the current to other two-winding combinations in a specified order according to a start-time period or according to the determination that a BEMF of the winding does not have a current that flows therethrough exceeds a reference value during the start-time period to start the DC brushless motor. The detection circuit is configured to measure the BEMF of the winding which the current does not flow therethrough.
[0013] The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic view of connections between a starting apparatus of this invention and internal windings of a DC brushless motor;
[0015] FIGS. 2A and 2B are schematic graphs of magnetic torque waveforms and BEMF waveforms according to an embodiment of this invention; and
[0016] FIGS. 3A and 3B are a flowchart of a second embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In the following description, this invention will be explained with reference to embodiments thereof. This invention relates to a starting apparatus for a direct current (DC) brushless motor and a method thereof in which, in response to the BEMF variation induced by the swing of the motor when the rotor rotates to a static equilibrium point, current is supplied to another two-winding combination to ensure the successful running of the motor. However, these embodiments are not intended to limit this invention to any specific context, application or particular implementation described in these embodiments. Therefore, these embodiments are described only for purposes of illustration but not limitation. In the following embodiments and attached drawings, elements unrelated to this invention are omitted from depiction; and, dimensional scales among the individual elements are exaggerated for ease of understanding.
[0018] The preferred embodiment of this invention is depicted in FIG. 1 , which schematically illustrates a starting apparatus 10 and connections between the starting apparatus 10 and internal windings of a DC brushless motor. In this embodiment, the DC brushless motor is a three-phase motor comprising a winding U, a winding V and a winding W with a central tap CT. The number of windings in the motor is not intended to limit this invention; rather, this invention is applicable to DC brushless motors with three or more windings. The starting apparatus 10 comprises a control circuit 11 and a detection circuit 12 . In this embodiment, the control circuit 11 is configured to generate a digital output signal 101 , which controls switch elements 121 , 122 and 123 disposed between the windings U, V, W and the power supply to regulate the power supplied to these windings.
[0019] Furthermore, the control circuit 11 receives an output signal 102 from the detection circuit 12 , which represents a BEMF generated by a winding which a current does not flow therethrough when the DC brushless motor is running. The detection circuit 12 is configured to measure the BEMF of the winding which a current does not flow therethrough. According to the output signal 102 and a start-time period, the control circuit 11 supplies a current to the windings in a specified order to start the DC brushless motor. In more detail, the control circuit 11 supplies a current flowing sequentially through the first winding and the second winding to excite a first phase, and then according to the start-time period or the determination that the BEMF of the winding does not have a current that flows therethrough (i.e., the third winding) and exceeds a reference value during the start-time period, the starting apparatus 10 switches the current to other two-winding combinations in a specified order shown in FIGS. 2A and 2B to start the DC brushless motor. That is, according to both the first BEMF of the third winding which a current does not flow therethrough and the start-time period, the control circuit 11 switches the current to the second winding and the third winding to switch to a second phase.
[0020] For example, the windings U, V and W are connected to the power supply terminal 111 , an input terminal 112 of the detection circuit 12 and a ground terminal 113 respectively through switching on the switch elements 121 , 122 and 123 by the control circuit 11 . The digital output signal 101 is adapted to control the connection relationships between the windings U, W and V and the power supply terminal 111 , an input terminal 112 of the detection circuit 12 and a ground terminal 113 . For example, when the winding U is connected to the power supply terminal 111 and the winding V is connected to the ground terminal 113 , the winding W will be connected to the input terminal 112 , in which case the BEMF generated across the winding W is just the input signal of the detection circuit 12 .
[0021] The control circuit 11 further comprises a delay circuit (not shown) configured to generate a delay time. The length of the delay time is adapted to prevent the control circuit 11 from determining that a pseudo BEMF crosses either a positive zero-crossing or a negative zero-crossing.
[0022] In more detail, the control circuit 11 determines whether the first BEMF crosses the positive zero-crossing point during the start-time period. If the first BEMF crosses the positive zero-crossing point, the current is switched to flow sequentially through the second winding and the third winding to switch to a second phase. Otherwise, after the elapse of the start-time period, the current is switched to flow sequentially through the second winding and the third winding to switch to the second phase.
[0023] Subsequent to switching to the second phase, the detection circuit 12 detects the second BEMF of the first winding in which a current does not flow therethrough, and the control circuit 11 switches the current to the second winding and the first winding when the second BEMF crosses a negative zero-crossing point to switch to a third phase. Thus, the starting process of the DC brushless motor is accomplished.
[0024] FIG. 2A illustrates a waveform diagram of magnetic torque and BEMF is illustrated therein to more clearly explain how the starting apparatus 10 starts the DC brushless motor. The waveform diagram includes the magnetic torque waveforms and the BEMF waveforms, and defines the forward direction of rotation. For example, with the windings U (i.e., the aforementioned first winding) and V (i.e., the aforementioned second winding), the switch elements 121 , 122 are coupled to the power supply terminal 111 and the ground terminal 113 respectively, and the central tap CT is coupled to the detection circuit 12 to complete a circuit, so that the control circuit 11 supplies a current to the windings U, V via the power terminal 111 to excite the U-V phase 201 (i.e., the aforementioned first phase). The magnetic torque of the U-V phase 201 is denoted as a curve 211 . The switch element 123 is coupled to the input terminal 112 so that no current flows through the winding W presently. In other words, the first BEMF (i.e., a curve 221 ) will be generated across the winding W. It should be noted that if the current is supplied to the windings U and V continuously, the static equilibrium point 204 can be observed on the magnetic-torque curve 211 . This is a characteristic of the DC brushless motors; that is, once the rotor rotates to the static equilibrium point 204 , it will come to a standstill and cease to rotate at the static equilibrium point 204 . This invention just drives a DC brushless motor by virtue of this characteristic.
[0025] Furthermore, the detection unit 12 detects the variations of the first BEMF continuously. When the rotor rotates the static equilibrium point 204 , it is rotating in the forward direction, and due to the inertia, the rotor will rotate towards the forward direction a little further before rotating in the reverse direction. At this point, the detection unit 12 will detect the first BEMF of the reverse direction (i.e., the curve 224 ). Because the BEMF varies on a continuous basis, the BEMF detected by the detection unit 12 at this point will abruptly jump from the curve 221 to the curve 224 , thereby giving rise to the positive zero-crossing point 225 . Hence, according to the output signal 102 from the detection circuit 12 , the control circuit 11 switches the current to flow sequentially through the windings V (i.e., the second winding) and W (i.e., the third winding), i.e., to switch to the V-W phase 202 (i.e., the aforementioned second phase). Then, the detection circuit 12 can detect the second BEMF of the winding U (i.e., the curve 222 ). Arrows before and after the positive zero-crossing point 225 in FIG. 2A are illustrated to assist in the further understanding of the aforementioned variations of the BEMF.
[0026] After the current is switched to the V-W phase 202 , the control circuit 11 determines whether the BEMF curve 222 crosses a negative zero-crossing 226 according to the output signal 102 . If the BEMF curve 222 crosses a negative zero-crossing 226 , the current is switched to flow sequentially through the windings V and U, i.e., switched to the V-U phase 203 (i.e., the aforementioned third phase) so that the motor can enter the normal driving mode after starting the DC brushless motor.
[0027] Furthermore, it is also possible that when being started, the rotor of the DC brushless motor rotates in the reverse direction according to the magnetic torque of the U-V phase 201 (i.e., the curve 211 ). In referring to FIG. 1 and FIG. 2B together, when subjected to the action of the magnetic torque shown between the points 304 and 305 on the curve 211 , the rotor rotates in the reverse direction, in which case the detection unit 12 detects the first BEMF in the reverse direction (i.e., the curve 224 ) of the winding W which a current does not flow therethrough. If the current is supplied to the windings U and V continuously, the first BEMF of the winding W will cross a positive zero-crossing point 324 when the rotor rotates beyond the point 304 , in which case the control circuit 11 switches the current to flow sequentially through the windings V and W (i.e., the third winding) according to the output signal 102 from the detection circuit 12 to switch the current to the V-W phase 202 . Then, the detection circuit 12 can detect the second BEMF of the winding U (i.e., the curve 222 ). It can be seen from the BEMF waveforms shown in FIG. 2B that a negative zero-crossing 325 occurs when the BEMF changes from the curve 224 to the curve 222 . Then, according to the output signal 102 , the control circuit 11 determines that the negative zero-crossing has occurred and then switches the current to flow sequentially through the windings V and U, i.e., to the V-U phase 203 , so that the motor enters the normal driving mode once started as described above.
[0028] In reference to FIG. 2A , it is also possible that the rotor of the DC brushless motor already stays at the static equilibrium point 204 in the stationary state, in which case exciting the U-V phase 201 will fail to rotate the rotor. Therefore, if the first BEMF does not cross the positive zero-crossing point during the start-time period, the control circuit 12 will switch the current to the windings V and W, i.e., to the V-W phase 202 , and then proceed with the aforementioned operations.
[0029] With the above arrangement of this invention, by supplying a current to two of the windings of the DC brushless motor, the DC brushless motor is rotated in the forward direction to excite a BEMF in the other winding. Then, in response to the variation of the BEMF induced by the swing of the motor when the motor rotates to the static equilibrium point, the current is switched to another two-winding combination to ensure successful running of the motor. In this way, a complex operational procedure is not needed to start the motor.
[0030] The second preferred embodiment of this invention is depicted in FIGS. 3A and 3B , which jointly depict the flow diagram of a method for starting a DC brushless motor. The DC brushless motor comprises a plurality of windings jointly connected to each other through a joint juncture. This method comprises the following steps. Initially, in reference to FIG. 3A , step 400 is executed to excite a first phase by supplying a current to a first winding and a second winding of the windings. Then, step 401 is executed to wait a delay time, in which the length of the delay time is adapted to avoid that a pseudo BEMF crosses either a positive zero-crossing point or a negative zero-crossing point. This is because the erroneous noise signals that are possibly generated when the DC brushless motor is started might cause a pseudo positive or pseudo negative zero-crossing of the BEMF, so a delay time is necessary to prevent this phenomenon from interfering with the starting process of the motor.
[0031] Next, step 402 is executed to measure the first BEMF of a third winding which the current does not flow therethrough. Then, step 403 is executed to determine whether the positive zero-crossing occurs during the start-time period, i.e., whether the first BEMF exceeds a reference value. If the positive zero-crossing occurs during the start-time period, step 405 is executed to switch to a second phase by switching the current to flow sequentially through the second winding and the third winding; otherwise, if the positive zero-crossing does not occur during the start-time period, step 404 is executed to determine whether the start-time period has elapsed. If the start-time period has elapsed, then step 405 is executed; otherwise, step 403 is repeated.
[0032] Next, step 406 is executed to measure a second BEMF of the first winding, and step 407 is executed to switch to a third phase by switching the current to flow sequentially through the second winding and the first winding when the second BEMF of the first winding does not have a current that flows therethrough and crosses the negative zero-crossing point. Now, the DC brushless motor has been started successfully to enter the normal driving mode. The normal driving mode will be understood by those skilled in the art upon reviewing FIGS. 2A and 2B and thus will not be further described herein.
[0033] In addition to the steps depicted in FIGS. 3A and 3B , the second preferred embodiment may also execute all the operations and functionalities of the first preferred embodiment. Those of ordinary skill in the art may readily understand how the second preferred embodiment executes these operations and functionalities based on the descriptions of the first preferred embodiment. Thus, this will not be further described herein.
[0034] Accordingly, according to the variation of BEMF induced by the swing of the motor when the motor rotates to a static equilibrium point, this invention supplies a current to another two-winding combination to ensure the successful running of the motor. This reduces the cost by eliminating the disposition of the Hall sensors and ensuring a proper and fast start of the DC brushless motor.
[0035] The above disclosure is related to the detailed technical contents and inventive features thereof. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.
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A starting apparatus for a direct current (DC) brushless motor and a method thereof are provided. The DC brushless motor comprises a plurality of windings presenting a joint connection via a common connection. The starting apparatus provides current to two of the three windings and rotates the DC brushless motor to obtain a Back Electro-Motive Force (BEMF) from the floating winding. Then, the starting apparatus provides a current to another two windings to operate the motor according to the variation of BEMF induced by the swing of the motor when it rotates to a static equilibrium point.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to valves and, more specifically, to a flow regulating valve that regulates the flow of fluid in one direction and allows the generally unregulated flow of fluid in the opposite direction.
2. Description of the Related Art
In vehicles employing hydraulic systems, it is known to employ valves that limit the flow of the hydraulic fluid through a fluid line leading to a hydraulic actuator such as a hydraulic motor or cylinder to a maximum flow rate. For example, in a combine harvester it is known to use an internal combustion engine to power a hydraulic pump. The hydraulic pump provides hydraulic fluid under pressure to a hydraulic circuit. Each of the driven wheels of the combine harvester may include a separate hydraulic motor that is powered by the hydraulic circuit. Each of the motors may be located in a separate loop in communication with the hydraulic circuit. By reversing the direction of flow through the individual loops with the use of a reversing pump, reversing valve or other suitable means, the rotational direction in which the wheel is driven may also be reversed.
In such a loop, it is known to provide two flow regulating valves, one on each side of the hydraulic motor. The flow regulating valves are positioned in the loop such that one of the valves limits the flow of hydraulic fluid through the hydraulic motor, or other hydraulically driven device, to a maximum flow rate in a first direction while the other valve limits the flow to a maximum flow rate in the opposite direction. During operation, while one valve is regulating flow, it is desirable for the other valve in the loop that is not performing a flow regulating function to freely pass the fluid therethrough with a minimal pressure drop and without restricting the flow rate of the fluid.
By providing flow regulating valves in each individual hydraulic motor loop, if one of the driven wheels begins slipping, the flow of hydraulic fluid to the slipping wheel will be limited to the maximum flow rate permitted by the valve. Limiting the flow rate of hydraulic fluid to the slipping wheel prevents excess flow of hydraulic fluid to the slipping wheel from depriving the remaining wheels of a sufficient flow of hydraulic fluid as well as preventing the uncontrolled spinning of the slipping wheel which can result in damage to the turf, cropland and/or tire. FIGS. 1 and 2 illustrate one known example of such a flow-regulating valve.
The valve 10 shown in FIGS. 1 and 2 includes a valve body 12 that receives outlet adapter 14 with an O-ring 15 or other suitable means providing a seal therebetween. Valve body 12 and outlet adapter 14 both include axially extending passages 16 and 18 , respectively, for conveying hydraulic fluid. Valve 10 also includes piston 20 , baffle member 22 and spring 24 which provide for the regulation of fluid flow through the valve. Valve 10 limits the flow of hydraulic fluid to a predetermined design flow rate when hydraulic fluid is flowing through valve 10 in the direction indicated by flow arrows 26 in FIG. 1 . When hydraulic fluid is flowing in this regulated direction, piston 20 will initially be in the position shown in FIG. 2 wherein spring 24 biases piston 20 away from baffle 22 to a point where radial flange 28 engages valve body 12 . The flow rate of hydraulic fluid through valve 10 is dependent upon the pressure differential across valve 10 . When the flow of hydraulic fluid through calibrated orifice 30 in the direction indicated in FIG. 1 increases, the pressure differential acting on piston 20 will also increase. When the pressure differential and resulting force on the piston 20 exceeds the biasing force of spring 24 , piston 20 will be biased towards baffle 22 . As piston 20 moves towards baffle 22 , the annular orifice 32 defined between piston 20 and baffle member 22 decreases in size thereby restricting the flow of fluid through the valve. By properly selecting the spring and valve dimensions, valve 10 may be used to limit the flow of fluid in the direction indicated in FIG. 1 to a maximum predetermined flow rate.
In FIG. 2 , the flow of hydraulic fluid through valve 10 is in the opposite return flow direction as indicated by flow arrows 27 . When fluid is flowing in this return direction, there is no fluid flow force to counteract the biasing force of spring 24 and annular orifice 32 maintains a constant size regardless of the flow rate or pressure differential of the hydraulic fluid. Consequently, valve 10 does not positively control the flow rate of the hydraulic fluid through the valve in the return direction and flow is limited by the size of the metering orifice 30 . In other words, the valve does not regulate the flow of fluid through the valve when the fluid is flowing in the direction indicated by arrows 27 in FIG. 2 but rather the limited size of metering orifice 30 restricts the flow of fluid through the valve resulting in a pressure drop across the valve and undesirable power losses and heating of the fluid.
Another example of a known flow compensating valve assembly is shown in U.S. Pat. No. 5,320,135. The valve assembly disclosed in this patent may be used with hydraulic cylinders found in hydraulic platform lifts. The compensator valve 1 includes a valve body 10 receiving a sleeve 12 having an upper portion 16 and a lower portion 18 . A piston 20 is sliding received within sleeve 12 and, as best seen in FIGS. 3–6 , a spring 30 is provided between the bottom end 19 of the lower sleeve portion 18 and the top end wall 21 of piston 20 . Piston 20 includes an axial main port 22 and a pair of relief ports 23 a and 23 b on its side wall periphery portion. In operation, as shown in FIG. 3 , when hydraulic fluid is traveling from the pump to the hydraulic cylinder from borehole 44 to bore 41 , as shown by the arrows, hydraulic fluid travels around and between the lower sleeve portion 18 and the inner wall portion 54 of the valve body 10 and into sleeve 12 through ports 15 a and 15 b. As shown, during this condition, piston 20 is forced toward bore hole 41 thereby causing relief ports 23 a and 23 b to be placed in communication with the relief region 56 of sleeve 12 . Thus, flow is provided through side relief ports 23 a and 23 b as well as through the axial main port 22 . When the flow direction is reversed, with fluid flowing from the hydraulic cylinder to the pump, and there is little or no back pressure as depicted in FIG. 4 , spring 30 maintains the piston 20 in the fully extended position thereby allowing flow through the ports 23 a and 23 b. When the flow from the hydraulic cylinder to the motor is increased, as depicted in FIG. 5 , piston 20 acts against the spring 30 and travels into sleeve 12 thereby closing off the fluid relief ports 23 a and 23 b such that flow occurs only through the main axial port 22 . As the hydraulic fluid pressure further increases as shown in FIG. 6 , the piston exerts yet a greater force against spring 30 traveling further into the sleeve 12 so as to partially block outlet ports 15 a and 15 b.
While the valve assembly disclosed in U.S. Pat. No. 5,320,135 may effectively regulate the flow of hydraulic fluid for the hydraulic cylinder of a hydraulic lift, it is not without shortcomings. If such a valve assembly were to be used to limit the flow of hydraulic fluid to a hydraulic motor by placing the valve in a hydraulic motor loop circuit, as shown in FIGS. 4–6 of U.S. Pat. No. 5,320,135, the fluid flow would initially have to overcome the resistance of spring 30 before the valve is moved from the condition shown in FIG. 4 to that shown in FIG. 5 . This could result in a relatively rough transition wherein the fluid flow initially increases rapidly while the valve was in the condition of FIG. 4 and then rapidly decreases as the valve is moved to the condition shown in FIG. 5 wherein ports 23 a and 23 b are closed. The flow rate could then resume its increase until the valve begins to close ports 15 a and 15 b as depicted in FIG. 6 . While this may be acceptable for the operation of a hydraulic lift, such a transition could result in the rough and unacceptable operation of a hydraulic motor driven wheel. This rough transition would likely be particularly evident when the direction of fluid flow to such a hydraulic motor was reversed and fluid flow was initially being increased.
An improved valve assembly is desired which may be used to efficiently regulate the flow of fluid in one direction to a hydraulic device without rapid or rough transitions and, in the other direction, allow unregulated fluid flow with minimal restriction thereby minimizing power losses and heating of the fluid.
SUMMARY OF THE INVENTION
The present invention provides a flow regulating valve that regulates the flow rate of a fluid through the valve in one direction and allows return fluid to efficiently flow through the valve in the opposite direction.
The invention comprises, in one form thereof, a valve assembly including a valve body defining a fluid passage extending through the valve body. The fluid passage has a first end and an opposite second end wherein the first end defines a first port through which fluid is communicated to and from the fluid passage and the second end defines a second port through which fluid is communicated to and from the fluid passage. A biasing element and a valve member are also provided. The valve member is moveably disposed within the fluid passage within the valve body and has a travel length extending from a first position relative to the valve body to a second position relative to the valve body. The biasing element biases the valve member along the travel length from the first position toward a third position disposed between the first and second positions. The valve member at least partially defines a variable first opening (e.g., variable annular opening 98 ), a second opening (e.g., metered orifice 62 ) and at least one third opening (e.g., openings 64 ). The first opening defines a variable constriction in the fluid passage between the first and second ends and has a size which progressively increases as the valve member moves from the first position toward the third position. The second opening and the at least one third opening define the second port wherein, when the valve member is disposed between the first position and the third position, the second port is defined substantially solely by the second opening and, when the valve member is in the second position, the second port is defined by both the second opening and the at least one third opening. The valve member defines a passage extending from the second port to the first opening and the biasing element is located outside the valve member passage. Fluid flow through the fluid passage in a first direction from the second end toward the first end exerts pressure upon the valve member and biases the valve member toward the first position. Fluid flow through the fluid passage in a second direction from the first end toward the second end exerts pressure upon the valve member and biases the valve member toward the second position.
The invention comprises, in another form thereof, a valve assembly including a valve body defining a fluid passage extending through the valve body. The fluid passage has a first end and an opposite second end. The first end defines a first port through which fluid is communicated to and from the fluid passage and the second end defines a second port through which fluid is communicated to and from the fluid passage. A biasing element and a valve member are also provided. The valve member is moveably disposed within the fluid passage within the valve body and has a travel length extending from a first position relative to the valve body to a second position relative to the valve body. The valve member further defines a third position along the travel length wherein the third position is disposed between the first and second positions. The valve member at least partially defines a variable first opening and the second port. The first opening defines a variable constriction in the fluid passage between the first and second ends and has a size that progressively increases as the valve member moves from the first position toward the third position. The second port is variably sized wherein the second port defines a first area providing fluid communication with the fluid passage when the valve member is in the third position and defines a second area providing fluid communication with the fluid passage when the valve member is in the second position with the second area being greater than the first area. The travel length includes a biased travel portion between the first and third positions wherein the biasing element biases the valve member from the first position towards the third position and an unbiased travel portion between the third position and the second position wherein the valve member is unbiased with respect to the biasing element. Fluid flow through the fluid passage in a first direction from the second end toward the first end exerts pressure upon the valve member and biases the valve member toward the first position. Fluid flow through the fluid passage in a second direction from the first end toward the second end exerts pressure upon the valve member and biases the valve member toward the second position.
The invention comprises, in yet another form thereof, a valve assembly including a valve body defining a fluid passage extending through the valve body. The fluid passage has a first end and an opposite second end. The first end defines a first port through which fluid is communicated to and from the fluid passage and the second end defines a second port through which fluid is communicated to and from the fluid passage. A spring is disposed within the fluid passage and is engageable with the valve body. A piston is moveably disposed within the fluid passage and is operably couplable with the spring. The piston has a travel length extending from a first position in the fluid passage to a second position in the fluid passage. The piston also defines a third position along the travel length wherein the third position is disposed between the first and second positions. The piston has a substantially cylindrical sidewall defining an axially extending passage through the piston and an end wall disposed at a first axial end of the piston. The piston at least partially defines a first opening, a second opening and at least one third opening. The first opening is in communication with the axial piston passage and is disposed at a second axial end of the piston opposite the first axial end. The first opening defines a variable constriction in the fluid passage between the first and second ends and has a size which progressively increases as the piston moves from the first position toward the third position. The end wall of the piston defines a second opening in communication with the axial piston passage and the piston sidewall defines at least one third opening proximate the end wall. When the piston is disposed between the first and third positions, the second port is defined substantially solely by the second opening and, when said piston is in the second position, the second port is defined by both the second opening and the at least one third opening. The spring is located outside the axial piston passage. Fluid flow through the fluid passage in a first direction from the second end toward the first end exerts pressure upon the piston and biases the piston toward the first position. Fluid flow through the fluid passage in a second direction from the first end toward the second end exerts pressure upon the piston and biases the piston toward the second position.
An advantage of the present invention is that it minimizes the restriction and enhances the return flow of fluid through the valve and thereby reduces power losses and the heat generated by the flow of return fluid through the valve in the unregulated direction. Additionally, by removing the spring from the interior of the piston, the calibration orifice of the piston may be enlarged thereby reducing the pressure drop experienced by fluid flowing through the calibration orifice and enhancing the operation of the valve for fluid flow in both the regulated and unregulated flow directions. The regulation of the fluid flow through the valve assembly in the regulated flow direction is also relatively smooth without abrupt transitions as the flow rate changes.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross sectional view of a conventional flow regulating valve.
FIG. 2 is another cross sectional view of the conventional flow regulating valve of FIG. 1 .
FIG. 3 is an exploded view of a valve in accordance with the present invention.
FIG. 4 is a cross sectional view of the valve of FIG. 3 wherein fluid is flowing in the regulated direction at less than the maximum flow rate.
FIG. 5 is another cross sectional view of the valve of FIG. 3 wherein fluid is flowing in the regulated direction at the maximum flow rate.
FIG. 6 is another cross sectional view of the valve of FIG. 3 wherein fluid is flowing in the unregulated direction.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the exemplification set out herein illustrates an embodiment of the invention, the embodiment disclosed below is not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
DETAILED DESCRIPTION OF THE INVENTION
A valve assembly 40 in accordance with the present invention is shown in an exploded view in FIG. 3 . Valve assembly 40 includes a valve body 42 having a passageway defined by three axially aligned cylindrical bore sections 44 , 46 , 48 of differing diameters. In the illustrated embodiment, valve member 50 takes the form of a piston 50 reciprocatingly disposed in valve body 42 . Piston 50 includes a cylindrical sidewall 52 that defines interior passage 54 extending from first axial end 56 of piston 50 to the opposite second axial end 58 of piston 50 . An endwall 60 is located at first axial end 56 and includes a metering orifice 62 . A plurality of circumferentially spaced openings 64 are located in sidewall 52 proximate first axial end 56 . Second axial end 58 of piston 50 is open, i.e., it does not include an endwall or otherwise define a restriction within axial passage 54 . The radially outer surface of sidewall 52 at second axial end 58 forms a tapered surface 66 which cooperates with baffle member 78 . Piston 50 also includes a radially outwardly extending flange 68 .
A coupling member 70 , which takes the form of a washer in the illustrated embodiment, is located between flange 68 and biasing element 76 . Washer 70 includes a planar annular element 72 having a lip 74 located at its outer circumference. In the illustrated embodiment, biasing element 76 is a helical spring and the portion of spring 76 which directly engages washer 70 is seated within lip 74 to maintain the proper engagement of spring 76 with washer 70 during operation of valve 40 .
A baffle member 78 is also shown in FIG. 3 and includes a cylindrical sidewall 80 having a first end 82 . First end 82 of baffle 78 cooperates with second axial end 58 and tapered surface 66 to define a variable opening 98 . A radially projecting flange 84 is used in the securement of baffle 78 within valve 40 . An interior partition 86 extends across the interior space of the baffle and includes a bleed hole 88 . Circumferentially spaced openings 90 are located in sidewall 80 with partition 86 being located between first end 82 and openings 90 .
Baffle 78 is fixed within valve assembly 40 between adapter body 92 and valve body 42 . Baffle 78 is fixed in place by spring 76 which biases radial flange 84 into engagement with adapter body 92 . Alternative methods of securing baffle 78 may also be employed. Such alternative retaining means for preventing baffle member 78 from moving toward piston 50 during reverse flow conditions could include a snap ring seated in an annular groove in cylindrical bore 48 , a radially inwardly projecting annular lip in bore 48 , or a step in bore 48 that would engage radial flange 84 . Dashed lines 48 a in FIG. 3 illustrate schematically represent such an alternative retaining means that could be formed by a snap ring or annular lip. The function of baffle 78 might also be incorporated into another component part of valve assembly 40 such as adaptor body 92 or valve body 42 . For example, baffle 78 could be integrally formed with adaptor body 92 . Adapter body 92 includes an interior fluid passage 94 that is in fluid communication with bore 48 to thereby form a fluid passage 100 extending through valve assembly 40 between first port 102 and second port 104 . An O-ring 96 is used to provide a seal between adapter body 92 and valve body 42 . Other suitable means for providing a seal may also be employed.
FIG. 4 illustrates valve assembly 40 with fluid flowing in a first direction from the second end 105 of fluid passage 100 to the first end 103 of fluid passage 100 as indicated by flow arrows 106 . The flow direction illustrated in FIG. 4 is the regulated flow direction of valve assembly 40 . As shown in FIG. 4 , the flow path of fluid through fluid passage 100 of valve assembly 40 begins with fluid entering passage 100 through second port 104 . When piston 50 is in the position shown in FIG. 4 , the second port is defined solely by an opening 62 which forms a metered orifice. Fluid enters axial passage 54 through second port 104 and subsequently passes through variable opening 98 to enter bore section 48 where it passes through and around spring 76 before entering openings 90 in baffle 78 . After passing through baffle 78 , the fluid enters passage 94 in outlet adapter 92 and then exits valve assembly 40 through first port 102 .
FIG. 4 illustrates the condition wherein the fluid flow and pressure differential on opposite sides of piston 50 is not sufficient to overcome the biasing force of spring 76 . In this condition, spring 76 biases washer 70 into engagement with end face 47 of bore 48 in valve body 42 . Relief bore 46 is configured to allow flange 68 to be received therein and prevent the entry of washer 70 . In the illustrated embodiment, this is accomplished by using a circular washer 70 having a diameter greater than cylindrical bore 46 , however, other geometric shapes may also be employed. When fluid is flowing in the direction indicated by flow lines 106 , a pressure differential between different points in the fluid path will exist and will generate forces acting upon piston 50 , primarily the pressure differential on either side of orifice 62 which acts upon end wall 60 , and will bias piston 50 to the position shown in FIG. 4 . At relatively low flow rates, the force acting on piston 50 generated by the pressure differential will be relatively low and be unable to overcome the biasing force of spring 76 .
FIG. 5 illustrates valve assembly 40 with fluid flowing in the same direction as shown in FIG. 4 but wherein the pressure differential on opposite sides of piston 50 is higher. In the condition illustrated in FIG. 5 , the force acting on piston 50 generated by the pressure differential is large enough to compress spring 76 and bias piston 50 toward baffle member 78 . As piston 50 is biased towards baffle 78 , annular opening 98 becomes progressively smaller and thereby acts to restrict the flow of fluid through fluid passage 100 . Generally, a higher pressure differential would result in a higher flow rate through a given fluid passage. However, due to the variable constriction in fluid passage 100 defined by variable opening 98 , opening 98 acts to constrict the flow of fluid through passage 100 and thereby counteracts the flow increasing effects of an increasing pressure differential. At a sufficiently high pressure differential, opening 98 may be completely closed with tapered surface 66 engaging baffle end 82 . If opening 98 is completely closed, a small quantity of fluid may still pass through bleed hole 88 and allow some fluid to be conveyed through fluid passage 100 . Thus, the operable coupling of spring 76 with piston 50 provides a restriction, i.e., opening 98 , that varies in response to the pressure differential of the fluid on opposite sides of the restriction and thereby provides a flow compensating mechanism which limits the flow rate of fluid through valve assembly 40 to a maximum value. The precise value of the maximum flow rate will be determined not only by the dimensions of opening 62 , the spring force of spring 76 and the configuration of variable opening 98 , but also by the properties of the fluid flowing through the valve assembly as will be recognized by those having ordinary skill in the art.
FIG. 6 illustrates valve assembly 40 with fluid flowing in a direction reverse to that depicted in FIGS. 4 and 5 as indicated by flow arrows 108 and sometimes referred to as the unregulated direction. When fluid flows in the direction depicted in FIG. 6 , if piston 50 is initially in the position shown in FIG. 5 , it will be biased by spring 76 into the position shown in FIG. 4 . At this position, a radial outer portion 73 of coupling member 70 engages endface 47 to limit the travel of the coupling member, e.g., washer 70 . Piston 50 will then be biased to the position shown in FIG. 6 due to the pressure differential and forces imparted to piston 50 by the fluid impinging upon piston 50 , primarily upon end wall 60 , as the fluid flows through valve assembly 40 . The travel of piston 50 will be stopped at the position shown in FIG. 6 due to the engagement of flange 68 with end face or ledge 67 between cylindrical passage sections 46 and 44 . Thus, piston 50 has a length of travel from a first position 50 a depicted in FIG. 5 to a second position 50 b depicted in FIG. 6 which has a biased portion and an unbiased portion with respect to spring 76 . Piston 50 also has a third position 50 c, depicted in FIG. 5 , between the first and second positions 50 a, 50 b. When piston 50 is located between the first position 50 a and third position 50 c, spring 76 exerts a biasing force on piston 50 urging it towards the third position 50 c, thus, that portion of the travel length of piston 50 between positions 50 a and 50 c is a biased portion. When piston 50 is located between positions 50 c and 50 b, piston 50 is unbiased with respect to spring 76 . As described above, however, piston 50 is biased by the flow of fluid either toward or away from baffle 78 when it is between positions 50 c and 50 b.
When piston 50 is between positions 50 a and 50 c shown in FIGS. 5 and 4 respectively, second port 104 is defined solely by metering orifice 62 which has a fixed area for the communication of fluid therethrough. As piston 50 moves from position 50 c to position 50 b shown in FIG. 6 , first end 56 of piston 50 is projected beyond cylindrical section 43 of valve body 42 exposing openings 64 in sidewall 52 . As openings 64 are exposed, the area of second port 104 is effectively enlarged enhancing the outflow of fluid from fluid passage 100 . In the illustrated embodiment, variable opening 98 is also enlarged as piston 50 moves from position 50 c ( FIG. 4 ) to position 50 b ( FIG. 6 ) and increases the gap between baffle end 82 and piston end 58 . It is not necessary for opening 98 to vary in area when piston 50 is between positions 50 c and 50 b because valve assembly 40 is not performing a flow regulating function when fluid flow positions piston 50 between 50 c and 50 b. The continued enlargement of opening 98 , however, whereby opening 98 has its largest area when piston 50 is in position 50 b, does advantageously enhance the flow of fluid through valve assembly 40 in the reverse or unregulated direction depicted in FIG. 6 .
When the valve assembly is in the condition shown in FIG. 6 and the flow of fluid is reversed, piston 50 will initially be in the position shown in FIG. 6 , however, since piston 50 is unbiased by spring 76 in this position, piston 50 will move to the position shown in FIG. 4 almost immediately upon the reversal of fluid flow due to the forces acting on piston 50 caused by the flow of fluid through valve assembly 40 and the flow rate will not be subject to a later rough transition caused by the closure of openings 64 . Thus, by providing a piston 50 with a travel length having a portion unbiased by spring 76 , the flow of fluid through valve 40 in the direction shown in FIG. 4 almost immediately closes openings 64 and allows the flow rate of the hydraulic fluid to be smoothly regulated.
It is also noted that the efficient flow of fluid through valve assembly 40 is enhanced by the use of a large diameter spring that is located radially outwardly of cylindrical sidewall 52 of piston 50 . By providing a spring 76 having a diameter 77 that is larger than the diameter 51 of piston 50 and locating spring 76 outside of the axial passage of the piston, opening 62 in end wall 60 can be made larger because end wall 60 no longer must engage spring 76 . The use of a larger metering orifice 62 facilitates the efficient conveyance of fluid through valve assembly 40 in both directions. By more efficiently conveying fluid through valve assembly 40 , the fluid will experience a smaller pressure loss and generate less heat as it passes through orifice 62 and valve assembly 40 .
Also seen in FIGS. 3–6 is an O-ring 110 located on cylindrical section 43 . O-ring 110 is used to provide a seal between valve body 42 and the structure to which valve body 42 is secured. In a typical installation, valve body 42 would be threaded into the port of a cast iron valve body. Similarly, O-ring 112 located on adapter body 92 is used to provide a seal between adapter body 112 and a fluid conduit or other fluid conveyance structure. In a typical installation, adaptor body 92 would be placed in communication with a fluid conduit, e.g., a hose or tube, leading to a hydraulic motor.
While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.
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A valve assembly that includes a valve body defining a fluid passage. First and second ends of the fluid passage define first and second ports for fluid flow. A spring and piston are located in the fluid passage. The piston has a travel length extending between first and second positions with a third position located therebetween. The spring biases the piston from the first toward the third position and is located outside the axial piston passage. The piston at least partially defines a first, second and at least one third opening. The first opening defines a variable constriction which increases in size as the piston moves from the first to third positions. The piston end wall defines the second opening and the piston sidewall defines the third openings. Movement of the piston from the third to second position exposes the third openings increasing the area of the second port.
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CROSS REFERENCE TO RELATED APPLICATION
This is the 35 USC 371 national stage of International Application PCT/FR99/01117 filed on May 11, 1999, which designated the United States of America.
FIELD OF THE INVENTION
The present invention relates to electric irons which comprise a sole plate heated by means of an electric heating resistance and a system of thermal regulation, in which a control member indicates the reference value of the temperature corresponding to the fabric to be ironed, a detector gives the image of the temperature of the sole plate, and a control system controls the opening or the closing, as a function of the difference between the reference temperature and the measured temperature, of the supply circuit of the electric heating resistance.
BACKGROUND OF THE INVENTION
In certain known electric irons of this type, there is provided a safety system detecting the position of the iron, on the heel or on the sole plate, and cutting the supply of the heating resistance when the iron is left in a vertical position on the heel during a period greater than a certain limit.
Such a system is adapted to avoid accidental burning of the user or his surroundings, when the iron is unused and left on. It also permits avoiding the apparatus being subjected to prolonged and useless heating cycles, when the latter is accidentally left on.
Such a system nevertheless has the drawback of using a physical position detector, which increases the cost of the apparatus, increases its size and has decreased reliability with time and the cycles of use.
SUMMARY OF THE INVENTION
The invention proposes overcoming these drawbacks and providing an iron of the type described above, provided with a safety system without a position detector, capable of detecting reliably the stoppage of use of the apparatus.
According to the invention, the iron comprises a safety system having an electronic module which:
a) receives from the control system the information as to closure of the supply circuit of the electric heating resistance,
b) produces over a fixed time interval the sum of the durations of supply,
c) and opens the supply circuit of the electric heating resistance if the value thus obtained is below a predetermined threshold value.
Thus the system detects a magnitude represented by the quantity of heat delivered by the apparatus, characteristic of contact of the sole with a cloth or with ambient air.
According to an advantageous characteristic of the invention, the electronic module comprises a switch mounted in series with the electric heating resistance, which is actuated in response to a signal delivered by a first counter.
On the other hand, the first counter comprises a programmable integrated circuit, which has at least one supply path, a reception path for a zero set signal, an outlet path, a means for the generation of an activated clock frequency upon turning on the iron.
Moreover, the first counter delivers an opening signal to a relay whose contacts form the switch, when it has carried out an operation of counting of a time lag greater than predetermined time T 1 , without receiving the zero set signal, T 1 being greater than T 2 .
Preferably, the first counter delivers simultaneously an opening signal to a relay whose contacts form the switch and a lockage signal for the means for generating associated clock frequency to the first counter, after it has carried out a counting operation of a duration greater than a predetermined time T 1 , without receiving a zero set signal, T 1 being greater than T 2 .
According to another characteristic of the invention, the safety system comprises rearming means that can be actuated by the user, so as to close the relay and reactivate the means for generating clock frequency associated with the first counter, when the iron is on.
The rearming means, when actuated by the user, emit a zero set signal simultaneously to the first and second counter.
According to another embodiment, the safety system comprises an electronic module which:
a) receives from the control system information as to the closure of the supply circuit of the electric heating resistance,
b) counts over a fixed time interval the number of alternations between open and closed conditions of the supply circuit of the electric heating resistance, and opens the supply circuit of the electric heating resistance if the number thus obtained is below a predetermined threshold value.
This other embodiment permits, again by observation of the operation of the heating resistance, determining whether the latter is frequently urged to compensate the heat losses of the sole plate, and to cut the supply in the contrary case, which is taken to be characteristic of a nonuse condition.
BRIEF DESCRIPTION OF THE DRAWINGS
The different characteristics as well as the advantages of the invention will become further apparent from the description which follows, given by way of non-limiting example, with reference to the accompanying drawings, in which:
FIG. 1 is an operational diagram of a safety system according to the invention;
FIG. 2 is an operational diagram of a safety system according to a preferred embodiment of the invention;
FIG. 3A is a graph connecting the electrical condition of the resistance and time, in a case of use; and
FIG. 3B is a graph connecting the electrical condition of the resistance and time in a case of non-use of an iron.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, there is shown the supply circuit 1 of the electric heating resistance ( 2 ) adapted to heat the sole plate of an iron, the electric power being supplied by the household supply ( 3 ). The iron is either a dry iron or a steam iron.
The temperature of the sole plate is regulated by means of a control member ( 4 ), generally actuated by the user, which fixes the reference temperature, by a temperature detector ( 5 ) located adjacent the sole plate and which gives the image of the temperature of the sole plate, and a control system ( 6 ), which actuates a first switch ( 7 ) disposed in the supply circuit ( 1 ) of the electric heating resistance ( 2 ), as a function of the difference between the temperature of the sole plate and the reference temperature, such that the temperature of the sole plate will be constantly located in a predetermined range about the reference temperature.
At present, this system of regulation is simply constituted by a mechanical thermostat or, in apparatus of a wider range, comprises a potentiometer and electronic regulation means.
The supply circuit ( 1 ) of the electric heating resistance ( 2 ) comprises, according to the invention, a second switch ( 8 ) actuated by an electronic module ( 9 ) when the safety system ( 10 ) detects a non-use condition of the apparatus beyond a certain limit.
The safety system ( 10 ) receives a signal ( 11 ) from the control system ( 6 ), representative of the condition of the first switch ( 7 ), and hence of the supplied or non-supplied condition of the electric heating resistance ( 2 ), the second switch ( 8 ) being closed under the initial condition of the safety system ( 10 ), at the moment of connection of the apparatus to the sector.
In FIG. 2, there is shown a safety system according to a preferred embodiment of the invention, in which the safety system ( 10 ) is supplied with alternating current by the domestic network ( 3 ), by means of a so-called “positive” route (P) and a so-called “neutral” route (N), said safety system ( 10 ) also retaining the potential at one of the terminals of the heating resistance ( 2 ) by means of a third path (X), such as said heating resistance ( 2 ) namely located between the “neutral” path (N) and the third path (X).
The safety system ( 10 ) comprises a first connector ( 12 ) with two paths permitting connecting the switch ( 8 ) with the heating resistance ( 2 ), the two inlet paths being the positive path (P) and the third path (X). The safety system ( 1 ) comprises a second connector ( 13 ) with two paths, which receives the reference potential by the neutral path (N) and the condition information as to the heating resistance ( 2 ) by the third path (X).
The electronic module ( 9 ) comprises two modules ( 14 , 15 ) processing the electric signals passing through the three paths (N, P, X) so as to obtain continuous signals of an intensity permissible to the components, namely respectively a reference potential (V ss ), a potential (V cc ) defining with it a supply voltage for the active components of the electronic module ( 9 ), and a potential for condition information (x) of the heating resistance ( 2 ).
The electronic module ( 9 ) comprises a first and second counter ( 21 , 22 ) each comprising a programmable integrated circuit, which has at least one supply path (A 1 , A 2 ) set to the potential (V cc ) when the apparatus is on, a reception path for a zero set signal (R 1 , R 2 ), and an output path (S 1 , S 2 ), and means for generating clock frequency supplied by a supply path of the means for generating the clock frequency (H 1 , H 2 ).
The electronic module ( 9 ) moreover comprises a first bipolar transistor ( 16 ), whose base is connected to the output path (S 1 ) of the first programmable integrated circuit ( 21 ) by means of a resistance ( 18 ), the emitter is connected to the supply path of the means for generating clock frequency (H 1 ) of the first counter ( 21 ), and the collector to the line of reference potential (V ss ); a second bipolar transistor ( 17 ) whose base receives the signal corresponding to the condition information potential (x) of the heating resistance, the emitter is connected to the supply path of the clock frequency generation means (H 2 ) of the second programmable integrated circuit ( 22 ), and the collector to the line of reference potential (V ss ).
The signal delivered by the first counter ( 21 ) on its output path (S 1 ) is transmitted to a relay ( 20 ), which causes opening of closing of the supply circuit of the heating resistance, via the switch ( 8 ) formed by its contacts.
Upon turning on the iron, the means for generating clock frequency of the first counter ( 21 ) are supplied and the heating resistance being supplied, the means for generating clock frequency of the second counter ( 22 ) are also supplied. The second counter ( 22 ) is incremented while the heating resistance ( 2 ) is supplied, and carries out the addition of the supply times of said resistance. The second counter ( 22 ) emits an end of cycle signal on its outlet path (S 2 ), via a resistance ( 19 ), as soon as it has carried out a counting operation of a duration greater than a predetermined time T 2 . This end of cycle signal is directed toward the zero set path (R 2 ) of the second counter ( 22 ) and in parallel to the zero set path (R 1 ) of the first counter ( 21 ).
If the first counter ( 21 ) has carried out a counting operation of a duration greater than a predetermined time T 1 , without having received a zero set signal on its reception path (R 1 ), it emits on its outlet path (S 1 ) a signal to the relay ( 20 ), which opens the supply circuit of the heating resistance, this cutoff signal also effecting, via the first transistor ( 16 ), the blocking of the clock frequency generating means of the first counter.
Rearmament means ( 23 ) are provided to permit the user to turn on the iron again and to restart the safety system, when the latter has cut off the supply of the heating resistance following the detection of a prolonged non-use condition.
These re-arming means ( 23 ), when they are actuated by the user, emit an impulse on the zero set paths (R 1 , R 2 ) of the first and second counters ( 21 , 22 ), which has the effect of re-establishing the outlet path (S 1 ) of the first counter ( 21 ) in its initial condition, and thus unblocking its clock frequency generating means and causing, by a new opening signal of the relay ( 20 ), the closure of the switch ( 8 ) and hence of the supply circuit of the heating resistance ( 2 ).
As a result of the system described above, the safety system according to the invention cuts the supply circuit of the heating resistance ( 2 ), reversibly thanks to the rearmament means ( 23 ) if in the course of a time interval T 1 , for example of the order of six minutes, the heating time of the heating resistance has not reached a limit T 2 , for example of the order of 25 seconds, which condition characterizes a non-use condition of the apparatus.
Thus, as can be seen in FIGS. 3A and 3B, it is possible to characterize a use condition corresponding to the graph 3 a , relative to a non-use condition corresponding to the graph 3 b , either by a larger total supply time, or by a higher frequency of the supply phases.
Thanks to this safety system, whether applied to a dry iron or a steam iron, there is obtained a reading of the image of the temperature of the sole plate which reflects either a thermal exchange with a cloth to be pressed to deduce the operating position of the sole plate, or a thermal exchange with the air to deduce the vertical position of the sole plate.
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An iron comprises a sole plate heated by an electrical resistance and a heat-regulating system, wherein a control member indicates the temperature set value, a sensor displays the sole plate temperature, and a management system controls the electrical resistance power supply circuit to be opened or closed, on the basis of the difference between the set value and the measurement. The iron comprises a safety system comprising an electronic module, which: a) receives from the management system information for closing the electrical resistance power supply circuit; b) produces over a fixed time interval the total supply times; and c) opens the electrical resistance power supply circuit if the resulting value is less than a predetermined threshold value.
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The present invention generally relates to a revolute joint or hinge, and more particularly to a revolute joint or hinge for the hood or trunk of a motor vehicle.
BACKGROUND OF THE INVENTION
Movable panels or covers, such as hoods and trunk lids, are typically attached to the body or frame of a motor vehicle by means of one or more hinges, pins, or other type of revolute joint. Such movable panels or covers provide easy access to otherwise covered and hidden parts of the vehicle, such as the engine and trunk. The panels may possess considerable weight. For example, the hood of a large truck may exceed 100 pounds. Significant effort may be required to open or close a heavy panel or cover. In addition, a heavy panel or cover may cause injury should it fall open or shut in an uncontrolled manner.
To reduce the effort of opening such panels and reduce the risk of injury, it is often desirable to provide a force about the pivot axis of the hinge to counteract the weight of the panel. Typically the counteracting force is provided by springs which are arranged so that they are operative at the fully opened and closed positions of the vehicle panel. For example, extension springs may be arranged so that they are stretched when the hood of an automobile is fully closed and so that the stretching of the springs creates a force about the pivot axis of the hinge which tends to assist a user in lifting the hood to an open position. Other lift assisting mechanisms may employ arrangements of compression springs, coil springs, gas-springs, torsion-bars and the like.
However, such mechanisms for reducing the effort needed to open or close a vehicle panel require many parts in addition to the parts needed merely to provide the hinged motion. The additional parts add to vehicle weight and complexity and may increase vehicle manufacturing, maintenance, and operating costs. Accordingly, it would be desirable to provide a simple hinged or revolute joint that provides assistance in opening or closing a panel or cover without the need for additional parts.
In addition to the foregoing, it is also often desirable to isolate panels and covers from other parts of the vehicle structure to accommodate relative motion between them. For example, vehicle bodies and frames flex and vibrate as the vehicle is driven over a roadway. Vehicle bodies and frames also bend and flex due to differences in the thermal expansion characteristics of various component parts of the vehicle body or frame. Flexing may cause the mounting points between a movable panel or cover and the vehicle body to move relative to each other. The relative motion of the mounting points may create significant and potentially destructive stresses in the panel. Isolating the panel from the mounting points may reduce the stresses imparted to the panel.
One means of isolating a panel is to provide an elastomeric resilient mount between the panel and mounting point. For example, rubber grommets may be provided around the bolts attaching a panel to a hinge. Such isolation mounts provide for limited motion between the panel and the mounting points. Another means of isolating the panel from the mounting points includes providing cylindrical elastomeric bushings located concentric with the pivot axis of the hinge. Yet another isolation method is to provide an additional hinge joint having an axis substantially aligned with the longitudinal axis of the vehicle. Combinations of these isolation techniques may also be used.
However, such isolation techniques also require many parts in addition to those merely needed to provide for hinged motion of the vehicle panel with respect to the vehicle body or frame. The additional parts also add to vehicle weight and complexity and may increase vehicle manufacturing, maintenance, and operating costs. Accordingly, it would be desirable to provide a hinged or revolute joint that provides isolation between the motion of the body or frame of a motor vehicle and a panel or cover attached to the vehicle.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are provided by an arrangement of tubes and elastomeric bushings. The tubes generally have a square cross-section and are juxtaposed in concentric and overlapping relation to each other. Pairs of concentric tubes are rotated along their longitudinal axis relative to each other so that corners of an inner tube are adjacent to the sides of an outer tube. Elastomeric bushings are inserted between the inner and outer tubes in the spaces adjacent to the sides of the inner tube.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will be understood upon consideration of the following detailed description taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout and in which:
FIG. 1 is an oblique view of an illustrative embodiment of a hinge joint in accordance with the principles of the present invention;
FIGS. 2A and 2B are, respectivley, end and side views of the hinge of FIG. 1 ;
FIG. 3 is an an view of the hinge of FIG. 1 in a rotated position;
FIG. 4 is an oblique view of a truck frame and forward tilting hood coupled by a hinge in accordance with the principles of the present invention;
FIG. 5 is an oblique view of the hinge assembly of FIG. 4 , shown in more detail and with some obscuring structures removed;
FIGS. 6 , 7 , and 8 are sectional views of the truck frame and hood of FIG. 4 , showing the hood in intermediate, closed, and open positions, respectively; and
FIGS. 9 and 10 are, respectively, end and cut-away side views of another illustrative embodiment of a hinge joint in accordance with the principles of the present invention.
DETAILED DESCRIPTION
FIG. 1 is an oblique view of a first illustrative embodiment of elastomeric hinge 10 constructed in accordance with the principles of the present invention. FIGS. 2A and 2B , show an end view and a partial cut-away side view of elastomeric hinge 10 . Referring to FIGS. 1 and 2 together, elastomeric hinge 10 includes inner member 12 having a generally square cross section. Outer members 14 and 16 are disposed about and overlap, but are rotated about their respective longitudinal axes by approximately 45 degrees relative to inner member 12 . As used herein, two objects overlap when at least a portion of one element extends inside a portion of the other object.
Preferably, inner member 12 and outer members 14 and 16 are tubes manufactured of metal, plastic, or other suitable material. Inner member 12 is shown as being a hollow tube, but may also be made of a solid bar. Outer members 14 and 16 preferably comprise square shaped tubes, but only the inner surface need be generally square in cross section and the outer surface may have other shapes as appropriate for the end use of elastomeric hinge 10 . Although, the corresponding surfaces of inner member 12 and outer members 14 and 16 are preferrably square-shaped in cross section, this need not be the case, and other geometrical shapes such as a triangle, pentagon, hexagon, and so on, may also be used.
Outer members 14 and 16 are prefereably approximately concentric with inner member 12 . This configuration provides the the most predictable hinge-axis behavior, in that the hinge-axis remains substantially stationary as the hinge is operated. However, under some circumstances, it may be desireable to laterally or vertically offset one or more of the tube axes when manufacturing the hinge. This may be used, for example, so that the axes become aligned when the hinge is used in a situation in which a large static load is present.
Elastomeric elements 18 and 18 ′ are disposed between inner member 12 and outer members 14 and 16 , respectively. Elastomeric elements 18 and 18 ′ are preferably cylindrical rods of natural rubber, but may be made of synthetic rubber or other elastomeric material and may have non-round cross sections. Elastomeric elements 18 and 18 ′ may also be composite structures in which different materials are used along their lengths or through their thicknesses. Preferably, elastomeric elements 18 and 18 ′ are pre-loaded in compression upon assembly of elastomeric hinge 10 . Advantageously, the pre-compression of elastomeric elements 18 serves to retain them in between inner member 12 and outer members 14 and 16 without the need to bond elastomeric elements 18 to the inner or outer element using adhesives or the like.
In use, one of outer members 14 and 16 is attached to the body or frame of a motor vehicle, while the other outer member is attached to movable panel or cover, such as the hood or trunk. Outer members 14 and 16 may be attached to their respective parts of the vehicle using clamping straps or other suitable methods of securely attaching elastomeric hinge 10 to the vehicle parts. For example, flanges with a suitable bolt hole may be welded onto outer members 14 and 16 , or may be formed when outer members 14 and 16 are manufactured, e.g., by extrusion or the like.
Operation of elastomeric hinge 10 is described in connection with FIG. 3 , wherein outer member 16 remains stationary while outer member 14 is rotated counterclockwise through an angle α. As outer member 14 is rotated, the inner surfaces of outer member 14 push against and tend to compress elastomeric elements 18 against the outer surfaces of inner member 12 . This imparts a torque to inner member 12 tending to rotate it counterclockwise about its longitudinal axis through an angle β. As inner member 12 rotates, the outer surfaces of inner member 12 push against and tend to compress elastomeric elements 18 ′ against the inner surfaces of outer member 16 . Because outer member 16 remains stationary, the force arising from the compression of elastomeric elements 18 and 18 ′ tend to counteract the force tending to rotate outer member 14 , for example, the weight of a vehicle hood.
In FIG. 3 , the rotation of inner member 12 is shown to be approximately half that of outer member 14 . That is, angle β is approximately one half of angle α. However, the actual relationship depends upon the relative compliance of elastomeric elements 18 and 18 ′. If elastomeric elements 18 and 18 ′ are substantially identical, then the relative rotation angles will be as shown in FIG. 3 . A hinge so constructed would tend to have a counteracting force that increases smoothly as the hinge is operated.
However, if elastomeric elements 18 and 18 ′ differ significantly, then the rotation angles α and β will also differ. For example, elastomeric elements 18 ′ may be made of a material that is significantly less compliant, i.e., stiffer, than the material used for elastomeric elements 18 . In such a hinge, inner member 12 would not rotate significantly as outer element 14 is rotated, until the torque imparted on inner element 12 by elastomeric elements 18 has risen enough to begin compressing elastomeric elements 18 ′. A hinge so constructed would have a lower counteracting force during an initial rotation as the more compliant elastomeric elements 18 are compressed, and a higher counteracting force during a later portion of the rotation as the less compliant elastomeric elements 18 ′ are compressed. Similar effects may be attained by changing the dimensions, e.g., the length, of elastomeric elements 18 ′ so that they differ from those of elastomeric elements 18 .
An elastomeric hinge such as that shown in FIGS. 1–3 may advantageously be used as a hinge for a truck hood as shown in FIG. 4 , wherein hood 40 is shown coupled to frame 42 by a pair of elastomeric hinges 44 and 46 . A more detailed view of the structure of the hinge joint is shown in FIG. 5 .
Brackets 52 are attached to the truck frame by suitable means such as bolts 53 . One end of each of elastomeric hinges 44 and 46 is attached to brackets 52 using clamping straps 54 , and the other end is similarly attached to brackets 55 using clamping straps 56 . Brackets 55 are attached to cross member 57 which in turn is attached to truck hood 40 of FIG. 4 .
Upon consideration of FIG. 3 , it is readily apparent that elastomeric hinge 10 is symmetrical with respect to rotation of outer member 14 . That is, rotation of outer member 14 in either a clockwise or counterclockwise direction gives rise to a counteracting force due to elastomeric elements 18 and 18 ′. This characteristic of the elastomeric hinge of the present invention may be used advantageously to provide assistance when both opening and closing truck hood 40 of FIG. 4 . For example, in FIG. 6 elastomeric hinge 46 and truck hood 40 are configured so that when the center of mass of truck hood 40 is vertically centered over the pivot axis of elastomeric hinge 46 , elastomeric hinge 46 is in its neutral position. In this configuration, fully closing truck hood 40 rotates elastomeric hinge 46 in one direction, whereas fully opening truck hood 40 rotates elastomeric hinge 46 in the other direction. In each case, compression of elastomeric elements 18 of elastomeric hinge 46 creates a force acting against the rotation of hood 40 , as shown in FIGS. 7 and 8 .
FIG. 9 shows an alternative embodiment of an elastomeric hinge constructed in accordance with the principles of the present invention. Elastomeric hinge 90 is formed of three generally concentric tubes including inner member 92 , middle member 93 , and outer member 94 . Elastomeric elements 96 are disposed between inner member 92 and middle member 93 , and elastomeric elements 98 are disposed between middle member 93 and outer member 94 . FIG. 10 is a side view of elastomeric hinge 90 , showing the interior components of elastomeric hinge 90 in partial cutaway.
In use, elastomeric hinge 90 is typically configured so that inner member 92 and outer member 94 are coupled to a vehicle hood and body. Rotation of the inner member 92 relative to middle member 93 causes compression of elastomeric elements 96 thereby imparting a torque to middle member 93 . Rotation of middle member 93 relative to outer member 94 causes compression of elastomeric elements 98 . Outer member 94 is prevented from rotating because it is fixedly attached to the vehicle body. The compression of elastomeric elements 98 , therefore, causes a torque or force tending to counteract the compression.
It should be noted that the different dimensions of elastomeric elements 96 and 98 may cause them to have different compliance characteristics. Accordingly, the assisting force provided by elastomeric hinge 90 may vary significantly as it is operated from fully open to fully shut. This characteristic may be advantageous in that the assisting force may be larger when a hood or other cover is fully open or fully shut, while the assisting force is near minimum when the hood is at an intermediate position. Alternatively, the dimensions or materials of elastomeric elements 96 and 98 may be chosen so that their respective compliance characteristics are similar and the assisting force varies gradually over the operating range of hinge 90 .
Thus, an elastomeric hinge particularly suited for use in motor vehicles has been disclosed. It will be readily apparent that the elastomeric hinge thus disclosed may be useful for other applications and that various modifications may be made to the disclosed embodiment without departing from the spirit and scope of the invention. Accordingly, one will understand that the description provided herein is provided for purposes of illustration and not of limitation, and that the invention is limited only be the appended claims.
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A hinge is provided suitable for attaching a hood to a car or truck. The hinge includes generally tubular members sharing a common axis of rotation. Elastomeric elements interposed between the tubular members provide isolation between the parts of the hinge. Relative rotation between the tubular members compresses the elastomeric elements creating a spring-force opposing the relative rotation. The hood, hinge, and vehicle may be configured so that the spring-force of the elastomeric elements assists in opening and/or closing of the hood.
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FIELD
The present disclosure is directed to pipeline monitoring and corrosion protection. Specific aspects of the disclosure are directed to establishing and maintaining electrical continuity between adjacent underground pipe sections and more particularly for providing electrical continuity between adjacent pipe sections that are otherwise insulated or isolated from one another.
BACKGROUND
Liquids, gases, water and wastewaters are commonly transported via pressurized pipelines a majority of which are buried. Once in place, such pipelines are subjected to various forms of damage including external damage, soil movements/instability and third party damage. Additionally, buried pipelines are subject to environmental damage. That is, buried pipelines, especially cast iron and steel pipelines, are susceptible to corrosion.
Buried pipelines usually receive one or more forms of external corrosion protection. A protective coating represents a primary form of protection while cathodic protection (CP) represents a secondary form of protection in some instances. The CP system is designed to protect the external pipeline surface against corrosion at coating defects that inevitably occur as the coating condition tends to deteriorate with time. In such corrosion protection systems, regular inspections are made to assess the rate of change in physical condition of the buried pipeline. Such inspection may provide an estimate of how much longer a pipeline can be expected to operate safely and productively and can also be used to plan for remedial action if this predicted life is below requirement
Various corrosion monitoring/inspection techniques are employed in the pipeline industry, such as test station potential readings and Close Interval Potential Surveys (CIPS). These techniques are aimed at assessing the CP effectiveness of the pipeline between permanent test stations. In this regard, pipelines are equipped with permanent test stations where electronic leads are attached to the pipeline to allow above-ground measuring of pipe-to-soil potential. This potential should be sufficiently cathodic to ensure adequate corrosion protection but not excessively cathodic to produce coating damage and/or hydrogen embrittlement.
In such techniques, an operator establishes an electrical connection to the pipeline by means of an above ground wire that extends between test stations. The pipeline potential is measured with a set of reference electrodes at ground level, positioned directly over the pipeline, at intervals of, for example, about 1 meter. The potentials measured above ground can provide an indication of a breakdown in the protection coating of the buried pipeline. For instance, a change in potential at a given location between testing periods or changes in potential relative to adjacent potentials, may indicate that the protective coating is breaking down or has been breached in the measured region of the pipeline. Common to such pipeline monitoring techniques and corrosion control techniques is the requirement that the pipeline itself to carry a current/voltage.
SUMMARY
Provided herein is a connecting strap or spanning strap that is adapted for use in interconnecting adjacent pipeline sections to provide electrical continuity. Various aspects of the spanning strap are based on the realization that different attachment mechanisms may benefit from differing geometries of the spanning strap. Specifically, it's been determined that the geometry of an attachment aperture extending through the connection strap for use in welding or soldering strapped an underlying surface may be advantageously designed.
According to the first aspect, a spanning strap is provided that includes an aperture with a peripheral edge that has a thickness that is reduced in relation to the thickness of the spanning strap. In such an arrangement, this peripheral edge more readily melts during a welding or soldering and thereby provides improved connection between the strap and an underlying pipe. According to this aspect, the spanning strap comprises a conductor/conductive metallic strap including an elongated body section extending between first and second ends. Generally, the strap has uniform thickness between a planar top surface and a planar bottom surface. First and second apertures are disposed proximate to the first and second ends of the metallic strap. A peripheral edge of at least one of the first and second attachment apertures has a thickness is less than one half of the thickness of the strap as measured between the planar top and bottom surfaces. In further arrangements, the peripheral edge thickness may be less than one fourth of the thickness and or the peripheral edge may come to a tapered point.
In another aspect, a spanning strap is provided that includes one or more frustoconical attachment apertures. In this aspect, a conductive metal strap extends between first and second ends and has a substantially uniform thickness between a planar top surface and a planar bottom surface. At least a first frustoconical aperture is disposed proximate to one end of the conductive metallic strap. A periphery of this apertures is disposed above a planar top surface of the metallic strap. In this regard, a slanting sidewall extends between the peripheral edge of the aperture and the planar top surface. Typically, this frustoconical sidewall is disposed and included angle between about 15 and 70° relative to the planar top surface. Likewise, a lower sidewall extends between the peripheral edge and the bottom planar surface of the strap. As will be appreciated, this lower sidewall forms a depressed or recessed surface relative to the planar bottom surface. In use, such a frustoconical aperture allows for preferentially attaching the metallic strap using differing types of attachment mechanisms. Further, the peripheral edge of the aperture may have a thickness that is less than the thickness between the planar top and bottom surfaces of the strap.
In any aspect, the spanning strap may further include a nonconductive coating that extends over at least a portion of the body section of the spanning strap area in such a coating provides where and corrosion protection for the spanning strap. In one arrangement, the nonconductive coating is polymeric material. In another arrangement, the nonconductive coating is formed of a heat shrink tubing applied to the body section of the metallic strap.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and further advantages thereof, reference is now made to the following detailed description taken in conjunction with the drawings in which:
FIG. 1 illustrates a cross-sectional side-view of a buried pipeline.
FIG. 2 illustrates a cross-sectional view of a portion of a pipe joint.
FIG. 3 illustrates a spanning strap applied to the joint of FIG. 2 .
FIG. 4 illustrates a pin brazing system.
FIG. 5 illustrates a spanning strap in accordance with aspects of the present invention.
FIG. 6 illustrates a cross sectional view of the strap of FIG. 5 .
FIG. 7 illustrates a perspective view of a frustoconical attachment aperture.
FIG. 8A illustrates a cross-sectional view of a frustoconical attachment aperture applied to a pipe surface for thermite attachment.
FIG. 8B illustrates a thermite weld encapsulating the frustoconical attachment aperture and connecting the attachment aperture to an underlying pipe.
FIG. 9A illustrates a cross-sectional view of a frustoconical attachment aperture applied to a pipe surface for pin brazing attachment.
FIG. 9B illustrates a pin braze connecting the frustoconical attachment aperture to an underlying pipe
DETAILED DESCRIPTION
Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the presented inventions. In this regard, the following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the disclosed embodiments of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions.
FIG. 1 illustrates a cross-sectional side view of an underground pipeline 100 including multiple pipe sections 102 a - n . Each pipe section 102 includes a bell end 104 and a spigot end 106 . See FIG. 2 . The spigot end 106 fits inside of the bell end 104 to form a joint between adjacent pipe sections. FIG. 2 illustrates an enlarged partial cross-sectional view of a pipe joint 120 in accordance with the bell and spigot pipe sections of FIG. 1 . As illustrated, a seal element 124 is included between the bell end 104 and the spigot end 106 to form a watertight connection there between. The seal element may include, for example, an o-ring/gasket or any other appropriate sealing element. Such sealing elements 124 often insulate and electrically isolate the spigot end 106 of a first pipe section 102 a from the bell end 104 of an adjacent pipe section 102 b . In such arrangements, electrical continuity does not exist between adjacent pipes and various corrosion monitoring and prevention systems may not be operative.
One exemplary pipeline corrosion monitoring system is the Close Interval Potential Survey (CIPS) technique. In CIPS, an operator establishes an electrical connection to the pipeline by means of a reference wires 130 , 132 that extends between above ground test stations 134 and 136 . See FIG. 1 . Each test station includes a lead wire that extends down to and is electrically connected to the buried pipeline. The pipeline potential is measured with a set of reference electrodes at ground level, positioned directly over the pipeline, at intervals of, for example, about 1 meter. The potentials measured above ground can provide an indication of a breakdown in the protection coating of the buried pipeline. For instance, a change in potential at a given location between testing periods or changes in potential relative to adjacent potentials, may indicate that the protective coating is breaking down or has been breached in the measured region of the pipeline. Accordingly, if a problem is identified, remedial measures may be taken.
Likewise, the pipeline may include galvanic corrosion protection that may be periodically connected to the pipeline (not shown). In such an arrangement, a wire connects a pipe section with a potential source and a second wire connects the potential source with an anode. The potential source (e.g., voltage source) drives an electronic current through the pipe section and into the anode. An impressed current of electrons then flows between anode and pipeline. The system causes the pipeline 100 to act as the cathode in an electrochemical reaction. Accordingly, the anode experiences corrosion rather than the pipeline. These corrosion monitoring and galvanic protection systems are presented by way of example and do not limit presented inventions.
As will be appreciated, the functionality for both pipeline monitoring and corrosion protection systems depends on the presence of electrical conductivity and/or continuity between the pipe segments 102 a - 102 n . Such conductivity is generally not an issue in pipelines where adjacent pipe sections are threaded or welded to one another. However, in pipelines where adjacent sections are coupled using a bell and spigot connection, the seal often prevents conductive contact between the adjacent sections. Accordingly, a conductive strap, which spans the pipe joint, typically interconnects electrically conductive surfaces of the adjacent pipe sections. See e.g., FIG. 3 . Such “spanners” 140 are sometimes formed as metallic straps (e.g. copper). As illustrated, the spanning strap 140 has a reverse bend slack joint 144 (e.g., an s bend) that allows for some expansion between the adjacent pipe sections 102 a , 102 b . In such instances, the ends of the spanner 140 may be welded or soldered to the adjacent pipe sections. These spanners are commonly interconnected to the pipeline during its construction when access to the pipe sections is readily available. However, the spanners can become dislodged over time. For instance, continued expansion or contraction of the pipeline may result in disconnection of one or both ends of the spanner 140 . Likewise, such spanners and their connecting points are themselves subject to corrosion. Accordingly, such spanners often require replacement in the field when access is limited and means for electrically connecting the spanner to the adjacent pipe sections is limited.
The present invention is based in part on the realization by the inventor that two primary means are utilized to connect such spanning straps in-field replacement applications: pin brazing and exothermic welding. Specifically, each of these methods provide small self-contained attachment mechanism for in-field connection. That is, such systems do not require an electric arc welder or brazing torch. This especially important in situations where the spanner is being placed on the inside of the pipeline and use of an arc welder or brazing torch is not desirable or feasible due to limited access into the pipeline and/or safety concerns.
Pin brazing is a method for forming a connection where a silver and flux-containing brazing pin is melted down in the eye of a conductor. The equipment comprises a battery powered brazing gun that is normally powered from batteries. FIG. 4 illustrates a pin brazing system 150 . The brazing pin 152 is made from a metal such as brass and is formed with a capsule, or head portion, and a control shaft or holding portion. The head portion is typically hollow containing a solder, such as a silver alloy and a flux material. The holding portion is designed to be received in a brazing gun 154 and will be disposed of after completion of the brazing process. In practical a ceramic ferrule 156 carried by the brazing-gun 154 receives the brazing pin 152 . The brazing gun 154 is connected to a positive pole and the metal surface, for instance of a pipeline, is connected to the negative pole of a power supply and control unit 158 . The end of a spanning strap is placed against a cleaned/grinded portion of the metal surface forming a brazing site. A brazing pin 152 is pressed into the brazing gun 154 and positioned against the metal surface within the circular aperture on the end of brazing strap. The pressure of the brazing pin against the metal surface is given by a mechanical spring in the brazing gun 154 .
When the circuit is closed by a relay through a switch in the brazing gun 154 a short circuit is created between the brazing pin 152 and the metal surface. The brazing pin 152 constitutes the electrode in the process. At the same time an electromagnet in the power supply and control unit 158 is activated, the force of which is dimensioned to overcome the force form the mechanical spring, to lift the brazing pin 152 up from the metal surface to a pre-set position above it, for example 2 mm, whereas a welding arc is formed between the brazing pin 152 and the metal surface. The solder and the fluxing agent fixed to the brazing pin 152 start melting down into the aperture soldering/welding the spanning strap to the underlying pipe.
Thermite welding, is a welding process for joining two electrical conductors, that employs superheated copper alloy to permanently join the conductors. The process employs an exothermic reaction typically of a copper thermite composition to heat the copper alloy. The process requires no external source of heat or current making it convenient for in field applications. The chemical reaction that produces the heat is an aluminothermic reaction between aluminum powder and a mixture of copper oxides. These reactants are usually supplied in the form of powders, with the reaction triggered using a spark from a flint lighter or electronic ignition source. Initiation often requires the use of a “booster” material such as powdered magnesium metal. Often, these powdered materials are prepared in pre-mixed shots the composition of which can vary based on their intended applications (e.g., cast iron vs. steel, etc).
The process commonly employs a graphite crucible mold which is typically placed on top of the conductors to be welded (e.g., spanning strap and underlying pipeline). Once positioned, the powered materials are placed within the mold, which is then closed. The molten copper/slag, produced by initiating the reaction, flows through the bottom of the mold and over and around the conductors to be welded (e.g., through an aperture in the end of the spanning strap) forming an electrically conductive weld between them. When the copper alloy cools, the mold is removed.
The present inventor has recognized that such connection methods benefit from different connection geometries between the spanner and an underlying surface. Specifically, it has been determined that by forming an aperture with through the end of a spanning connector a specific geometric configuration, the strength and/or electrical conductivity of these bonds can be enhanced. Specifically, the inventor has recognized that for both pin brazing and thermite welding, it is desirable that the periphery of an attachment aperture be thin (e.g., in relation to the thickness of the spanning strap) to facilitate its melting while the pin is arcing or while the copper/slag flows out of the mold and onto the surface. Further, the inventor has recognized that for thermite welding, it is preferable for the thermite weld to extend around and beneath the lower periphery of the aperture as well as above and around and/or over the upper periphery of the aperture. In this regard, the periphery of the aperture is encased in the solidified copper alloy providing a stronger connection between the strap and underlying pipe.
In accordance with these recognitions, the inventor has produced a spanning strap 200 that provides enhanced interconnection irrespective of whether thermite welding or pin brazing is utilized to attach to the spanning strap 200 to an underlying surface (e.g., pipe). See FIG. 5 . As shown, the strap is made of conductive metal strap (e.g., copper) that may be supplied in desired lengths. As will be appreciated, the length of the strap may be varied based on the size of the pipeline on which the strap is utilized. For instance, small water pipelines (e.g., 12 inch) may utilize a strap that is between about 10 and 14 inches long and for example, 1-2 inches in width. In contrast, large diameter pipelines (e.g., 56 inch) may utilize larger straps and/or multiple straps. In this regard, such straps may be 20-36 inches in length. Furthermore, if necessary the width and/or thickness of the straps may be increased to provide greater conductivity.
In one arrangement, the spanning strap 200 is formed of a copper strip to allow for easy hand forming to a pipe contour. In the illustrated embodiment, the strap further includes an insulative cover 210 . In one arrangement, this insulative cover is formed of a polyethylene jacket having a thickness of approximately 0.08 inches. However, it will be appreciated that the thickness of this jacket may be increased or decreased depending on the intended application. Such a jacket may be formed as a coating or, for example, as a tube (e.g., heat shrink tubing) fit to the outside surface of the strap. This insulative jacket provides a number of benefits for the spanning strap. Specifically, when applied to the outside surface of a pipeline, the insulative jacket reduces the interaction of the spanning strap with surrounding media (e.g., ground) reducing the corrosion over the body of the strap. Likewise, on inside pipe applications, the insulative jacket 210 provides a wear covering for the generally ductile (e.g., copper) body of the spanning strap 200 . For instance, in applications where the strap is placed on the inside surface of a large water main, users may chip away mortar from the inside surface of the pipes until conductive services are exposed. Upon interconnecting the ends of the strap to the exposed surfaces, these exposed end surfaces may be covered with a mortar. However, to provide flexible coupling between the adjacent pipes, the midsection 208 of the spanning strap must be exposed within the pipe. Accordingly, absent the insulative jacket 210 , the spanning strap is exposed and subject to wear and corrosion from fluids passing through the pipe. Accordingly, the incorporation of the insulative cover reduces or eliminates such wear/corrosion.
As shown, the spanning strap includes a first end 202 a and a second end 202 b separated by a midsection 208 the length of which may, as noted, be varied depending on desired use. Each end 202 a , 202 b includes an attachment aperture 220 a , 220 b (hereafter 202 , 220 and unless specifically referenced). The attachment apertures 220 provide a connection point for interconnecting the spanning strap 200 to an underlying pipe. Instead of being simple holes formed through the ends 202 of the spanning strap 200 , the attachment apertures have a reduced thickness about their peripheral edges to facilitate boding. Further, the attachment apertures may also be formed as raised eyelets as best illustrated by FIG. 6 (a cross-sectional view of FIG. 5 ) and FIG. 7 . As shown, the attachment apertures are frustoconical in shape. In this regard, the central opening of the apertures 220 (e.g., the peripheral edge 226 ) is raised above a first surface (e.g., top surface) of the strap 200 and depressed/recessed below a second surface (e.g., bottom surface) of the strap 200 . Specifically, referring to FIGS. 6 and 7 it is noted that the peripheral edge 226 of the aperture 220 is raised above a first top surface 212 of the spanning strap and depressed/recessed below a second bottom surface 214 of the spanning strap 200 . In this regard, the top peripheral edge 226 of the attachment aperture 220 is the termination of a conical sidewall 224 that extends from the generally planar top surface 212 of the strap. This upper sidewall 224 wall is typically disposed at an angle Φ of between about 15 degrees and about 70 degrees relative to the top surface. See FIG. 8A . Further, the thickness ‘t’ of the peripheral edge 226 of the aperture is significantly thinner than the thickness T of the spanning strap. See FIG. 7 . This reduced rim thickness ‘T’ of the top edge 226 improves bonding of the strap during attachment procedures.
FIG. 8A illustrates a bonding strap 200 disposed on the top surface of a pipe section 102 . As shown in cross-section, the top edge 226 has thickness that is less than one-half or even less than one-fourth of the thickness of the bonding strap 200 . In some arrangements, the peripheral edge may come to a sharp point. As noted, this thin edge around the perimeter of the attachment aperture has been found to more readily melt during attachment procedure. That is, this thin edge section of the attachment aperture more readily melts when subjected to either thermite welding or pin brazing. In this regard, the thin edge 226 provides a better connection between the weld and the bonding strap and hence the bonding strap and the underlying pipe.
While providing a thinner rim/edge to improve melting of the aperture edge into the attachment means, the geometry of the frustoconical attachment aperture 220 provides further benefits for both thermite welding as well as pin brazing. As illustrated in FIG. 8 b , upon forming a thermite weld 240 the frustoconical shape attachment aperture allows for a portion of the thermite weld 240 to extend below the bottom/underside surface 228 of the frustoconical aperture. In addition to extending below the underside surface 228 of the aperture, a portion of the weld 240 may also extend over the top and outside surface 224 of the frustoconical opening 220 . In this regard, the peripheral edge 226 , in addition to being melted into the weld 240 , is trapped between the weld. That is, the weld extends below and over the top of a portion of the frustoconical sidewall. In this regard, the sidewall is trapped between upper and lower portions of the weld and thereby providing a further securement of the bonding strap to the underlying pipe 102 .
In relation to pin brazing, the frustoconical aperture likewise produces improved bonding with the underlying pipe. As illustrated in FIGS. 9 a and 9 b , the attachment aperture may again be utilized interconnect a bonding strap 200 to an underlying pipe 102 . However, in this arrangement, rather than placing the recessed surface of the frustoconical attachment aperture adjacent to the surface of the pipe 102 , the strap 200 may be turned over to place the raised rim/edge surface of the frustoconical aperture extending from the top surface of the bonding strap against the surface of the pipe section 102 . In this regard, the small cross-section top edge 226 of the attachment aperture is disposed against the surface of the pipe section 102 . Accordingly, when the pin brazing system 150 is activated, and the pin 152 arcs rather than having to melt the entire thickness of the bonding strap, all that is required is that the reduce cross-section of the frustoconical attachment aperture 220 melt in order to secure the bonding strap to the underlying surface. As will be appreciated, once melting is initiated at the edge 226 melting may proceed rapidly up the sidewall of the frustoconical aperture 220 . It has been found that utilization of such a frustoconical/thin edged apertures provides better bonding around the entirety of the aperture in pin brazing applications and thereby improves the strength and conductivity of the weld.
As discussed above, the frustoconical attachment apertures provide benefits for at least first and second different types of bonding applications. Accordingly, most embodiments of the strap will have first and second frustoconical apertures on the first and second ends that are like-configured. That is, both apertures will extend above a first surface (e.g., top surface) and below a second surface (e.g., bottom surface). However, it will be appreciated that in some applications it may be desirable to offset the direction of the apertures. Generally, these apertures will have an opening that is between ⅜ of an inch and ¾ of an inch. Further, it will be appreciated that the size of the aperture may be selected based at least in part on the conductivity requirements of the underlying pipe.
The foregoing description of the presented inventions has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described hereinabove are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
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Provided herein is a connecting strap or spanning strap that is adapted for use in interconnecting adjacent insulated and/or electrically isolated pipeline sections to provide electrical continuity. Various aspects of the spanning strap are based on the realization that different attachment mechanisms may benefit from differing geometries of the spanning strap. Specifically, it's been determined that the geometry of an attachment aperture extending through the connection strap for use in welding or soldering strapped an underlying surface may be advantageously designed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to displaying and storage of backdrops for use with photographs and stage productions. More particularly, the invention relates to systems and methods of changing, displaying and storing backdrops.
2. State of the Art
In photography, stage productions and other instances where it is desirable to create an illusion of a particular time or place or of no particular time or place, a moveable backdrop is required to set the proper look and feel of the environment required by the situation. As needs change, the backdrop environment must be changed to match the need.
Because a backdrop is typically suspended high above the floor, a user must climb a ladder to change most of currently available backdrops. Further these backdrops require the use of wrenches, screwdrivers, pliers, or other tools to remove the old backdrop and install the new one. Not only is it inconvenient to change a backdrop from the top of a ladder, it can also be dangerous.
In response to this difficulty, some backdrop systems have been developed that contain more than one backdrop on a rotating wheel. Thus, if one desires to change a backdrop, the first backdrop is rolled back onto its spool, the wheel is rotated, and the next back drop is lowered. Other systems employ a number of backdrops in a single loop. All of these systems suffer from the same limitations. They are expensive to purchase and if the user wants to obtain a new series of backdrops, the entire loop or wheel must be replaced. Furthermore, in the current systems,
Some photographers have resorted to using a backdrop attached in a makeshift manner to a wall or thrown over a simple rope, wire or framework. When a change of backdrop is needed, the first backdrop is pulled down and the new backdrops is taped up or thrown over the wire or framework. This can result in damage to the backdrops which frequently cost hundreds to thousands of dollars. Moreover, it leads to a less than professional atmosphere at a photographic studio where image is paramount. When backdrops are used without a proper storage system, they are frequently stored in piles in the corner of the studio, or on storage shelves, where they may suffer additional damage.
Therefore it would be advantageous to provide a method and a device for quickly changing a backdrop without the use of ladders, scaffolding, catwalks, or other elevated devices. Where multiple backdrops are used, a method for safely storing backdrops is needed to preserve the life and appearance of the cloth or cloth-like material while making them readily available for use.
BRIEF SUMMARY OF THE INVENTION
One aspect of the present invention is a backdrop system that can be used for photography, stage productions, or other instances where a backdrop may be desired. The backdrop system has a spool on which a backdrop can be either temporarily or permanently attached and wound in a flat and unwrinkled condition. A mount is provided for attaching the spool to a lifting device. The lifting device can adjust the vertical position of the spool. A rolling device is also connected to the spool for rolling and unrolling the backdrop on the spool. The lifting device can be configured to raise or lower the spool to any position from ground level to the ceiling or other upper limit. The spool is readily removable from the mount and can be removed when the spool is in the lowered vertical position. The lowered vertical position may be when a user is standing, kneeling, or sitting at ground level. The backdrop system may also provide for the horizontal adjustment of the spool.
The attachment of the spool to the mount may be configured with male mating protrusions in the mount with female mating apertures in the spool. In other embodiments, male mating protrusions may be in the spool and female mating apertures in the mount. Alternatively, a combination of male and female mating parts may be in both the spool and the mount. The attachment can be made by inserting male mating protrusions into the female mating parts and twisting the mount or spool to the locked position. When the spool is in the attached and rotated position, a lock may be engaged securing the spool to the mount of the lifting device.
For many uses of the backdrop system, it may be desirable to have more than one backdrop. In such instances, the system may have a plurality of backdrops. The plurality of backdrops may each be secured on a separate spool or stored by other means and fastened, each in turn of use, to the same spool. The plurality of backdrop spools may be stored, for example, on a storage rack. Additionally, the spools may be configured to receive a storage stopper in an end and be propped against a wall for storage. The backdrop system may be configured to accommodate and adjust for spools of varying lengths.
The backdrop spool has an elongated tube portion with a first end and a second end. Adjacent both the first end and the second end of the spool, a flange is presented. The flanges may comprise attachment points for receiving mating members of the lifting spool. Further the flanges may have a lock for securing the backdrop spool to the lifting spool. Such locks may be a locking pin. Further the locks may be a hook and latch, a bolt, a spring lock, or the like.
The lifting device may be driven by motor or may be manually operated. In one embodiment, the lifting device comprises a lifting spool, such as a wheel, for attachment to the backdrop spool. The lifting spool may be weighted with ballast. A flexible strap, cable, rope, or cable may be looped around the lifting spool and windably attached to a sheave of a motorized or manual lift. The hoist may have a split sheave that is configured to receive the strap from the lifting spool at the first end of the backdrop spool and the strap from the lifting spool at the second end of the backdrop spool.
The system is also configured to allow for the rolling or unrolling of the backdrop on the backdrop spool. In one embodiment, the rolling and unrolling are accomplished simultaneously with the vertical adjustment of the backdrop spool. In this embodiment, the lift motor or manual lift may power the rolling and unrolling of the backdrop. Alternatively, the rolling and unrolling of the backdrop may be powered by a motor or manual means independent of the raising and lowering of the backdrop spool.
The control of the raising and lowering and the winding and unwinding of the backdrop spool can be accomplished in a variety of ways. For example, the raising and lowering may be controlled by directly activating the lifting device. Alternatively the lifting device may be controlled by wireless or wired remote control. Likewise the rolling of the backdrop on the backdrop spool may be directly controlled or through indirect remote control.
The present invention also relates to a method of changing a backdrop. The method includes the step of lowering a backdrop spool to which the backdrop is attached from a first height to a second height. Alternatively the method may include lowering the lifting spools on a suspension system without a backdrop spool from the first height to a second height. In general the first height will be a height above the ground level such as at or near the ceiling or a room and the second height will be a height at which a user can easily reach the spool while maintaining contact with the floor. Once the backdrop spool is lowered, the backdrop spool may be removed from the suspension system. A second backdrop spool may then be obtained and attached to the suspension system and the spool is raised to the first height.
The method may also contain the step of winding the first backdrop on the backdrop spool prior to lowering it. The winding may be performed prior to lowering the backdrop spool from the first height to the second height or may be performed after the backdrop spool is lowered to the second height. The winding may also be performed simultaneously with the raising or lowering of the backdrop, or may be performed independently of the raising or lowering of the backdrop.
Other features and advantages of the present invention will become apparent to those of skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a front perspective view of one embodiment of a backdrop system according to the present invention.
FIG. 2 is a side perspective view of one embodiment of a backdrop system according to the present invention.
FIG. 3 is a detailed perspective view of a suspension system of one embodiment of a backdrop system according to the present invention.
FIG. 4A is a perspective view of a backdrop spool of one embodiment of a backdrop system according to the present invention.
FIG. 4B is a bottom perspective view of a backdrop spool flange according to one embodiment of the present invention.
FIG. 4C is a top perspective view of a spool flange according to one embodiment of the present invention.
FIG. 5 is an exploded view of a lifting spool mount of one embodiment of a backdrop system according to the present invention.
FIG. 6 is a perspective view of a lifting spool mount of one embodiment of a backdrop system according to the present invention.
FIG. 7 is a perspective view of a backdrop spool connected to a lifting spool mount of a lifting device according to one embodiment of the present invention.
FIG. 8 is a perspective view of a spool storage system according to one embodiment of the present invention.
FIG. 9A is a perspective view of an alternative embodiment of a lifting mount with an integrated motor according to one embodiment of the backdrop system of the present invention.
FIG. 9B is a perspective view of an alternative embodiment of a lifting mount without an integrated motor according to one embodiment of the backdrop system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Although the foregoing description contains many specifics, these should not be construed as limiting the scope of the present invention, but merely as providing illustrations of some exemplary embodiments. Similarly, other embodiments of the invention may be devised that do not depart from the spirit or scope of the present invention. Features from different embodiments may be employed in combination. The scope of the invention is, therefore, indicated and limited only by the appended claims and their legal equivalents, rather than by the foregoing description. All additions, deletions, and modifications to the invention, as disclosed herein, which fall within the meaning and scope of the claims are to be embraced thereby.
Referring to FIGS. 1 , 2 , and 3 a backdrop system 10 is presented. The backdrop system can be used in for example a photographer's studio, in stage productions, or other instances. The backdrop system 10 has a spool 12 that can be suspended from a lifting device 14 . The spool 12 is configured to receive thereon a backdrop 16 . The backdrop 16 can be a fabric backdrop or other flexible materials that can be wound on the spool 12 . The backdrop 16 can have a scene presenting the illusion of another place. Alternatively the backdrop may be dyed, colored, or painted to present a suitable background for a photograph, video conference, stage production, or other event.
The spool 12 is suspended from the lifting device 14 . The lifting device 14 has a hoist 15 . The hoist comprises lifting spool mounts 30 , 32 on either end 18 , 20 of the spool 12 , a set of straps 22 , 24 , a sheave 26 , a pulley 27 , and a motor 28 . The lifting spool mounts 30 , 32 are configured to be attached to opposite ends 18 , 20 of the spool 12 . The first end 34 , 35 of the straps 22 , 24 are secured to an attachment point 36 , 37 such as an eyebolt. The straps 22 , 24 run downward from the attachment points 36 , 37 and around the lifting spool mount wheels 31 , 33 . The first strap 22 runs from the mount wheel 31 to a pulley 27 and across to the sheave 26 . The second strap 24 runs from the lifting spool mount wheel 33 to the sheave 26 . In the illustrated embodiment a split sheave 26 has a partition 38 between the chambers 39 , 40 that receive the first and second straps 22 , 24 . In an alternative embodiment, a single chambered sheave (not shown) may be used. It will be appreciated that any flexible material may be used in place of the straps 22 , 24 such as rope, cable, chain, or the like. In one present embodiment nylon strap is used.
The sheave 26 may be turned by an electric motor 28 or by manual drive means. This embodiment is such that when the sheave 26 is turned in a first direction, the straps 22 , 24 are drawn around the mount wheels 31 , 32 on both ends of the spool 12 . The straps 22 , 24 turn the spool in one circular direction, winding or unwinding the backdrop 26 . When the sheave 26 is operated in the opposite direction, the straps 22 , 24 are drawn in the opposite direction around the mount wheels 31 , 32 and the spool 12 is rotated circularly in the opposite direction, winding or unwinding the backdrop 16 .
Additionally, by rotating the sheave 26 in a first direction, the straps 22 , 24 are drawn onto the sheave thereby raising the spool 12 . When the sheave 26 is rotated in the opposite direction, the straps 22 , 24 are unrolled from the sheave 26 thereby lowering the spool 12 .
In this embodiment, the rolling and/or unrolling of the backdrop 16 may done at the same time as the raising and lowering of the spool 12 . If a user wishes to maintain the rolled or unrolled condition of the backdrop 16 while raising or lowering the spool 12 , a hand placed on the spool to stop the rolling while operating the sheave drive motor 28 will maintain the rolled or unrolled position of the backdrop 16 .
The lifting device may also have a screw drive system for raising and lowering the spool 12 . In such an embodiment a screw is turned against a threaded block, driving the assemblies on both sides upward or downward.
To allow for the horizontal adjustment of the backdrop, the pulley 27 , sheave, motor, and attachment points 36 , 37 can be secured to trolleys 40 that are set in a track 42 . The trolleys 40 and track 42 allow a user to adjust the horizontal position of the backdrop 12 . Such horizontal adjustment may be made while the spool is in the raised or lowered position. The adjustment is made by applying a force in the direction in which one desires to move the backdrop. Such horizontal adjustment can allow a photographer to use varying lighting techniques, by placing one or more lights behind the backdrop 12 . The horizontal adjustment of the backdrop 12 may be either manual or powered by a motor that moves the trolleys 40 in the desired direction.
Referring now to FIG. 4A , one embodiment of a spool 12 is presented. The spool 12 has an elongated cylinder 44 . The cylinder 44 may be a hollow tube of such material as metal, plastic, fiber glass, or cardboard. Alternatively the cylinder 44 may be a solid structure such as a wood dowel. In one present embodiment, the cylinder is an aluminum tube having a diameter of about 3 inches. It will be appreciated that the length and diameter of the cylinder 44 may vary depending on the desired use of the backdrop system 10 .
The backdrop spool 12 can also have fasteners 46 whereby the backdrop 16 may be secured to the spool 12 . In the illustrated embodiment, the fasteners 46 are hook and latch type fasteners. Alternatively other fasteners 46 may be used such as adhesives, snaps, rivets, screws, and the like. In other embodiments it may be desirable to roll the backdrop 16 on the spool 12 without the use of fasteners. In such embodiments, the friction of the wound backdrop 16 on the backdrop spool 12 may suffice to hold the backdrop 16 during the rotation of the spool 12 .
The spool 12 has a first end 18 and a second end 20 . A flange 48 can be attached to both ends 18 , 20 of the backdrop spool 12 . The flanges 48 can be constructed independently from the cylinder 44 . The flanges 48 can be molded from plastic, or may be cut or molded from wood, cardboard, metal, fiberglass, and the like.
One particular embodiment of a flange 48 is shown in more detail in FIGS. 4B and 4C . The flange 48 has an inner ring 50 and an outer ring 52 . The inner ring 50 has a protrusion 51 extending away from the generally flat flange 48 . The protrusion 51 has an outside diameter that is selected to fit snugly within the inside diameter of the tubular cylinder 44 of the spool 12 . A series of ribs 54 are run the length of the inside diameter of the protrusion 51 . The ribs 54 serve the dual purpose of strengthening the protrusion 51 and providing attachment points if the flange 48 is to be attached to the spool 12 by screws or rivets 49 . Alternatively, the flange 48 may secured to the cylinder 44 by an adhesive or by friction.
The outer ring 52 has a plurality of slots 56 with an enlarged notch 58 . As will be discussed below, the slots 56 and notches 58 , serve as female mating members for the attachment of the flange 48 and the backdrop spool 12 to the lifting spool mount 30 of the hoist system 15 .
One embodiment of a lifting spool mount 30 , 32 is shown in FIG. 5 and 6 . The mount 30 , 32 has two flanges 60 , 62 joined by a central cylinder 64 . The flanges 60 , 62 and the cylinder 64 create a channel 65 for receiving the straps 22 , 24 of the hoist. The cylinder 64 can be coated with a non-slip surface or may be lined on the exterior with a rubbery material to provide a tactile surface for gripping the straps 22 , 24 .
The cylinder 64 can be an integrated part of one of the flanges 60 , 62 . Alternatively, a short pipe 61 can be secured to a rim 67 that extends outwardly from the inner ring 63 .
Ballast 78 in the interior of the cylinder 64 stabilizes the lifting spool mounts 30 , 32 . The weight of the ballast provides a downward force providing for smooth and correct operation of the hoist when a spool 12 is not attached to the lifting spool mounts 30 , 32 . The ballast 78 may be a metal disk 78 or alternatively may be a fluid contained within a bladder (not shown) in the center of the cylinder 64 . Other examples of ballast may include metal, glass, lead shot, wood or plastic balls, metal filings, rocks, concrete or other similar materials.
Referring to FIG. 6 , the flanges 60 , 62 of the lifting spools 31 , 33 have an inner ring 63 and an outer ring 61 . The outer ring 61 of the flange 60 that will be positioned next to the flange 48 of the spool 12 has slots 66 in which T-shaped protrusions 68 can be inserted and secured by adhesives, screws, or friction. Alternatively, the T-shaped protrusions 68 may be molded as an integral part of the flange 60 . The T-shaped protrusions 68 serve as male mating members for the attachment of the lifting spool mount 30 , 32 to the backdrop spool 12 .
A lock 70 is also located in the outer ring 61 of the flange 60 . The lock of the illustrated embodiment is a pin lock 71 . The pin lock includes a bushing 72 molded into the outer ring 61 . The bushing 72 may be made of metal such as brass. The bushing has one or more external grooves used to retain the bushing 72 in the flange 61 and two internal grooves 73 . A detent pin 76 is inserted into the bushing 72 . When the ball 77 of the detent pin 76 is in a groove 73 , the pin 76 is locked in place in that position and cannot move without the imposition of some force. Thus, the pin 76 has two locked positions corresponding to when the pin is in either groove 73 . A first locked position is with the pin 76 protruding from the band 72 and extending into the channel between the two flanges 60 , 62 of the mount 30 . The second locked position is with the pin 76 protruding from the band 72 and extending toward the side of the flange 60 with the T-shaped protrusions 68 , which provides a locking function against the rotational motion of backdrop spool mating flange 48 .
Referring to FIG. 7 the attachment of the spool 12 to a lifting spool mount 30 is illustrated. The attachment is made by inserting the T-shaped protrusions 68 of the lifting spool mount flange 60 into the notches 58 of the spool flange 48 . When all of the T-shaped protrusions of one flange 60 are inserted into the notches 58 , either flange 48 , 60 is rotated thereby positioning the bases of the T-shaped protrusions 68 in the elongated slots 56 of the spool flange 48 . The connected flanges can be locked in place by pushing lock pin 76 from the first position to the second position and into the notch 58 of the flange 48 .
Other locks can be used to lock the connected flanges 48 , 60 together. For example, a locking segment (not shown) can attached to a spring steel strip fastened to the opposite side of lifting spool flange 60 from the T-shaped protrusions 68 , taking the place of lock pin assembly 70 . When flanges 48 , 60 are at their extreme rotated position, the spring strip moves a lock block into a space in both mating flanges 48 , 60 and prevents further flange rotation with relation to the other flange.
In certain embodiments the lifting spool mount flange 60 or the backdrop spool flange 48 has a short tube section (not shown) that is fastened permanently into, and extents outwardly from lifting spool flange 60 and fits snuggly within the center of the corresponding spool flange 48 . This tube section provides shear strength to the combined backdrop spool 12 and lifting spool mount 32 assembly.
Referring now to FIG. 8 , one alternative for storing the spools 12 and backdrops 16 is illustrated. A stopper 90 made of rubber or other compressible material is configured with a rounded bottom 92 and a stem 94 . The stem 94 has a diameter selected to fit within the opening 47 at either end of the spool 12 . The stem 94 of the stopper 90 can be inserted into this opening 47 creating a base for the spool 12 . The spool 12 may then be propped up against a wall or in a closet with the stopper 90 preventing the spool from slipping on the floor or from being damaged in contacting the floor.
Referring now to FIGS. 9A and 9B an alternative embodiment of the backdrop system 110 is shown. In this embodiment, much of the backdrop system 110 remains the same as the first described embodiment 10 . However, the straps 122 , 124 do not serve the dual purpose of height adjustment and rotation of the spool. Rather, the ends 123 , 125 that are distant from the sheave 26 are detached from the attachment points 36 , 37 and secured to attachment points 180 , 181 adjacent the first and second flanges 160 , 161 of the spool mounts 132 , 133 . Thus by engaging the motor 28 or manual hoist, the spool mounts 132 , 133 are raised and the spool 12 is not rotated. This embodiment may be used as a standalone product or may easily be retrofitted to the backdrop system 10 .
The rotation of the spool 12 is achieved by a motor 182 operably attached through a reduction gearing system to the first mount flange 160 . The motor 182 may have a cord 184 that is plugged into a power source. In such instances it may be desirable to have a cord 184 that is spring coiled or wound on a retracting spool such that the cord 184 does not become tangled in the spool, straps, or other parts of the backdrop system 110 . Alternatively, the motor 182 may be battery powered eliminating the cord 184 . The motor 182 can be activated by a wireless or wired remote control or may be activated by directly turning on the motor 182 .
The second flange 161 is attached to a freewheeling bearing assembly 186 allowing free circular rotation in either direction. The first and second flanges 132 , 133 have T-shaped protrusions 168 or other attachment devices for securing the mount 130 to the spool 12 , being locked in place by locking assemblies 70 . When the motor 182 is activated an attached spool 12 may rotate in either direction. Stopping the motor 182 halts the rotation of the spool 12 in by force of gear ratio resistance. Alternatively, a locking or braking mechanism may be applied to halt the rotation of the spool 12 .
The present invention also relates to a method of changing a spool 12 containing a backdrop 16 . The spool 12 may be lowered from a first height to a second height. Generally, the first height is at a position substantially above the floor such as near the ceiling. The second height is generally a position where a user may reach the spool while maintain direct contact with the ground.
Once the spool 12 is lowered, a user may detach the spool 12 from lifting spool mounts 30 . In the illustrated embodiment, the removal of the spool is accomplished by unlocking the lock 70 . If the lock is a locking pin 76 the unlocking is done by sliding the locking pin 76 from a locked position to an unlocked position. Once the lock 70 is unlocked, the spool flanges 48 or lifting spool mount flanges 60 , 160 , 161 are rotated such that the T-shaped protrusions 68 , 168 of the mount flanges 60 , 160 , 161 are positioned in the notches 58 of the spool flanges 48 . The T-shaped protrusions may then be removed from the notches 58 and the spool 12 is detached from the mount 60 .
A second spool 12 may then be obtained and attached to the mount 60 of the suspension system. The attachment is done by reversing the detachment steps, namely, putting the T-shaped protrusions 68 , 168 in the notches 58 and rotating the flanges 48 , 60 , 160 , or 161 until the T-shaped protrusions are at the end of the notches 58 . The lock 70 is then activated securing the spool 12 in place. The spool 12 and backdrop 16 may then be raised back up to a position at or near the first position.
In certain embodiments the changing of the backdrop 16 may include winding the backdrop 16 on the spool 12 prior to lowering the spool 12 . In other embodiments, the backdrop 16 may be wound on the spool 12 as it is lowered or after it is lowered. It will be appreciated that at certain times it may be advantageous not to have any spool 12 or backdrop 16 on the suspension system.
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This invention relates to the use of suspended materials as a backdrop for photography or stage productions. The suspended materials may be stored on a spool device. Such spool devices may include tubes or spindles constructed of metal, of cardboard, of plastic or other lightweight and inexpensive materials. The spool device may also include means for attaching the tube or spindle to a lifting device. Such attachment means may include a pair of interconnectable coupling devices, one fixed to the spool and the second attached to the lifting device.
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RELATED APPLICATIONS
[0001] This application claims benefit under 35 USC 119(e) of U.S. Provisional Application Nos. 61/314,493, filed Mar. 16, 2010; and 61/374,719, filed Aug. 18, 2010, both of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of recovering Rhenium (Re) from Re-bearing materials.
BACKGROUND
[0003] Rhenium (Re) is one of the rarest metals on earth and found almost exclusively in copper sulfide ore deposits containing extractable quantities of molybdenum (Mo). Re is found within the molybdenite fraction of this specific type of copper (Cu) ore. As a result, a number of processes have been developed to isolate Re from this fraction.
[0004] U.S. Pat. No. 3,739,549 recovers Re from ore material by using a roasting process. The Mo and Re is first separated from the Cu by a froth floatation process. The Mo and Re containing fraction is then subjected to a roasting process to separate the Mo and Re. The Re is converted to a large extent to rhenium heptoxide (Re 2 O 7 ) which is volatile and passes off with the gaseous effluents resulting from roasting. The flue gases are subjected to a wet-scrubbing process, wherein the flue gas containing Re 2 O 7 is captured and condensed in a scrubbing solution. The Re 2 O 7 containing scrubber solution is then processed by known techniques to produce ammonium perrhennate, i.e., NH 4 ReO 4 . Ammonium perrhennate is the primary source form for the production of Re metal. A majority of the world's Re supply is produced by extraction methods that isolate Re from Cu/Mo/Re ores. However, the process is limited to recovering Re from these types of ores and is not a practical for recovering Re from other Re-bearing materials. A second but smaller source of Re is recycled Re.
[0005] Re has a number of industrial uses. For example, U.S. Pat. No. 5,562,817 discloses the use of a Re-platinum (Pt) alloy as a catalyst for catalytic reforming. Catalytic reforming is a chemical process that converts petroleum refinery napthas with low octane ratings into high-octane liquid products. Re can also be added to high-temperature super alloys that are used to make components, such as jet engine parts (see U.S. Pat. No. 6,936,090). The scarcity and cost of Re has brought about the development of a number of methods that are used to recover Re, in particular from Re-bearing product and materials.
[0006] For example, United States Patent Application Publication No. 2003/0119658 relates to a process for the recovery of rhenium from a spent Re-bearing catalyst by heating the catalyst in an oxidizing atmosphere at a temperature effective to sublime a portion of the rhenium as a volatized oxide. The Re and Pt in the catalysts can be recovered. However, the process is limited to recovering these metals from spent catalysts.
[0007] The recovery of Re from super alloy waste and residue materials is also commercially interesting. Super alloys generally contain 50 to 80% of nickel, 3 to 15% by weight of at least one or more of the elements cobalt (Co), chromium (Cr), and aluminum (Al) and 1 to 12% by weight of one or more of the elements Re, tantalum (Ta), niobium (Nb), tungsten (W), Mo, hafnium (Hf) and Pt. United States Patent Application Publication No. 2009/0255372 discloses a process for recovering Re and other valuable metals from a super alloy containing waste or residue material by digesting the super alloy material in a salt melt. The salt melt contains 60-95% by weight of NaOH and 5-40% by weight of Na 2 SO 4 . The Re and other metals can then be recovered with the use of known techniques such as selective precipitations and ion exchange techniques. For example, Re is recovered by passing the digested material containing Re over an ion exchange column (see also U.S. Pat. No. 6,936,090). However, the process does not describe being able to recover Re from a variety of materials and suggests recovering Re from ion exchange columns.
[0008] Thus, a need exists for a method that can recover Re from a variety of Re-bearing materials at a low cost.
[0009] The present invention provides for an economical method of extracting Re and other valuable metals from Re-bearing materials, including nontraditional forms of industrial Re-bearing materials, which were previously overlooked as a source from which to extract Re because no economical extraction process existed. For example, a number of Re-bearing materials have been disposed of in landfills dues to the lack of a process that could efficiently recover Re. In some instances, this Re-bearing material was treated in nickel/cobalt recycling processes but only for the recovery of nickel and cobalt constituents and not for the Re content. Once subjected to those nickel/cobalt recycling processes, the Re was alloyed or otherwise diluted to the extent where the possibility of efficiently recovering Re with previously known methods was remote if not impossible.
SUMMARY
[0010] The present invention is based on the discovery of an efficient and effective method for selectively recovering Re from. Re-bearing materials. The method is able to efficiently recover Re and/or other metals such as Cu, Co, Cr, Mo, Ta, Ti, Hf, PGM and W from a variety of Re-bearing materials containing such metals.
[0011] The term “leach” as used herein means to wash, extract, or perform a chemical reaction to separate a soluble element or compound from an insoluble material.
[0012] The phrase “insoluble residue” means an element in free form or compound incapable of or that resists dissolving in a particular solvent.
[0013] A “rhenium-bearing material” is any material that contains Rhenium (Re). This includes waste, residue, ore, ore concentrate, byproduct, processed, and/or unprocessed material. Re-bearing materials include nickel, cobalt, and/or molybdenum-bearing manufacturing sludge residues, wastes, and byproducts. These materials have a physical consistency of a powder, sand or sludge and are typically comprised of metal compounds, metal alloys, metal grinding polishing fines, etchant compounds, and mixtures thereof. Re-bearing materials also include granular filter media, fibrous filter media, abrasive grinding material and plasma deposition overspray particles. In one aspect of this invention, the Re-bearing material is a super alloy waste, sludge, byproduct, or residue resulting from the manufacturing and/or subsequent repair of high-temperature industrial turbines, turbine components, superconductor components, vacuum plasma metal deposition processes, and bimetallic reforming catalyst materials.
[0014] The phrase “substantially pure” means that a given compound has a purity of about 90-99% be weight of the collected material.
[0015] A “platinum group metals” (PGM) includes metals such as platinum (Pt), ruthenium (Ru), rhodium (Rh), iridium (Ir), Osmium (Os), and palladium (Pd).
[0016] A “scrubber” is a device that can be used to remove particulates and/or gases from industrial exhaust streams. For example, the term “scrubber” includes devices that use liquid to wash metal-bearing materials from a gas stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The drawing is a flowchart exemplifying a method for separating and recovering Re and other metal from a raw material containing Ni, Co, Cr, PGM and Re.
DETAILED DESCRIPTION
[0018] A variety of Re-bearing materials can be processed in accordance with the present invention. For example, the drawing shows that these materials may include super alloy residues and wastes that contain Re 20 , Re-bearing plasma spray deposition overspray residues 40 , other source materials such as Re-bearing ore materials 50 , and/or Re-bearing waste materials and cermet catalysts 60 .
[0019] When the Re-bearing material is from a super alloy waste or residue material 20 such as a machining fluid or filter media, the super alloy waste or residue material 20 is first mixed with a slurry liquid 10 such as an aqueous solution. The aqueous solution and super alloy waste or residue material 20 is vigorously stirred or subjected to a media emulsification process 30 to form a Re-bearing mixture. The Re-bearing mixture is then combined with other Re-bearing materials such as the super alloy residues and wastes that contain Re 20 , Re-bearing plasma spray deposition overspray residues 40 , other source materials such as Re-bearing ore materials 50 , and/or Re-bearing waste materials and cermet catalysts 60 to form a leaching slurry 70 .
[0020] The super alloy residues and wastes that contain Re 20 , Re-bearing plasma spray deposition overspray residues 40 , other source materials such as Re-bearing ore materials 50 , and/or Re-bearing waste materials and cermet catalysts 60 are optionally subjected to a comminution process 80 prior to being added to the leaching slurry 70 . A variety of comminution processes 80 can be used to crush the materials into a powder in preparation for subsequent processing methods that generally require a fine particle size.
[0021] All metals are solubilized in the leaching slurry 70 , where acids are added to the slurry in an amount sufficient to solubilize the metals in the form of their corresponding metal salts. The leaching slurry 70 is preferably kept at a pH below 2, and preferably below 1. A variety of acids can be used to obtain this pH but typically a mixture of hydrochloric acid and nitric acid is used. For example, the slurried materials are acidified, preferably with hydrochloric acid (HCl) or a mixture of HCl and nitric acid (HNO 3 ) commonly referred to as aqua regia (AR). The acidified solution is agitated for up to 24 hours, and preferentially 4 to 6 hours to allow sufficient reaction time to convert contained metals in their alloyed metallic state to their corresponding metal salts.
[0022] The reactions are exemplified as follows:
[0000] Me 0 +HCl=MeCl+H +
[0000] Me 0 +HNO 3 =MeNO 3 +H + Scheme 1
[0000] where Me=any metal.
[0023] Any remaining insoluble residues from the filtered leaching slurry 90 can be further processed to recover valuable metals that may be present in the residues 300 . For example, insoluble residues from 90 can contain compounds and metals such as Ni, Co, Cr, platinum group metals, and other metals. The insoluble residues are then reformulated/compounded 310 into other metal bearing materials to produce a metal concentrate. The reformulated/compounded material 310 is optionally mixed with other metal concentrates that occur naturally or are in secondary form 305 . For example, the reformulated/compounded material 310 can be processed with a Ni concentrate 305 to obtain a metal concentrate that contains Ni, Co, and other platinum group metals 315 .
[0024] The resulting filtrate from the filtered leaching slurry 90 is subjected to a selective Re precipitation process 100 , creating an insoluble Re compound, while other metals remain as their soluble salts. In one embodiment of this invention, the Re precipitation process 100 comprises first oxidizing contained Re to the heptavalent state (ReVII) by the addition of an oxidizing agent, preferentially permanganate or peroxide, then adding sulfide, preferentially sodium hydrosulfide (NaHS), to the filtrate from 90 while maintaining an acidic pH and preferably ranging from a pH of less than 1 to 5. Rhenium sulfide (Re 2 S 7 ), as well as platinum group metal sulfides, precipitate under these conditions preferentially over other contained metals.
[0025] The reaction is exemplified as follows:
[0000] 2ReCl 7 +7NaHS=Re 2 S 7 +7NaCl+7HCl Scheme 2
[0026] The sulfide can be added as any compound capable of providing the required H 2 S, but it is preferentially sodium hydrosulfide (NaHS) or hydrogen sulfide (H 2 S) gas. The addition of sulfide at this low pH will cause for the evolution of H 2 S gas, requiring that the reaction vessel be either vented through a gas scrubbing device, or be a closed vessel so as to prevent the escape of H 2 S fumes. The release of H 2 S fumes can be minimized by the slow addition of the sulfide compound, allowing reaction to the desired Re 2 S 7 without significant release of H 2 S.
[0027] This precipitate is then filtered 110 to create a Re sulfide filtercake 120 . For example, the precipitate from 100 is typically filtered 110 to separate a Re sulfide filtercake 120 from the solution resulting from filtration step 110 . Filtration can be achieved by methods and devices known to those skilled in the art.
[0028] However, in most instances, the Re sulfide filtercake 120 is formulated and dried 130 to yield a Re sulfide product 150 . The Re sulfide filtercake 120 is dried 130 as necessary using devices and methods known to those skilled in the art to produce a Re sulfide concentrate product 150 . The Re sulfide concentrate product 155 contains up to about 100,000 parts per million Re, or up to about 10% by weight of Re. The Re sulfide concentrate product can be optionally isolated and sold as a finished commercial product itself 155 . For example, the Re sulfide concentrate product 155 has a variety of industrial applications. For example, the Re sulfide concentrate product 155 can be used in petrochemical cracking catalysts, automotive catalysts, textiles and water treatment methods.
[0029] When the Re sulfide produced 150 is found to also contain significant concentrations of platinum group metals (PGM's) the rhenium sulfide product is processed by methods normally used for recycling of spent Re/PGM catalysts. The rhenium sulfide with PGM's 900 is subjected to a roasting process 910 in a roaster at temperatures greater than 700° C., and preferably greater than 750° C., sufficient to oxidize the rhenium sulfide to rhenium heptoxide via the following reaction:
[0000] 2Re 2 S 7 +21O 2 +heat=2Re 2 O 7 (sublimes)+14SO 2
[0030] In the reaction, the rhenium heptoxide is then immediately sublimed to flue gas 180 discharged from the roaster, and captured in scrubbing solution 190 . The Re containing scrubber solution is then treated with ammonium chloride 700 to produce ammonium perrhennate.
[0031] The remainder after roasting 920 is then processed for PGM recovery by established methods.
[0032] Alternately, the rhenium sulfide produced 150 may sometimes contain insignificant PGM concentrations, and then the Re sulfide concentrate product is preferentially formulated with molybdenum Re-bearing concentrates 160 , which have been derived from porphyry copper molybdenum floatation 820 , an established mining industry process for the recovery of Mo/Re contained in select copper ores. For example, a porphyry copper ore flotation process 800 is used to obtain a Mo, Cu, Re containing concentrate. A Mo/Re flotation 820 is used to produce a Mo/Re concentrate 160 and a Cu containing fraction. The Mo/Re concentrate is mixed with the Rhenium sulfide concentrate product 150 . The Cu containing fraction is separately recovered as a Cu concentrate 825 .
[0033] The material from Re sulfide concentrate product 150 and Mo/Re flotation product 820 is then subjected to a roasting process 170 (see e.g., U.S. Pat. No. 3,739,549). The Re is sublimed during the roasting process 170 .
[0034] The combination of Re sulfide and the Mo/Re product provides an enriched Re-containing flue gas 180 . The Mo concentrates obtained from the roasting process 170 are recovered as MoO 2 175 .
[0035] The enriched Re-containing flue gas 180 is forwarded to a scrubber 190 where the sublimed Re is condensed and solubilized in a scrubber solution. The scrubber 190 treats the Re-containing flue gas 180 so that a solution containing Re is obtained 400 . The solution containing Re 400 is treated with an ammonia salt and subjected a solid/liquid separation filterpress 410 to obtain an ammonium perrhennate product 420 . Spent liquid 195 from the scrubber 190 can be disposed of or reused in the process. Spent liquid from filtration step 410 can also be disposed of, or reused in the process.
[0036] For example, Re sublimed from the Mo concentrates is condensed and captured in flue gas scrubbing liquors as perrhennate (ReO 4 ) 400 . The scrubbing liquors containing ReO 4 are then treated by the addition of ammonium chloride 700 to produce a substantially pure ammonium perrhennate 420 , which is crystallized as a white crystalline material, and is used as the primary supply to most of the world for further refining and consumption of Re. The liquid from the solid/liquid separation 410 can be disposed of or even reused in the process 215 .
[0037] The liquid from the solid-liquid separation of 110 is also further processed. For example, the pH of the filtrate from the solid-liquid separation of 110 is precipitated by raising the pH of the solution to 8.5 to 10, preferably 9.0 to 9.5 to produce a solution containing insoluble metal compounds 200 . Hydroxides such as NaOH (caustic soda) or KOH can be added to raise the pH.
[0038] The reaction is exemplified as follows:
[0000] MeCl 2 +2NaOH=Me(OH) 2 +2NaCl Scheme 3
[0000] where Me=any metal.
[0039] This resulting precipitate is then filtered 220 to produce a metal containing filtercake 230 . For example, the filtercake 230 can contain Ni, Co, and platinum group metals. Spent water from filtration step 220 can then be disposed of or reused 225 . The filtercake 230 is further formulated/compounded 310 to produce a metal containing concentrate 315 , such as Ni, Co, platinum group concentrate. The formulated/compounded material 310 is optionally combined with other feedstocks 305 and/or insoluble residues 300 to produce the metal containing concentrate 315 . Filtration methods and devices known to those skilled in the art can be used for this filtration step.
[0040] The foregoing description of the invention has been presented describing certain operable and preferred embodiments. It is not intended that the invention should be so limited since variations and modifications thereof will be obvious to those skilled in the art, all of which are within the spirit and scope of the invention.
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The present invention relates to a method of recovering rhenium (Re) and other metals from Re-bearing materials.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Provisional application No. 61/067,776 file Mar. 1, 2008.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
DESCRIPTION OF ATTACHED APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to the field of pest control and more specifically to a non-toxic, environmentally friendly process for preventing the encroachment or reentry of termites from a structure.
[0005] Controlling termites has always been a problem. In the past they have been controlled by chemicals that kill them upon contact or which are placed around or within a structure to provide long-term control. In most cases these chemicals are toxic and must be dispensed with care, usually by a professional trained to handle them. Most of the chemicals that are effective for killing termites present danger to the environment. It would be beneficial if a permanent method of controlling termites were developed that does not use harmful chemicals. The currently available compositions for controlling termites are not satisfactory in all respects because comparatively large areas around building structures, or the buildings themselves, usually have to be treated with large amounts of insecticide. That can lead to subsequent problems especially in houses, more especially when persistent pesticides are used. Subterranean termites, which are the most widespread, require warm air and a moist environment. In order that such termites always have access to the necessary moisture, they must have a direct connection to moist soil. Damage by termites that are active underground is almost always associated with damage to wood.
[0006] U.S. Pat. No. 7,264,796 describe the use of treated wood to prevent damage by termites. U.S. Pat. Nos. 7,282,212, 7,157,078, 6,875,440 all are examples of using a pesticide to control termites. U.S. Pat. No. 6,803,051 describe the use of a multi-layer barrier containing pesticide to control termites.
[0007] U.S. Pat. Nos. 7,488,523, 7,464,499, and RE39,223 all describe the use of barriers to prevent the encroachment of termites into a structure.
[0008] None of these described the approach of the present invention that is to prevent termites from reentering a structure when they leave to obtain water. The present invention allows for a simple means of controlling termites or their eggs that are already within a structure without the use of harmful pesticides.
BRIEF SUMMARY OF THE INVENTION
[0009] The primary object of the invention is to provide an improved method for termite control that does not require toxic or environmentally harmful chemicals.
[0010] Another object of the invention is to provide a method for termite control that is permanent and does not require retreatment.
[0011] Another object is to provide a method of controlling the termites that are already inside a structure.
[0012] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0013] Termites like the darkness. When they are nesting in a structure, eventually they need water. They will tunnel vertically to find water however if they cannot find water they will travel horizontally outside the structure to seek water from the soil around the perimeter. Unexpectedly it has been found that exposure to light for more than three hours will disorient the termite and it will die from dehydration before being able to find water and return to the darkness. In accordance with a preferred embodiment of the invention, there is disclosed a process for preventing the re-entry of termites into a structure by constructing a collar around the structure that does not allow the termites to survive when exiting the structure to seek water. The collar is composed of any material capable of surviving exposure to the elements. Nonexclusive examples of the material of construction include but are not restricted to metal, plastic or concrete. The collar should be at least two inches wide preferably 6 inches or more wide. This has been found to provide enough barrier to the termites reaching water from outside the perimeter of the structure so that become dehydrated and die. The collar must be pitched to not allow any water to collect on it or to drain back to the structure being protected.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0015] The method involves constructing a collar around the base of the entire circumference of a house or other structure where termite protection is desired. The collar is a minimum of 2 inches wide preferably 6 inches wide and is pitched so that no water will collect on it and any water will drain from the intersection of the outside wall of the structure and the collar to the ground. The collar may be constructed of any material that doesn't collect moisture and does not provide food for the termites. These materials include but are not restricted to concrete, plastic, or metal. The collar must in tight contact with the outside wall in order not to provide a gap where the termites may by-pass the collar and enter the ground without traveling across the collar. Termites must transverse the collar in order to get water from the ground. The termites cannot survive the exposure to the light for the time it takes them to transverse the collar and therefore they die from lack of water.
[0016] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form 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 process for preventing the re-entry of termites into a structure by constructing a collar around the structure that does not allow the termites to survive when exiting the
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to techniques for locating a target object which call for the use of radiation which is emitted in the direction of the object and detected after back-reflection from this latter.
2. Description of the Prior Art
The highest standards of accuracy are at present achieved by means of radiations of the laser type. Depending on requirements, a locating operation of the above-mentioned type can prove useful either for measuring the distance of the object according to the time taken by the radiation to travel the distance from the emitting source to the object and from the object to the detection system or for determining the angular position of the object with respect to a reference direction, or alternatively for controlling a number of different functions related to the presence of such an object in the field of view in a more complex equipment unit.
In order to gain a precise idea of these possibilities, reference may be made more specifically to applications in the field of firing simulation in order to determine whether the located object constituting the target would or would not have been hit by a real shot corresponding to the same characteristics as the simulated shot. In this sphere of application, it is common practice to employ laser radiation for locating the target in angular position with respect to a reference axis and if necessary for determining its distance. It is also known to impart a scanning movement of small amplitude to the detecting laser beam. This scanning motion has the effect of maintaining the beam "locked" on the target during displacements of this latter.
SUMMARY OF THE INVENTION
The essential aim of the invention is to improve these techniques by better processing of the data which can be supplied by a radiation beam employed for spatial location of an object and more particularly with the full degree of precision which a laser is capable of achieving. To this end, the invention proposes to vary the sensitivity of detection as a function of the distance of the detected object so as to compensate for the incidence of this distance on the angular width of the area in which the presence of the object is to be detected.
The invention is thus directed to a method for locating an object involving detection in the form of an electric signal of the echo of a radiation beam emitted in the direction of the object and reflected from this latter. The distinctive feature of the method lies in the fact that said signal is subjected to a correction treatment in order to compensate for variations in angular range of detection sensitivity as a function of the distance of the object.
A signal treatment of the type mentioned above can consist in particular in imposing on the detection signal a minimum threshold which is variable in a predetermined manner as a function of the radiation transit time which elapses between emission of the beam and detection of the echo and which, as is well known, is representative of the distance between the detected object and the emission and detection equipment. A very similar solution consists in imposing a constant minimum threshold on the signal by subjecting it beforehand to a variable gain in a manner which is predetermine as a function of the same transit time.
The compensation provided by the invention is likely to prove highly useful under many different circumstances. In particular, in the case of firing simulation already mentioned, the signal thus compensated can advantageously be employed for controlling a beam-scanning movement, the intended function of which is to maintain the direction of the beam in a target-object detection situation. The scanning range can accordingly be maintained at a low value, even in the case of targets which are close together. It is in fact apparent in this case that there is no advantage to be gained by scanning the field of view at an angle which, in respect of a non-compensated detection sensitivity, would be wider as the target is closer whereas accuracy of determination of the angular position of the target would at the same time be reduced. It is in any case possible to establish the laws of variation in threshold or in gain as a function of the distance (or of the time of transit of radiation between emission, target and detection), with the result that the angular divergence of the scanning movement is substantially constant irrespective of the distance of the target.
It will be already understood, however, that the invention extends to all applications of the target-location method defined in the foregoing. The invention also extends to devices comprising all suitable means for carrying out said method.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features of the invention will be more apparent upon consideration of the following description and accompanying drawings, wherein:
FIG. 1 is a flow diagram showing the different steps of the method described;
FIG. 2 is a diagram of detection indicatrices in respect of target objects at different distances and will serve to explain the usefulness of the method of detection in accordance with the invention as applied to the field of firing simulation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In firing simulators, it is standard practice to employ laser-beam detection for locating a target both in angular position with respect to the simulator and in distance of the simulator from the target, and to utilize the results of this target location for making a comparison with the trajectory of a simulated projectile or missile which makes it possible to determine whether the corresponding shot is correct or in other words whether a real shot conforming to the same characteristics would have hit the target or not. French Pat. No. 81 11574 gives a detailed description of a firing simulation system. In addition, this patent specification explains how the target is continuously tracked after detection by subjecting the same laser beam to a scanning movement of small amplitude in the vicinity of the target. The beam scan is in fact controlled in such a manner as to produce a rearward return of the movement each time the beam no longer detects the presence of the target.
As shown in FIG. 1, the essential equipment comprises a laser source 1, deflectors 2 which serve to subject the direction of emission of the laser beam to a scanning movement along two perpendicular axes, and a laser detector 3 which is sensitive to the echo received after back-reflection from the target when the direction of the laser beam is suitably oriented.
The problem now solved by the invention relates to the variation in response of the laser detector according as the target detected is more or less close or more or less distant. This distance from target to detector is expressed in a conventional manner by the time taken by the laser radiation to perform a round-trip traversal over the distance from emission source to target, and back from this latter to the detection unit. This transit time is detected at 4 in FIG. 1 in the form of a time signal which is then transmitted to a telemeter 5 and this latter converts said signal in order to represent the results directly as values of distance.
It is customary practice to represent the variations in detection sensitivity as a function of the target distance by what are known as detection indicatrices. These are curves which represent by means of bulged sensitivity lobes the area over which detection is possible by means of a predetermined equipment unit. Strictly speaking, rather than use the term sensitivity, it is in fact more appropriate to speak of detectibility, that is, the capacity of the equipment for target detection by laser emission-reception. There are thus shown in FIG. 2 three detection indicatrices each in respect of a predetermined target position. Thus the indicatrix 11 having the greatest length is for the short-distance target; the most compact indicatrix 13 is for the long-distance target; and the intermediate indicatrix 12 corresponds to a medium-distance target position. Angular deviations, namely those of the target or those of the laser beam are expressed by relative displacements on each side of the axis of indicatrices whilst the intensity of response to detection is plotted along this axis.
Referring now to FIG. 1, it is apparent that the deflectors 2 having a laser-beam scanning function transmit a signal to a coding device 6 for producing a coded position datum which characterizes the position of the laser beam in elevation and in azimuth at each instant. In conventional simulators, this item of information or datum is transmitted to an angular deviation measurement device 7 in response to an echo detection signal which represents the simultaneous reception of an echo by the laser detector 3. The angular deviation measurement device 7 thus indicates the angular position of the target. When echo detection is utilized for continuous tracking of the target by the laser beam, a complementary device (not shown in the drawings) initiates the return of the scanning movement as soon as the detector 3 no longer receives the echo by means of a system for controlling the deflectors in dependence on the same echo detection signal as in the foregoing. An object of the present invention is precisely to effect a preliminary correction of this echo detection signal as will hereinafter be explained in greater detail.
The angular divergence or range of the scanning movement is expressed in FIG. 2 by the angular displacements of the beam about the origin 0 or point of emission of the beam. Between the extreme orientations in which the echo continues to be received, the widths "seen" by the detection indicatrices are represented by the segments 14, 15 and 16 respectively in the case of the three indicatrices, namely the short-distance, medium-distance and long-distance indicatrices, when use is made of a conventional simulator. The degree of accuracy in detection of the angular position of the targe proves to be highly variable according to the distance of said target and the quality of the aim cannot be assessed in the case of targets located close together.
In order to overcome these disadvantages, the invention makes it possible to transfer the width seen by each indicatrixtto its extremity. To this end, the echo detection signal is subjected to a correction treatment which, by means of the device 10 in FIG. 1, provides at least partial compensation for the variations in detectibility or sensitivity of detection as a function of the target distance. By suitable calibration of the correction law, it is even possible to ensure that the widths seen by the indicatrices are located at 16, 17, 18 : this corresponds to an angular scanning range which remains constant when the target comes progressively closer to the simulator.
This result is obtained by imposing on the laser echo detection signal a minimum amplitude threshold which varies according to the distance of the target or more precisely according to the transit time of the laser beam detected at 4. This threshold is relatively high in the case of a short transit time (curve 19 in FIG. 2) and relatively low in the case of long transit times (curve 20) The law governing the variations in threshold as a function of the transit time is established by preliminary calibration and recorded at 8 (FIG. 1).
The signal representing the transit time which is delivered at 4 is transmitted at 8 for selection of the corresponding threshold. At 9, the echo detection signal delivered by the laser detector 3 is compared with the threshold signal delivered by the device 8 and is transmitted by means of the device 10 in order to constitute the corrected echo detection signal to be subsequently employed, only on condition that its amplitude is higher than the selected threshold value.
By way of alternative to the foregoing, the same correction can be performed by maintaining the minimum threshold value imposed on the final echo detection signal at a relatively low but constant value and by increasing the amplitude of the initial signal derived from the laser detector 3 by a gain whose value varies according to the laser beam transit time which has been detected. The law of variation of the gain as a function of time as imposed by a device which is similar to the device 8 of FIG. 1 then corresponds to an increase in gain with time and therefore in the distance of the target.
It is apparent that, as in the case of the previous solution, the effect of the alternative embodiment just mentioned is that a corrected echo detection signal is obtained in respect of bemm orientations located within an angle of divergence which remains substantially constant for all target distances within a predetermined range.
The invention is clearly not limited in any respect to the distinctive features specified in the foregoing or to the details of the particular embodiment which has been chosen for the purpose of illustrating the invention. In regard to the particular embodiment hereinabove described by way of example as well as it constituent elements, all types of variants may be contemplated without thereby departing either from the scope or the spirit of the invention, which thus includes all equivalent means.
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In a method for locating an object such as a target for firing simulation in which the echo of a radiation beam emitted in the direction of the object and reflected back from the object is detected in the form of an electric signal, the signal is subjected to a correction treatment in order to compensate for variations in detection sensitivity as a function of the distance of the object. The signal treatment primarily consists in imposing on the signal a variable minimum threshold or a constant threshold with a variable preliminary gain. The variations take place in accordance with a predetermined correction law as a function of the time which elapses between emission of the radiation and detection of the echo.
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FIELD OF THE INVENTION
The present invention relates to improvements in structures and methods for supporting and anchoring conductive wires near walls, baseboards, floors and moldings, and which facilitates removal of the wires with and without the anchoring structure.
BACKGROUND OF THE INVENTION
In U.S. Pat. No. 5,514,834 to Harry I. Zimmerman, a number of mechanical orientations of flanged conduit was disclosed which were advantageous in wiring and re-wiring applications. The structures disclosed enabled a wide variety of structures to be used which would be embraced and supported by gaps between base board and floor, and between carpeting and base boards or vertical walls.
In each of the configurations, the main theme was engagement by the use of a length of material. The length of material was frictionally engaged within a space between base board and floor or between carpet and a baseboard or vertical wall. The cross sectional profile of the engagement member represented either a linear extension to be pushed into an existing gap, or a modified linear member such as having an undulating extent or ribs in order to enable the linear member to be somewhat compressed. Compression occurred in the linear material directly through its plastic construction, in the undulating member by a straightening of the extent of the undulations while the member was under compression, or in the barbed member by bending displacement of the barbs.
In some of the orientations the amount of work necessary to obtain a secure engagement was dependent upon the type of gap which was present. In other cases, where the gap being engaged was uneven, either by uneven workmanship at the wall or base board or by an uneven floor, the conduit would be held securely in some places and not held securely in others.
A useful improvement to the conduit would be structure enabling the conduit to find an even level of engagement with the structures available. This would provide a more consistent support for the conduit despite inconsistencies in the support structures, present such as wall, baseboard, floor and carpet. The structure would not only provide a consistency in engagement and support, but would also provide consistency to the installer by providing feedback as to whether the installation motions were sufficient to result in an even installation.
In some instances, especially where the conduit and holding portion are integrally formed, the removal of the structure can damage it. Where the anchoring structure continues to be held by the wall, stripping or base board, the wire and insulation can be damaged. What is needed is a conduit in which the anchoring structure can be detached where it is held too tightly by, or has become integrated into the holding structure.
The needed structure should be held in place by using natural structures on the base board and which provide a "snap" or "click" to the installer during the installation. The degree to which the conduit is held in place should not be unduly severe and should not prevent the conduit from being easily removed. The needed conduit should promote safety, including the safety of having the wires together, as well as the safety from making certain that the conduit is held securely in place.
SUMMARY OF THE INVENTION
An improved conduit has a cross sectional profile which generally provides an elongate support structure having at least one anchoring structure extending from the support structure to engage any groove on a base board structure to enable the conduit to be "snapped" into a place of consistent support, to provide an extra measure of safety. Generally, the conduit will be pushed down directly against the support structure to enable the support structure to either become anchored or to flex against and secure the engagement of the anchoring structure. A variety of embodiments take advantage of the widest variety of corner configurations in order to provide the widest applicability of the conduit. In one embodiment, the anchoring structure has a thinned connection to the main conduit to facilitate controlled detachment of the anchoring structure in instances where the anchoring structure is bound too tightly or where the anchoring structure becomes stuck to the anchoring structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of the conduit having a triangular wire support boundary, and a locking rib positioned from the flat side of a vertical support;
FIG. 2 is an end view of the embodiment of FIG. 1 and gives a better view of the relationship of the wire support boundary and the locking rib;
FIG. 3 is a sectional view of a floor, wall, and carpet and illustrating how the conduit of FIGS. 1 and 2 would be implaced in a typical application having a base board and wall structure;
FIG. 4 is a perspective view of the conduit in a typical application extending through a tight radius to accommodate a corner;
FIG. 5 is a variation of FIG. 2 and having a pair of anchoring structures extending from a straight flange, one anchoring structure spaced above the other;
FIG. 6 is a variation of FIGS. 1 and 2 where the a single anchoring structure has a right triangular shape when viewed in cross section;
FIG. 7 is a variation on FIG. 6 and having a pair of spaced apart anchoring structures of right triangular shape;
FIG. 8 is a variation on FIGS. 1 and 2 and having a curved elongate structure curving underneath the conduit portion and having a single anchoring structure;
FIG. 9 is a variation on FIG. 8 and having a pair of anchoring structures and a curved elongate structure curving underneath the conduit portion;
FIG. 10 is a variation on FIG. 9 and having a rectangular anchoring structures and an outward curving elongate structure;
FIG. 11 is a variation on FIG. 10 and having a pair of rectangular anchoring structures and an outward curving elongate structure;
FIG. 12 illustrates a conduit portion having a dual flange portion having an inwardly curved portion and a straight portion having a single anchoring structure;
FIG. 13 illustrates a conduit portion having a curved elongate structure curving underneath the conduit portion and a single triangular shaped anchoring structure;
FIG. 14 is a variation on FIG. 9 and having a pair of triangular shaped anchoring structures and a curved elongate structure curving underneath the conduit portion;
FIG. 15 is a variation on FIG. 10 and having a triangular anchoring structure and an outward curving elongate structure;
FIG. 16 is a variation on FIG. 11 and having a pair of triangular anchoring structures and an outward curving elongate structure;
FIG. 17 illustrates a conduit portion having a dual flange portion having an inwardly curved portion and a straight portion having a single triangular anchoring structure;
FIG. 18 illustrates a straight, but angled flange portion angled underneath the conduit portion and having a single anchoring structure;
FIG. 19 illustrates a conduit having an angled elongate structure angled underneath the conduit portion and having a pair of rectangular anchoring structures;
FIG. 20 illustrates a conduit having a rectangular anchoring structures and an outward angled elongate structure;
FIG. 21 illustrates a conduit having a pair of spaced apart rectangular anchoring structures and an outward angled elongate structure;
FIG. 22 illustrates a conduit having a dual flange portion having an inwardly angled portion and a straight portion having a pair of spaced apart anchoring structures;
FIG. 23 illustrates a solid wire encasement conduit portion having a curved elongate structure curving underneath the conduit portion and a single rectangular shaped anchoring structure;
FIG. 24 illustrates a solid wire encasement conduit portion having a curved elongate structure curving underneath the conduit portion and a pair of spaced apart rectangular shaped anchoring structure;
FIG. 25 illustrates a solid wire encasement conduit portion having a curved elongate structure curving away from underneath the conduit portion and a single rectangular shaped anchoring structure;
FIG. 26 illustrates a solid wire encasement conduit portion having a curved elongate structure curving away from underneath the conduit portion and a pair of spaced apart rectangular shaped anchoring structures;
FIG. 27 illustrates a solid wire encasement conduit portion having a curved elongate structure curving underneath the conduit portion and a single rectangular shaped anchoring structure;
FIG. 28 is an open triangular conduit having a straight flange portion with a single rectangular shaped anchoring structure;
FIG. 29 is an open triangular conduit having a straight flange portion with a pair of spaced apart rectangular shaped anchoring structures;
FIG. 30 is an enclosed circular conduit having a straight flange portion extending tangentially away from the circular conduit and having a single rectangular shaped anchoring structure;
FIG. 31 is an enclosed circular conduit having a straight flange portion extending tangentially away from the circular conduit and having a pair of spaced apart rectangular shaped anchoring structures;
FIG. 32 is a sectional view of a floor, wall, and carpet and illustrating how the conduit of FIG. 30 would be implaced in a typical application having a base board and wall structure;
FIG. 33 is an irregularly shaped conductor structure having a solid conduit portion carrying a series of spaced apart conductors, and having a single straight flange with a single rectangular anchoring structure;
FIG. 34 is an rectangular cross shaped conductor structure having a solid conduit portion carrying a series of spaced apart conductors, and having a single straight flange with a single rectangular anchoring structure;
FIG. 35 is a conduit having a triangularly shaped conduit portion and a flange which extends away from a corner of the triangularly shaped conduit at a 45° angle from the legs and perpendicular to the hypotenuse of the triangle and having a single straight flange with a thinned area of material due to a pair of notches;
FIG. 36 is a conduit having an arc shaped conduit portion and a flange which extends away from a corner of the triangularly shaped conduit at a 45° angle from the legs and perpendicular to the arc shaped side of the conduit portion and having a single straight flange with a thinned area of material due to a pair of notches;
FIG. 37 is a sectional view of an irregularly shaped conduit having a solid section for carrying a pair of conductors, especially for power usage and having an angled anchoring structure and a slightly curved flange;
FIG. 38 is a sectional view of an irregularly shaped conduit having a solid section for carrying a pair of conductors, especially for power usage and having an angled anchoring structure and a slightly curved flange connected by a thinned area resulting from the presence of a single notch;
FIG. 39 is a perspective view of the irregularly shaped conduit of FIG. 38 and illustrating removal of material such that the flange portion extends from the conduit intermittently along the length of the conduit;
FIG. 40 is a rear view of the conduit shown in FIG. 39 to better illustrate the intermittent nature of the flange portions along the length of the conduit;
FIG. 41 is a sectional view of a floor, wall, and carpet and illustrating how the conduit of FIGS. 38-40 would be implaced in a typical application having a base board and wall structure;
FIG. 42 is a sectional view of a conduit member similar to that shown in FIG. 2, with a straight connection between the flange portion and the conduit portion.
FIG. 43 a variation of FIG. 5 and having a pair of anchoring structures extending from a straight flange, one anchoring structure spaced above the other, with a straight connection between the flange portion and the conduit portion;
FIG. 44 is a variation of FIG. 6 where the a single anchoring structure has a right triangular shape when viewed in cross section, with a straight connection between the flange portion and the conduit portion;
FIG. 45 is a variation on FIG. 7 and having a pair of spaced apart anchoring structures of right triangular shape, with a straight connection between the flange portion and the conduit portion;
FIG. 46 is a variation on FIG. 8 and having a curved elongate structure curving underneath the conduit portion and having a single anchoring structure, with a straight connection between the flange portion and the conduit portion;
FIG. 47 is a variation on FIG. 9 and having a pair of anchoring structures and a curved elongate structure curving underneath the conduit portion, with a straight connection between the flange portion and the conduit portion;
FIG. 48 is a variation on FIG. 10 and having a rectangular anchoring structures and an outward curving elongate structure, with a straight connection between the flange portion and the conduit portion;
FIG. 49 is a variation on FIG. 11 and having a pair of rectangular anchoring structures and an outward curving elongate structure, with a straight connection between the flange portion and the conduit portion;
FIG. 50 illustrates a conduit portion having a dual flange portion, with a straight connection between the flange portion and the conduit portion, and having an inwardly curved portion and a straight portion;
FIG. 51 illustrates a conduit portion having a curved elongate flange structure, with a straight connection between the flange portion and the conduit portion and a single triangular shaped anchoring structure;
FIG. 52 illustrates a conduit portion having a curved elongate flange structure, with a straight connection between the flange portion and the conduit portion and a pair of triangular shaped anchoring structures;
FIG. 53 illustrates a conduit portion having a curved elongate flange structure, with a straight connection between the flange portion and the conduit portion and a single triangular shaped anchoring structure;
FIG. 54 illustrates a conduit portion having a curved elongate flange structure, with a straight connection between the flange portion and the conduit portion and a pair of triangular shaped anchoring structures;
FIG. 55 illustrates a conduit portion having a curved elongate flange structure, with a straight connection between a split flange portion having an inwardly curved portion and a straight portion having a single triangular shaped anchoring structure;
FIG. 56 illustrates a conduit portion having an angled elongate flange structure, with a straight connection between the flange portion and the conduit portion and a single rectangular shaped anchoring structure;
FIG. 57 illustrates a conduit portion having an angled elongate flange structure, with a straight connection between the flange portion and the conduit portion and a pair of rectangular shaped anchoring structures;
FIG. 58 illustrates a conduit portion having an angled elongate flange structure, with a straight connection between the flange portion and the conduit portion and a single rectangular shaped anchoring structure;
FIG. 59 illustrates a conduit portion having an angled elongate flange structure, with a straight connection between the flange portion and the conduit portion and a pair of spaced apart rectangular shaped anchoring structures;
FIG. 60 illustrates a conduit portion having a split flange structure, with a straight connection between the flange portion and the conduit portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion having a pair of rectangular shaped anchoring structures;
FIGS. 61 illustrates a conduit having a solid fill conduit portion and an inwardly curving flange portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion and having a single rectangular anchoring structure;
FIG. 62 illustrates a conduit having a solid fill conduit portion and an inwardly curving flange portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion and having a pair of rectangular anchoring structures;
FIG. 63 illustrates a conduit having a solid fill conduit portion and an outwardly curving flange portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion and having a single rectangular anchoring structure;
FIG. 64 illustrates a conduit having a solid fill conduit portion and an outwardly curving flange portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion and having a pair of spaced apart rectangular anchoring structures;
FIG. 65 illustrates a conduit having a hollow arc shaped conduit portion and having a split flange structure including an inwardly curving portion, with a straight connection between a split flange portion having an inwardly angled portion and a straight portion and a straight portion and having a single rectangular anchoring structure;
FIG. 66 illustrates an open triangular conduit having a flange with a straight connection to the conduit portion and having a rectangular anchoring structure;
FIG. 67 illustrates an open triangular conduit having a flange with a straight connection to the conduit portion and having a pair of rectangular anchoring structures;
FIG. 68 is an enclosed circular conduit having a straight flange portion with a straight connection to the conduit portion and extending tangentially away from the circular conduit and having a single rectangular shaped anchoring structure;
FIG. 69 is an enclosed circular conduit having a straight flange portion with a straight connection to the conduit portion and extending tangentially away from the circular conduit and having a pair of rectangular shaped anchoring structure;
FIG. 70 is an irregularly shaped conductor structure having a solid conduit portion carrying a series of spaced apart conductors, and having a single straight flange, with a straight connection to the conduit portion, and with a single rectangular anchoring structure;
FIG. 71 is an rectangular cross shaped conductor structure having a solid conduit portion carrying a series of spaced apart conductors, and having a single straight flange with a straight connection to the conduit portion and with a single rectangular anchoring structure;
FIG. 72 is a conduit having a triangularly shaped conduit portion and a flange with a straight connection to the conduit portion and which extends away from a corner of the triangularly shaped conduit at a 45° angle from the legs and perpendicular to the hypotenuse of the triangle and having a single straight flange, the reversibility to allow for the wire to be applied to in both the left and right handed application;
FIG. 73 is a conduit having an arc shaped conduit portion and a flange with a straight connection to the conduit portion and which extends away from a corner of the triangularly shaped conduit at a 45° angle from the legs and perpendicular to the arc shaped side of the conduit portion and having a single straight flange;
FIG. 74 is a conduit having a hollow inside area for carrying conductors and which has a reduced area portion defined by a pair of opposing notches, and an extended flange portion especially useful for placement under carpeting;
FIG. 75 is a conduit having a hollow inside area for carrying conductors and which has a reduced area portion defined by a pair of opposing notches, and an extended flange portion with a straight connection to the conduit portion and especially useful for placement under carpeting;
FIG. 76 is a sectional view of a floor, wall, and rug and illustrating how the conduit of FIGS. 74 & 75 would be implaced in a typical application having a base board and wall structure;
FIG. 77 is a sectional view of a floor, wall, and carpet and illustrating how the conduit of FIG. 8 would be implaced in a typical application having a base board and carpet structure;
FIG. 78 illustrates the use of the conduit structure shown in FIG. 36 with a pair of conductors, and with the flange extending away from the wall, and used as power transmission wiring and extending from a wall plug, then turning at the bottom and engaging a space within a baseboard;
FIG. 79 illustrates a sectional view taken along line 79--79 of FIG. 78 and illustrating the twisting motion as the flange is brought around to engage the base board;
FIG. 80 illustrates the use of the conduit structure shown in FIG. 36 with a pair of conductors, and with the flange extending toward the wall and partially removed during the vertical extent of the conduit, and used as power transmission wiring and extending from a wall plug, then turning at the bottom and engaging a space within a baseboard;
FIG. 81 illustrates a sectional view taken along line 81--81 of FIG. 80 and illustrating the turning motion as the continues near the base board and engages the space between the base board and floor.
FIG. 82 illustrates the conduit of FIG. 35 in transition from horizontal engagement between a floor and base board to vertical placement between wall and molding and illustrating the advantage of removal of the flange when the conduit is not needed;
FIG. 83 is a view taken along line 83--83 of FIG. 82 and illustrating a slight twist to enable close conforming seating in the corner between wall and molding;
FIG. 84 is a variation showing a triangular rib located on both sides of the flange, even where the flange curves or extends underneath the conduit portion;
FIG. 85 illustrates a conduit design having a rectangular rib on either side of a flange extending at a 45° angle to form a structure which facilitates true ambidextrous or right and left hand orientation installation; and
FIG. 86 illustrates a solid conduit having a flange with a pair of rectangular ribs on both sides of the flange.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a perspective view of a conductor structure 11 illustrates a conduit portion 13 and a flange portion 15. Within the conduit portion 13 are a series of insulated wires 17, within a conduit space 19. This is a schematic showing, and in practice, the conduit space 19 may be eliminated and filled in with insulative material and the wires then provided within the insulation.
Immediately below the conduit portion 13, the flange portion 15 is connected through a thinned area of material shown as formed with a pair of opposing notches 21 and 23, notch 21 facing the rear side of the conductor structure 11 and notch 23 facing the front side of the conductor structure 11. The notches 21 and 23 are shown as being round notches, but any shape will suffice, the main idea being a reduced cross sectional area of material per unit length separating the flange portion 15 from the conduit portion 13.
Immediately below the notch 23, the flange portion 15 extends straight down at the front side. Immediately below the notch 21, the flange portion 15 has a rearwardly extending rib 25. The rib 25 is shown as a rectangular shape and extending from the generally vertical extent of the flange, but the rib 25 can be differently shaped and can extend at an upwardly or downwardly angle from the flange portion 15.
In addition, a series of vertically extending thinned areas or notches 27 can be seen located periodically along the length of the flange portion 15. In operation, the flange portion 15 is inserted into any available crack or thin space near the base of a wall. The flange portion 15 is flexible and easily fittable into a flange space. Flange spaces include vertical spaces between molding and wall, between carpet tacking and molding or wall, as well as others. Flange spaces also include horizontal spaces between floor and molding, tacking, walls and wall support structures. The flange portion 15 can fit equally well into either a vertical, horizontal, or angled flange space.
Referring to FIG. 2, an end view of the conductor structure 11 gives a better view of the structure and illustrates directly the reduced cross sectional area 29 existing at the mid point of the two notches 21 and 23. Instead of two equally opposing notches 21 and 23, a larger notch may be used on only one side of the conductor structure 11 and which comes sufficiently near to the other side that a reduced area cross section 29 is produced.
The operation of the conductor structure 11 is as follows. Where the wires or insulated wires 17 are already present within the conduit space 19, the conductor structure 11, with the flange portion 15 extending down, is inserted into a flange space. The rib 25, particularly as located below the conduit portion 13 can help the conductor structure 11 find and lock into a stabilizing structure. For example, where the conduit space is horizontal, the flange portion 15 can fit just under the entrance to a horizontal conduit space to "lock" the flange portion 15 into place. The degree of lock will depend upon a variety of factors, including width of the conduit space, availability of other structures, and the combined shape and spacing of the rib 25 and the flange portion 15.
Where a vertical conduit space is available, there may be other structures upon which the rib 25 can interfit. Further, rib 25 represents useful structure which can perform several functions. First, where the conduit space is wider than would form a snug fit with the flange portion, the combination of widths of the flange portion 15 and rib 25, particularly where these two structures may be bent toward each other, helps to form an anchoring structure which can accommodate some variability in conduit space. Second, where a wide anchoring space is available, the flange portion 15 can be compressed to form a spring structure with single or multiple undulations and which can provide upward pressure against the rib 25 as it engages some other structure. Where this action is present, installation will occur with a "clicking" or "snap" feedback to the installer, indicating a successful placement.
Third, note that the rib 25 is somewhat below the conduit portion 13. This is important in installations with carpeting where the conductor structure 11 needs to be sufficiently high and above the carpeting or other obstruction level. The rib 25, as will be seen, will exist as single or multiple structures and will lie along the flange portion 15. In FIGS. 1 and 2 it is shown at the top of the flange portion 15. Fourth, the reduced area cross section 29 enables the removal of the conductor structure 11 from a conduit space to which the flange portion 15 is "stuck" or attached. In this case, the conductor structure 11 is separated from the flange portion 15 by controlled tearing of the reduced area cross section 29. Where only a short portion of the flange portion 15 is "stuck", the adjacent sections of flange portion 15 will not continue to be torn away from the conduit portion 13 due to the presence of vertical notches 27. In addition, the flange portion 15 can be selectively torn away when the flange portion 15 is not needed. The vertical notches 27 can provide a "through" space, actually dividing flange portion 15 into segments, or it can be an incomplete notch, creating a reduced area cross section from which adjacent sections of the flange portion 15 can be "torn" away. This prevents a stuck section of flange portion 15 from harmfully grabbing the overall conductor structure 11 and perhaps tearing the main volume of insulative material which could expose the wires.
Referring to FIG. 3, a view is shown where the rib 25 engages a notch 31 along the bottom of base molding 33 attached to a wall 35. To the left of the base molding 33 is a length of carpet tacking 37 which supports carpeting 39. A length of carpet padding 41 lies to the left of the carpet tacking 37, and both lie over the floor 43. FIG. 3 is an example in which the notch 31 engages the rib 25 and in which the flange portion 15 is springlingly bent to put some pressure against the notch 31--rib 25 engagement.
Referring to FIG. 4, an example of the conductor structure 11 in a corner environment is illustrated with the carpet 39 removed in order to illustrate how easily the structure of the invention can corner accommodate and extend through a corner turn. The locking mechanism provided by the rib 25 nearly doubles its holding ability at a corner, by virtue of additional outward forces opposing the bending.
Referring to FIG. 5, a conductor structure 51 is shown having a flange portion 53 having a pair of ribs 55. Again, the notches 21 and 23 are present creating the reduced area cross section 29, although a reduced cross sectional connection area is one variation and as will be seen this is a separate embodiment from one not having such reduced cross sectional area. Here the ribs 55 are parallel and spaced apart. The operational idea in FIG. 5 is two. First, the operative rib 55 may be located much lower on the flange portion 53. Second, two or more ribs 55 may be used. In some sections of the wall 35, a notch 31 may be located lower down or higher up, especially with respect to the floor 43. Where the notch 31 is higher, it will be easily engageable by the upper of the two ribs 55 shown. Where the notch 31 is lower, the lower of the two ribs 55 may be more advantageous for engagement. Three or more ribs may be used.
Referring to FIG. 6, a conductor structure 61 is shown having a flange portion 63 having a single triangular shaped rib 65. The rib 65 is positioned to have a horizontal top profile portion and an angled lower portion. This forms a small continuous ratchet which makes the conductor structure 61 easier is to install and slightly more difficult to de-install, as is the case where any one-sided locking mechanism is used. Again, the notches 21 and 23 are present creating the reduced area cross section 29, although a reduced cross sectional connection area is but one variation.
Referring to FIG. 7, a conductor structure 71 is shown having a flange portion 53 having a pair of triangular shaped ribs 65. Again, the notches 21 and 23 are present creating the reduced area cross section 29, although a reduced cross sectional connection area is but one variation. Here the ribs 55 are parallel, of even extent and angle and are spaced apart. They may be of different extent, angle and located closely together or spaced apart.
Referring to FIG. 8, a conductor structure 81 is shown having a curved flange portion 83, when view from the transverse direction and curving underneath the conduit portion 13. The curved flange portion 83 has a single rectangular shaped rib 85 which extends generally perpendicularly with respect to the section of the curved flange portion 83 from which it extends. The formed curvature of the curved flange portion 83 assists in helping an installer to have the flange portion 83 consistently bend in one direction. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 9, a conductor structure 91 is shown having a curved flange portion 93, when view from the transverse direction and curving underneath the conduit portion 13. The curved flange portion 93 has a pair of rectangular shaped ribs 95 which extends generally perpendicularly with respect to the section of the curved flange portion 93 from which it extends. The formed curvature of the curved flange portion 93 assists in helping an installer to have the flange portion 93 consistently bend in one direction, underneath the conduit portion 13. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 10, a conductor structure 101 is shown having a curved flange portion 103, when view from the transverse direction and curving toward the back side of and away from a direction underneath the conduit portion 13. The curved flange portion 103 has a single rectangular shaped rib 105 which extends generally perpendicularly with respect to the section of the curved flange portion 103 from which it extends. The formed curvature of the curved flange portion 103 assists in helping an installer to have the flange portion 103 consistently bend in one direction, away from the area underneath the conduit portion 13. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 11, a conductor structure 111 is shown having a curved flange portion 113, when view from the transverse direction and curving toward the back side of and away from a direction underneath the conduit portion 13. The curved flange portion 113 has a pair of rectangular shaped ribs 115 which extend generally perpendicularly with respect to the section of the curved flange portion 113 from which it extends. The formed curvature of the curved flange portion 113 assists in helping an installer to have the flange portion 113 consistently bend in one direction, away from the area underneath the conduit portion 13. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 12, a conductor structure 121 is shown having a split tailed flange portion including a vertical tail portion 123 and a curved tail portion 125, when view from the transverse direction. The curved tail portion 125 curves toward the front side of and in a direction underneath the conduit portion 13. The vertical tail portion 123 has a single rectangular shaped rib 127 which extends generally perpendicularly with respect to the section of the vertical tail portion 123 from which it extends. The split nature of the flange, including the curved tail portion 125 and vertical tail portion 123 assists in helping an installer to accommodate relatively large flange spaces. The opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 13, a conductor structure 131 is shown having a curved flange portion 133, when view from the transverse direction and curving underneath the conduit portion 13. The curved flange portion 133 has a single triangular shaped rib 135 which extends generally perpendicularly with respect to the section of the curved flange portion 133 from which it extends. The formed curvature of the curved flange portion 133 assists in helping an installer to have the flange portion 133 consistently bend in one direction. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 14, a conductor structure 13 is shown having a curved flange portion 143, when view from the transverse direction and curving underneath the conduit portion 13. The curved flange portion 143 has a pair of triangular shaped ribs 145 which extends generally perpendicularly with respect to the section of the curved flange portion 143 from which it extends. The formed curvature of the curved flange portion 143 assists in helping an installer to have the flange portion 143 consistently bend in one direction, underneath the conduit portion 13.
Referring to FIG. 15, a conductor structure 151 is shown having a curved flange portion 153, when view from the transverse direction and curving toward the back side of and away from a direction underneath the conduit portion 13. The curved flange portion 153 has a single triangular shaped rib 155 which extends generally perpendicularly with respect to the section of the curved flange portion 153 from which it extends.
Referring to FIG. 16, a conductor structure 161 is shown having a curved flange portion 163, when view from the transverse direction and curving toward the back side of and away from a direction underneath the conduit portion 13. The curved flange portion 163 has a pair of triangular shaped ribs 165 which extend generally perpendicularly with respect to the section of the curved flange portion 113 from which it extends.
Referring to FIG. 17, a conductor structure 171 is shown having a split tailed flange portion including a vertical tail portion 173 and a curved tail portion 175, when view from the transverse direction. The curved tail portion 175 curves toward the front side of and in a direction underneath the conduit portion 13. The vertical tail portion 173 has a single triangular shaped rib 177 which extends generally perpendicularly with respect to the section of the vertical tail portion 173 from which it extends. Again, the dual tail portions 173, 175 assist in helping an installer to accommodate relatively large flange spaces.
Referring to FIG. 18, a further embodiment is shown as a variation on the embodiments earlier seen and in which the flange member is generally straight, but angled with respect to its extension away fro the conduit portion 13. Where the flange is sufficiently flexible, the angled orientation will help produce consistency in the installation.
A conductor structure 181 is shown having a single, angled flange portion 183 angled to be located underneath the conduit portion 13. The flange portion 183 has a single rectangular rib 185 which may be located at any position along the length of the flange portion 183. Referring to FIG. 19, a further embodiment is shown as a conductor structure 191 is shown having a single, angled flange portion 193 angled to be located underneath the conduit portion 13. The flange portion 193 has a pair of rectangular ribs 195 which may be located at any position along the length of the flange portion 193. Referring to FIG. 20, a conductor structure 201 is shown having a single, angled flange portion 203 angled in a direction away from the area underneath the conduit portion 13. The flange portion 203 has a single rectangular rib 205 which may be located at any position along the length of the flange portion 203.
Referring to FIG. 21, a conductor structure 211 is shown having a single, angled flange portion 213 angled in a direction away from the area underneath the conduit portion 13. The flange portion 213 has a pair of rectangular shaped ribs 215 which may be located at any position along the length of the flange portion 213.
Referring to FIG. 22, a conductor structure 221 is shown having a split angled flange portion including a vertical straight tail portion 223 and an angled straight tail portion 225, when viewed from the transverse direction. The straight tail portion 225 is angled toward the front side of and in a direction underneath the conduit portion 13. The straight tail portion 223 has a pair of rectangular shaped ribs 227 which extends generally perpendicularly with respect to straight tail portion 223.
Referring to FIG. 23, a conductor structure 231 is shown having a solid conduit portion 233 which supports individually insulated wires 17, although bare wires could also be supported. The use of individually insulated wires will assist in terminating the individual conductors at a terminal box or connector, relieving the necessity to individually insulated the conductors near their terminal portions. In addition, the solid conduit portion is shaped as an arc extending between the end of a horizontal surface at the front side and the end of a vertical surface at the back side.
Conductor structure 231 has a curved flange portion 235, when viewed from the transverse direction and curving underneath the conduit portion 233. The curved flange portion 235 has a single rectangular shaped rib 237 which extends generally perpendicularly with respect to the section of the curved flange portion 235 from which it extends. The formed curvature of the curved flange portion 235 assists in helping an installer to have the flange portion 235 consistently bend in one direction. Again, the opposing notches 21 and 23 are present creating the reduced area cross section 29 previously seen.
Referring to FIG. 24, a conductor structure 241 is shown having a curved flange portion 243, when view from the transverse direction and curving underneath the conduit portion 233. The curved flange portion 243 has a pair of rectangular shaped ribs 245 which extend generally perpendicularly with respect to the section of the curved flange portion 243 from which it extends.
Referring to FIG. 25, a conductor structure 251 is shown having a curved flange portion 253, when viewed from the transverse direction and curving away from a position underneath the conduit portion 233. The curved flange portion 253 has a single rectangular shaped rib 255 which extends generally perpendicularly with respect to the section of the curved flange portion 253 from which it extends.
Referring to FIG. 26, a conductor structure 261 is shown having a curved flange portion 263, when view from the transverse direction and curving underneath the conduit portion 233. The curved flange portion 263 has a pair of rectangular shaped ribs 265 which extend generally perpendicularly with respect to the section of the curved flange portion 263 from which it extends.
Referring to FIG. 27, a conductor structure 271 is shown having a split tailed flange portion including a vertical tail portion 223 and a curved tail portion 225, when view from the transverse direction. The curved tail portion 225 curves toward the front side of and in a direction underneath a conduit portion 227 which is a hollow conduit having an external shape the same as conduit portion 233, but also having an internal space 228 for carrying the wires 17. The vertical tail portion 223 has a single rectangular shaped rib 229 which extends generally perpendicularly with respect to the section of the vertical tail portion 223 from which it extends. The split nature of the flange, including the curved tail portion 225 and vertical tail portion 223 assists in helping an installer to accommodate relatively large flange spaces.
Referring to FIG. 28,, an end view of an open conductor structure 281 illustrates an open conduit portion 283 supporting several wires 17. The conduit space 19 opens at a lateral opening 285. This enables the user to add or remove the wires 17 as necessary, especially laterally, without having to insert the wires is in the end of the open conduit portion 283. The lateral opening 285 enables the structure 281 to be purchased as a stand-alone structure within which the user can add wiring to his needs, including coax, telephone wires, and the like. In addition, the user can buy the structure 281 to accommodate existing wiring to cover and better support such wiring.
Conductor structure 281 is shown having a straight flange portion 287, when viewed from the transverse direction extends straight down and generally parallel to the rear side of the conduit portion 283. The straight flange portion 287 has a single rectangular shaped rib 289 which extends generally perpendicularly with respect to the section of the straight flange portion 287 from which it extends. Referring to FIG. 29, a further embodiment is shown as an open conductor structure 291 and has an open conduit portion 283, again supporting several wires 17. The conduit space 19 opens at a lateral opening 285. Conductor structure 281 is shown having a straight flange portion 297, and having a pair of rectangular shaped ribs 299 which extends generally perpendicularly with respect to the section of the straight flange portion 297 from which it extends.
Referring to FIG. 30, an end view of a further embodiment of a conductor structure is shown as conductor structure 301 having an enclosed conduit portion 303 supporting several wires 17. A small linear portion 305 of the conduit portion 303 tangentially extends away from the conduit portion 303 and provides support for a straight flange portion 307. The straight flange portion 307 has a single rectangular shaped rib 309.
Referring to FIG. 31, an end view of a further embodiment of a conductor structure is shown as conductor structure 311 having an enclosed conduit portion 313 supporting several wires 17. A small linear portion 305 of the conduit portion 313 is also present, and a straight flange portion 335 has a single rectangular shaped rib 309.
Referring to FIG. 32 a view is shown the embodiment of FIG. 30 where the rib 309 engages notch 31 along the bottom of base molding 33 attached to a wall 35, similar to that shown in FIG. 3.
Referring to FIG. 33, an irregularly shaped conductor structure 341 has a solid conduit portion 343 which may carry a series of spaced apart conductors 345. The external surface of the solid conduit portion 343 may be made of a variety of shapes to cooperate with a variety of base molding 33 and wall 35 styles. A straight, downwardly extending flange portion 347 has a single rectangular shaped rib 349. The notches 21 and 23 are also present.
Referring to FIG. 34, a rectangularly shaped conductor structure 351 has a solid conduit portion 353 which may carry a series of spaced apart wires 17. A straight, downwardly extending flange portion 355 has a single rectangular shaped rib 357. The notches 21 and 23 are also present.
Referring to FIG. 35, a closed triangularly shaped conductor structure 361 has conduit portion 13 which may carry a series of wires 17. The overall shape of the conduit portion is defined by a horizontal bottom side 362, a vertical back side 363 and a sloping hypotenuse, or front side 364. A flange portion 365 extends down and away from the junction of the bottom side 362 and the back side 363 at a 45° angle with respect to each of the sides 362 and 363.
In a conductor structure of the class of conductor structure 361, the flange portion 365 will generally extend away from the conduit portion 13 at an angle equilateral from the meeting point of the two sides, in this case 362 and 363. One formula which helps to define this is to state that the angle of the flange portion 365 with respect to both of the sides 362 and 363 will be 180° minus half of the angle with which the sides 362 and 363 meet. For example, where the sides 362 and 363 meet at a 90° angle, the angle of the flange portion 365 with respect to either of the walls 362 or 363 will be 180°-(90°/2)=135°. Likewise for a conduit portion having an equilateral triangular shape, the two sides will meet at a 60° angle, and the angle with respect to either of the adjacent walls will be 180°-(60°/2)=150°. Having the flange portion, such as 365 bisect the meeting angles of the adjacent walls provides maximum utility and enables the flange portion 365 to be bent in either direction which is most advantageous depending upon the particulars of the installation desired. This overcomes any problems associated with the reversibility required with left or right handed applications.
Notches 21 and 23 are present, although they are likewise turned 45°, but keep their orientation with respect to the length of the flange portion 365. This angled orientation of the flange portion 365 enables the conduit structure 361 to be easily attached into flange spaces which are vertical, horizontal, and in between. Further, it enables the conduit structure 361 to be used in two configurations most easily illustrated using the triangular shape of FIG. 36, which is triangular for illustrative purposes. For example, where side 362 is twice as short as side 363, the conduit structure 361 can be flipped to more evenly match the available space.
Referring to FIG. 36, a closed arc segment shaped conductor structure 371 has conduit portion 227 as was shown in FIG. 27, and may carry a series of wires 17. The overall shape of the conduit portion 227 is defined by a horizontal bottom side 372, a vertical back side 373 and an arc side 374 arcing between the ends of the bottom side 372 and the back side 373. A flange portion 375 extends down and away from the junction of the bottom side 372 and the back side 373 at a 45° angle with respect to each of the sides 372 and 373.
Referring to FIG. 37, an irregularly shaped conductor structure 381 has a more natural shape, but incorporates many of the structures previously described. It has a pair of conductors 383 suspended within a unitary body 385. A flange portion 387 is continuous with the body 385. A naturally formed notch 389 defines an engagement surface 391 which functions similar to the top surface of one of the rectangular ribs 25 previously described. A conduit structure 393 is shown in FIG. 38, but having a single groove 395 formed in one side of a flange portion 397 to produce a reduced area of material 399 with which to enable a "tearing away" of the conduit portion 385. Placement of notch 389 also helps during installation where the insulation material separating the conductors 383 is to be stripped away to expose the bare conductors 383.
Referring to FIG. 39, a perspective view of the conduit structure 393 illustrates a variation wherein the flange portion 397 is formed as a series of individual structures periodically occurring flange structure portions 401 along its length. The groove 395 is still present to produce the reduced area of material 399 with which to enable a "tearing away" of the conduit portion 385 from one or more of the periodically occurring flange structure portions 401.
Referring to FIG. 40, a view of the conduit structure 393 from the rear side illustrates the periodicity of the flange structure portions 401 and the notch 389 can be seen.
Referring to FIG. 41, a view similar to that of FIGS. 3 and 33 illustrates the placement of the conduit structure 393.
Beginning with FIG. 42, a version of the conduit structures previously shown are further illustrated without the pair of opposing notches 21 and 23. FIGS. 42, 43, 44, 45, show versions of conduit structures 431, 441, 451, and 461 related to the conduit structures 11, 51, 61 and 71 of FIGS. 2, 5, 6, & 7. The conduit structures 431, 441, 451, and 461 have integrally formed flange portions 433, 443, 453, and 463, which have rectangular ribs 435, 445, or triangular ribs 455, 465.
Likewise, FIGS. 46-73 illustrate conduit structures not having the pair of opposing notches 21 and 23, and FIGS. 46-73 correspond to FIGS. 8-36. FIGS. 46-73 illustrate conduit structures 471, 481, 491, 501, 511, 521, 531, 541, 551, 561, 571, 581, 591, 601, 611, 621, 631, 641, 651, 661, 671, 681, 691, 701, 711, 721, 731, and 741. The other numbering will be correspondingly the same as FIGS. 8-36.
Referring to FIG. 74 a further embodiment is shown in looking into an end section as a conduit structure 751. Conduit structure 751. Conduit structure 751 has a hollow conduit portion 755 (which could also be solid) in which a pair of conductors 757 are supported. This application is also useful for transport of electrical power and particularly underneath structures and withing flange spaces which are elongate. One particular use is for support underneath carpeting and the like where the increased area of the elongate flange support 753 can help hold the conduit structure 751 in place. The pair of opposing notches 21 and 23 producing a reduced cross sectional area 29 are present between the elongate flange support 753 and the conduit portion 755.
Referring to FIG. 75, a further embodiment is shown looking into an end section as a conduit structure 761. Conduit structure 761 is the same as was described for FIG. 75 except that the notches 21 and 23 are absent.
Referring to FIG. 76, an example of the conduit structure 751 shown in place underneath carpet 39 and adjacent to a base molding 33. In practice, this configuration would also function well where electrical line needs to be placed along the edge of carpet in an open area. It would provide a finished look to the edge of the carpet while at the same time extend power or other electrical signal along the carpet without the need for taping a bulky round cord to the floor 43.
Referring to FIG. 77, the conductor structure 81 of FIG. 8 is shown along the bottom of base molding 33 attached to a wall 35. To the left of the base molding 33 is a length of carpet tacking 37 which supports carpeting 39. The length of carpet padding 41 lies to the left of the carpet tacking 37, and both lie over the floor 42. Note that the conduit portion 13 lies at least partially above the carpet 39.
FIG. 78 illustrates the use of the conduit structure 361 shown in FIG. 36 with a pair of conductors, and with the flange 365 extending away from a wall 791, and used as power transmission wiring and extending from a wall plug 793, then turning at the bottom and engaging a space underneath base molding 33.
FIG. 79 illustrates a sectional view taken along line 79--79 of FIG. 78 and illustrating a pair of conductors 795 and a twisting motion of the conduit structure 361 as the flange is brought around to engage the base board; FIGS. 78 and 79 illustrate that the conduit structure 361 can extend either to the left or to the right and that the conduit structure 361 can twist about 160° in either direction and can thus extend horizontally in either direction at the lower extent of its vertical travel toward the floor.
FIG. 80 illustrates the use of the conduit structure 361 shown in FIG. 36 with a pair of conductors 795 as was seen in FIG. 79, but with the flange 365 extending toward the wall 791 and not seen in FIG. 80. In this orientation, not as much twisting is required at the lower extent of the travel at the floor 43. The plug 793 is simply reversed and all other aspects of the FIG. 81 are similar to that as was shown in FIG. 79.
FIG. 81 illustrates a sectional view taken along line 81--81 of FIG. 80 and illustrating a pair of conductors 795 and a very slight twisting motion of the conduit structure 361 to place it in position for the beginning of the flange 365 which occurs along the length of the conduit structure 361 near the floor 43. This illustrates the advantage of a tear away flange 365.
As a final showing of the advantages of a tear away flange such as flange 365, the conduit structure 361 is shown in transition from a horizontal extent with flange 365 engaged underneath the base molding 33, to a transition to a vertical portion between a vertical molding 831 and a wall 833. Beginning at the point of vertical transition, and continuing upward, the flange 365 is removed to enable the conduit structure 361 to fit in a corner 835 between the vertical molding 831 and wall 833. Although the corner 835 is presumably a 90° corner, and the mostly equilateral cross sectional shape of the conduit structure 361 is about 60°, and thus not a flush fit on any two adjacent sides, the removal of the flange 365 enables a sufficient fit so that undue twisting of the conduit structure 361 is not necessary. If twisting did occur, and with removal of the flange 365 over the vertical portion, the vertical extent for the majority of travel along the vertical molding 831 would appear the same.
Referring to FIG. 83, a view along line 83--83 of FIG. 82 shows the extremely slight twisting which occurs as the terminal extent of the flange 365 is reached and the conduit structure 361 extends upward.
FIG. 84 illustrates a closed triangularly shaped conductor structure 851 having conduit portion 13 which may carry a series of wires 17. The overall shape of the conduit portion is defined by a horizontal bottom side 852, a vertical back side 853 and a sloping hypotenuse, or front side 854. A flange portion 855 carries a pair of triangular ribs 857 on the side of flange portion 855 continuous with back side 853, and a single triangularly shaped rib 859 on the side of the flange portion 855 adjacent horizontal bottom side 852. In this configuration, the conductor structure 851 can "hook" to the inside as well as "click" into and onto structures on both sides of the structure 851.
Referring to FIG. 85, a closed triangularly shaped conductor structure 861 has conduit portion 13 which may carry a series of wires 17. A flange portion 863 extends down and away at a 45° from the junction of a pair of sides 865. The notches 21 and 23 are present. A pair of rib structures 867 having rectangular shape oppositely extending from the flange 863 just below the notches 21 and 23, create a bi-laterally symmetrical structure, except for the insulated conductors 17 which may be carried within the conduit space 19. This design enables a single design of conductor structure, such as conductor structure 861 to be used both for right hand and left hand applications, as well as applications which require switching from one sided engagement to engagement on the other side, such as where a wire turns toward a reverse direction and the structure from which it depends is found to be on the other side.
FIG. 86 illustrates a solid conduit 871 having a solid conduit portion 873 and having two pairs of rectangular ribs 875, each pair of ribs extending from a different side of a flange 877. This configuration allows both "inside" and "outside" engagement of structures.
While the present invention has been described in terms of a conduit structure as well as structures for both anchoring, supporting, and securing electrical conductors, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many similar devices. The present invention may be applied in any situation where electrical conductor support is needed.
Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.
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An improved conduit has a cross sectional profile which generally provides an elongate support structure having at least one anchoring structure extending from the support structure to engage any groove on a base board structure to enable the conduit to be "snapped" into a place of consistent support. Generally, the conduit will be pushed down directly against the support structure to enable the support structure to either become anchored or to flex against and secure the engagement of the anchoring structure. A variety of embodiments take advantage of the widest variety of corner configurations in order to provide the widest applicability of the conduit.
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PRIORITY
[0001] The present invention claims priority under 35 USC section 119 based upon a provisional application which was filed on Jul. 11, 2008 with a Ser. No. 61/134,554
FIELD OF THE INVENTION
[0002] The present invention relates to hoses and more particularly to a fireman's hose for foam which may include a substantially non-collapsible hose section and a compressible hose section.
BACKGROUND
[0003] Through the ages, water has been used as the method to extinguish all types of fires. When there is a fire call, the responding department takes its fire engine filled with water, and the standard woven fire hose which is collapsible, is used to deliver the water. Water is substantially not compressible, especially under pressure and the standard woven fire hose remains substantially rigid due to the pressurized water. This rigid, water filled hose should generally maintain a passageway for the water to flow and may not be normally susceptible to crushing, kinking or disruption by the fire fighter while maneuvering the fire hose.
[0004] One of the more difficult and dangerous functions of interior structure fire fighting requires that fire-fighting personnel be in close proximity with the fire to extinguish the fire. In this dangerous situation, the fire fighter will require increased maneuverability and flexibility of the hose, in order to direct the water stream in as many positions and directions as necessary to cover the entire room and contents involved in the fire with water from the hose of the fireman.
[0005] In Mar. 9, 1982, a new invention, titled ‘Foam Generating Fire Fighting Device’, U.S. Pat. No. 4,318,443, also known as CAFS (Compressed Air Foam (System), was developed. This new method of generating foam includes compressible gasses, such as air, Nitrogen, Helium, Argon, Halogenated gas, Freon, Carbon Dioxide, or combinations of any compressible gas.
[0006] CAFS has proven to be far more effective than previous water in fire fighting applications. This compressible foam flow has caused a new problem with the standard compressible soft woven fire hose, designed to deliver non compressible water. The combination of the compressible foam and the compressible hose results in a CAFS method of generating foam that is susceptible to foam degradation caused by crushing, or kinking of the hose, in close vicinity fire fighting conditions, such as interior structural fire fighting. If the hose is turned away from a straight line, the hose may kink or collapse, reducing or eliminating the flow of foam. Alternatively, this kinking or crushing may cause breaking of the bubbles in the foam, releasing the beneficial gasses before they reach the fire, and otherwise disrupting smooth flow of the foam through the foam discharge end of a standard woven fire hose. This defeats the advantages of the bubble structure as a carrier of the fire suppressant gasses and liquids in the form of foam.
[0007] There are many prior art devices which are employed to be used in the aid of fire fighting, but none that promote safety with the typical woven fire hose filled with a Compressed Air Foam fluid. Normal fire fighting hoses appear to be too soft to support the compressed air foam and its use in a close vicinity fire attack.
[0008] Kinking of the standard woven fire hose can degrade the foam discharge, which can immediately cause a very dangerous condition for the fire fighter in an interior fire fight. This standard woven fire hose is generally light weight and easy to deploy and remove.
SUMMARY
[0009] A firefighting device adapted to discharge a fluid to put out a fire may include a hose connected to a source of the fluid, including: a collapsible section connected to the source of the fluid; and a non-collapsible section connected to the collapsible section adapted to discharge the fluid.
[0010] The non-collapsible section may be connected to a valve to turn off and turn on the fluid, and the valve may be a break apart nozzle.
[0011] The fluid may be a foam agent, and the source may be a fire engine truck.
[0012] The length of the non-collapsible section maybe substantially between 2 feet and 10 feet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which:
[0014] FIG. 1 illustrates an exploded view of the system of the present invention;
[0015] FIG. 2 illustrates a cross-sectional view of the system of the present invention.
DETAILED DESCRIPTION
[0016] To prevent this kinking and foam degradation, the present invention proposes a solution, which is a section of non-collapsible hose which may be used in combination with a collapsible hose. The non-collapsible hose may be positioned where most of the kinking may occur, namely at the end of the hose that the firefighter is using to discharge the foam. The non-collapsible hose may be shorter than the collapsible hose in order to retain the advantages of lightweight and ease of deployment. The collapsible hose does not result in reduced effectiveness of the foam as it is being applied. The non-collapsible hose may be sufficiently flexible to be turned or rotated without affecting the characteristics of the foam. The present invention may refer to this non-collapsible hose as a Non-Collapsible Foam Extension Hose. This Non Collapsible Foam Extension Hose may be a predetermined length of flexible, kink-resistant hose, capable of having a memory in order to regain or return to the original shape after being deformed which may have been caused by crushing or twisting. The Non-Collapsible Foam Extension Hose may be formed from material found in either, the Niedner Reel-Tex hose, Canadian Patent No. 2168497, or any other non-collapsible type of hose that would accomplish the same purpose as the Niedner brand of non-collapsible type hose.
[0017] The Non-Collapsible Foam Extension Hose may detachably connect to the discharge end of the standard soft woven fire hose. The typical length for standard collapsible fire hose may be in 50′ (foot) lengths, and 100′ (foot) lengths which may collapse and lay flat when stored on board the fire truck.
[0018] The Non-Collapsible Foam Extension Hose may be formed in any size length but may be formed in a length which is substantially less than the collapsible fire hose where example may be formed in a predetermined lengths from 2′ (foot) lengths, to 10′ (foot) lengths. Shorter lengths of the non collapsible hose may be used to reduce the cost and improve bulk storage of the non collapsible hose in limited storage areas of the fire trucks.
[0019] This Non-Collapsible Foam Extension Hose should provide a full flow, stable foam discharge and easy maneuverability, which will improve safety and effectiveness for the fire fighter/nozzle man, while eliminating the danger of kinking, or crushing of the compressible hose at the discharge end of the standard soft woven fire hose, while improving fire suppression capabilities of the foam discharge.
[0020] A full flow break-a-part nozzle (shut off valve) may be connected to the discharge end of the Non-Collapsible Foam Extension Hose for control of the foam discharge.
[0021] The diameter of the Non-Collapsible Foam Extension Hose may be selected to cooperate with the diameter of standard fire and industrial hoses, with diameters from 1″ (inches) to 6″ (Inches) or other appropriate diameter. These specifications may depend on the needs of the service industry, and the compressed air foam application. The Non Collapsible Foam Extension Hose may be formed with appropriate connectors or couplings that may allow connection to other couplings or connections that may be used for fire or industrial applications, that will fit the selected diameter of the Non-Collapsible Foam Extension Hose produced. These couplings or connections may include the standard industrial type male and female couplings on the ends of the non-collapsible foam extension hose and the collapsible hose, and will be attached at the time of production, or in the field with special fittings that accomplish the same purpose. The Non-Collapsible Foam Extension Hose may be selected to match your cooperate with the diameter of the non-collapsible hose.
[0022] Examples of fittings, couplings or connectors are the industrial cam lock fittings, fire department National Standard Threads (NST), fire department Stortz fittings, and Iron Pipe Thread (IPT).
[0023] FIG. 1 illustrates an exploded view of the system of the present invention and illustrates a non-collapsible hose section 101 which may be referred to as a non-collapsible foam extension hose which may be an elongated cylinder 103 which may include a central passageway 105 which may extend the entire length of the non-collapsible hose section 101 . The non-collapsible hose section 101 is shown as a substantial cylinder however, other shapes such as elliptical are within the scope of the present invention. The central passageway 105 may include a circular cross-section or may have other shape cross-section such as oval, rectangular or other appropriate cross-sections. The non-collapsible hose section 101 may include a first connector 107 at a distal end of the non-collapsible hose section 101 and a second connector 109 at a proximal end of the non-collapsible hose section 101 . The non-collapsible hose section 101 may operate without the second connector 109 . The non-collapsible hose section 101 may be connected to a valve member 111 at the second connector 109 . The valve member 111 may be any type of valve to facilitate the dispensing of the foam agent.
[0024] The non-collapsible hose section 101 may be connected to a compressible hose section 113 at the first connector 107 and may cooperate with a third connector 115 to form a connection which may be substantially fluid tight with the compressible hose section 113 . FIG. 1 additionally illustrates a foam agent generator 117 to generate the foam agent 119 which may be foam adapted to put out fires, and the foam agent generator 117 which may be a fire truck or other type of firefighting equipment may generate the foam agent 119 under pressure. The distal end of the compressible hose section 113 may be connected to an outlet of the foam agent generator 117 and may include a passageway 121 for the foam agent to be conducted through the compressible hose section 113 and conducted through a passageway 105 of the non-collapsible hose section 101 and to be dispensed from either the non-collapsible hose section 101 or alternatively from the valve member 111
[0025] FIG. 2 illustrates a cross-sectional view of the system of the present invention and illustrates a non-collapsible hose section 101 which may be referred to as a non-collapsible foam extension hose which may be an elongated cylinder 103 which may include a central passageway 105 which may extend the entire length of the non-collapsible hose section 101 . The non-collapsible hose section 101 is shown as a substantial cylinder however, other shapes such as elliptical are within the scope of the present invention. The central passageway 105 may include a circular cross-section or may have other shape cross-section such as oval, rectangular or other appropriate cross-sections. The non-collapsible hose section 101 may include a first connector 107 at a distal end of the non-collapsible hose section 101 and a second connector 109 at a proximal end of the non-collapsible hose section 101 . The non-collapsible hose section 101 may operate without the second connector 109 . The non-collapsible hose section 101 may be connected to a valve member 111 at the second connector 109 . The valve member 111 may be any type of valve to facilitate the dispensing of the foam agent.
[0026] The non-collapsible hose section 101 may be connected to a compressible hose section 113 at the first connector 107 and may cooperate with a third connector 115 to form a connection which may be substantially fluid tight with the compressible hose section 113 . FIG. 1 additionally illustrates a foam agent generator 117 to generate the foam agent 119 which may be foam adapted to put out fires, and the foam agent generator 117 which may be a fire truck or other type of firefighting equipment may generate the foam agent 119 under pressure. The distal end of the compressible hose section 113 may be connected to an outlet of the foam agent generator 117 and may include a passageway 121 for the foam agent to be conducted through the compressible hose section 113 and conducted through a passageway 105 of the non-collapsible hose section 101 and to be dispensed from either the non-collapsible hose section 101 or alternatively from the valve member 111
[0027] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.
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A firefighting device adapted to discharge a fluid to put out a fire may include a hose connected to a source of the fluid, including: a collapsible section connected to the source of the fluid; and a non-collapsible section connected to the collapsible section adapted to discharge the fluid. The non-collapsible section may be connected to a valve to turn off and turn on the fluid, and the valve may be a break apart nozzle. The fluid may be a foam agent, and the source may be a fire engine truck. The length of the non-collapsible section maybe substantially between 2 feet and 10 feet.
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The present invention relates to a straw for use in drinking cups. More particularly, the present invention relates to a drinking straw having an orienting finger to be inserted into a mating recess in the underside of a cup lid and ridges on a portion of the upper part of the straw to facilitate insertion of the straw through a hole in the lid.
BACKGROUND OF THE INVENTION
A variety of reusable straw assemblies are known in the art for use in drinking cups. Flexible elastomeric straws made of various materials, such as silicone, have been used, as have two piece straw assemblies. The latter typically consist of a lower straw mounted on the underside of a lid and an upper straw mounted on the top of a lid, to form an integral straw assembly. Straws having various elements preventing their accidental removal from the cup, such as lips, collars on the outside of the cup lid, and the like, are also known.
Nonetheless, most of these designs are laborious and time-consuming to assemble, difficult to clean, and of limited durability.
The art has also failed to provide a straw assembly optimally suited for use in a spillproof drinking cup of the type disclosed in U.S. Pat. No. Des. 366,809 to Green or U.S. Pat. No. 5,273,172 to Rossbach et al., which are licensed to the assignee of the present invention. These cup assemblies include a cup, a threaded or snap-on lid, a hole through the lid to accept a straw, and a cap mounted on the lid and rotatable about a horizontal axis to fold, seal and enclose the protruding top of the straw.
A typical disposable plastic straw could be used in these cup assemblies. The drawbacks of such a straw are evident. The plastic would rapidly be weakened and split by the bending motion required in the sealing cap. A standard straw would have to be cut to fit the dimensions of the cup and sealing cap. Furthermore, a standard straw would tend to slip and rest directly on the bottom of the cup, limiting the suction action of the straw. In addition, the straw could be difficult to insert through the hole in the lid without bending and buckling. The sealing action of these cups also would be limited by the thin, semi-rigid walls of the straw. Only a partial seal would be effected.
SUMMARY OF THE INVENTION
Against the foregoing background, it is a primary object of the present invention to provide a straw assembly that is durable and easy to clean, and quick and easy to assemble and use.
It is a further object of the present invention to provide such a straw assembly that is safe in that component parts cannot be readily disassembled by an infant.
To the accomplishment of the foregoing objects and advantages, the present invention, in brief summary, comprises: a straw assembly having a flexible first segment and a second segment. The first segment has a first end and an opposite, drinking end. The first segment further includes a retaining shoulder at a fixed distance from the drinking end, and an orienting finger extending from the retaining shoulder. The first segment preferably also includes at least one longitudinal glide ridge extending inwardly from the drinking end.
The present invention also provides a cup assembly comprising a cup, a lid removably mounted on the cup having an aperture therethrough, a flexible straw element adapted to be inserted through the aperture from the underside of the lid, and a sealing cap mounted on the lid adjacent to the aperture. The flexible straw element includes a plurality of longitudinal glide members, a retaining shoulder adapted to arrest the movement of the straw element through the aperture when a predetermined portion of the straw element protrudes through a top side of the lid, and an orienting finger adapted to engage a single location on the underside of the lid, such that the glide members face the sealing cap when the sealing cap is in an open position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective view of a straw assembly of the present invention;
FIG. 2 is a side perspective view of the straw assembly of FIG. 1 mounted in a cup lid;
FIG. 3A is a cross-sectional representation of the assembly of FIG. 2 when the straw assembly is open for use; and
FIG. 3B is a cross-sectional representation of the assembly of FIG. 2 when the straw assembly is sealed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention is designed for use in combination with the Power Bottle USA spill-proof cup, as substantially disclosed in U.S. Pat. No. 5,273,172 to Rossbach et al., and U.S. Design Pat. No. 366,809 to Green. Accordingly, these patents are incorporated herein by reference.
Referring to the drawings and, in particular, FIGS. 1, 2 and 3, the straw or straw assembly is generally represented by reference numeral 10. The straw 10 is at east a two-piece straw adapted to be inserted in a leak-roof cup 12. The two-piece straw 10 includes an elongated lower segment 14 and an elongated, but shorter, upper segment 16. The upper segment 16 has a first or rear end 20 and a second or drinking end 38. The upper segment 16 also has a radially extending shoulder 18, preferably positioned toward the first end 20, and a finger 22 extending from the shoulder 18 and virtually perpendicular thereto. The upper segment 16 includes a plurality of longitudinal or axial ridges 24 extending along part of the outer circumferential surface of the upper segment to form a ridged surface 25.
The cup lid 28 has an inner surface 30, an outer or top surface 32, and an opening 26 through the inner and outer surfaces. The inner surface 30 also has an indentation 34. In addition, cup lid 28 includes a sealing post 35 (see FIGS. 3A and 3B).
The upper segment 16 is inserted through opening 26 in cup lid 28. The shoulder 18 of upper segment 16 is designed to stop the upper segment's forward progress when an appropriate length is protruding from outer surface 32, and to prevent the straw from being pulled through the opening. The protruding length provides sufficient exposure of straw 10 to enable a child or other user to suck easily on the straw. Preferably, the length is limited, on the other hand, to a length that can be enclosed by sealing cap 36. In this preferred embodiment, sealing cap 36 is mounted on pivots 37 situated on either side of opening 26. In an alternate preferred embodiment, sealing cap 36 is mounted to slide horizontally over the straw.
The finger 22 engages indentation 34 to further secure straw 10 and to orient the straw's ridged surface 25 properly in relation to sealing cap 36. When finger 22 is properly engaged in indentation 34, ridged surface 25 faces the open sealing cap 36. The ridges 24 facilitate the sliding of sealing cap 36 over the straw's surface, and enable the easy insertion and removal of straw 10 through opening 26.
The upper segment 16 is made of a flexible, safe material that can be cleaned. The preferred material is silicone, thermoplastic elastomer (TPE) or polyvinyl chloride (PVC). The lower segment 14, which is not placed in the child's mouth and is used to transport liquid under suction from the lower portion of the cup, is made of a more rigid material, such as, for example, polyethylene, polypropylene or PVC. The material in the upper segment 16 may be more expensive than the preferred material of the lower section 14.
The ridges 24 act as glide enhancers, to a certain extent, by preventing a total contact of straw 10 against plastic cap or lid. As discussed above, this allows straw 10 to remain stable and stationary during use, but allows it to slide easily when pushed by the sealing cap 36 to a closed position. The ridges 24 also make upper segment 16 easier to grip and insert, especially when it is wet from cleaning or exposure to the liquid to be dispensed. Preferably, ridges 24 are closely adjacent to one another. In addition, ridges 24 preferably are evenly spaced, and are located on approximately half (or a 180° arc) of the circumference of upper segment 16. If ridges 24 are disposed about the entire circumference of upper segment 16, insufficient compression or adhesion may occur between the upper segment 16 and sealing post 35 for a leakproof seal. The ridges 24 preferably extend from drinking end 38 to retaining shoulder 18.
The lower segment 14 is adapted to fit within the first end 20 of upper segment 16 to form a unitary straw assembly. As discussed above, this two-piece design allows the parts of the straw to be fabricated from different materials having different characteristics. Preferably, upper segment 16 is formed of a flexible, strong, elastomeric material such as surgical grade silicone, TPE or PVC. This allows it to be soft to drink from and easy to clean, while also enabling it to be bent and sealed repeatedly with minimal force and without cracking or ripping. Lower segment 14 can be constructed of a sturdier, stiffer material such as polyethylene, polypropylene or PVC. This facilitates the joinder of the two segments 14,16, as the stiffer lower segment can easily be inserted into the upper segment. This design also lowers the cost of manufacturing straw 10, and allows lower segment 14 to be disposable, if desired. In addition, the two-piece design makes cleaning easier, as the two pieces are shorter than a single piece unit. Accordingly, it is easier to ensure that the segments 14,16 are clean, as the center sections of each segment are less distant from the ends than in a longer straw.
Various modifications can be made to this preferred embodiment. For example, the assembly does not need to comprise two separate pieces. Two pieces of disparate materials can be molded together to form a unitary straw having most of the attributes of the preferred embodiment described above. The straw 10 can also be made entirely of silicone or other flexible material. Furthermore, the configuration of shoulder 18 and finger 22 can be varied without affecting the function they perform. In addition, if used with a cup lid having a different internal configuration, finger 22 need not be orthogonal to shoulder 18. A cup lid having a loop extending from its inner surface could accept a finger extending straight out from the end of the shoulder (in essence, the shoulder and finger are one uniform structure).
The design of ridges 24 can also be varied. The ridges 24 need not extend the entire distance from drinking end 38 to shoulder 18, but their spacing and depth can be modified. In addition, as discussed above, straw 10 of the present invention is useful in a variety of cups having various sealing means and configurations.
The invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
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A straw assembly has a flexible first segment with at least one longitudinal glide ridge extending inwardly from a drinking end thereof, a retaining shoulder at a fixed distance from the drinking end, and an orienting finger extending from the retaining shoulder.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims benefit of U.S. Provisional Patent Application Ser. No. 60/815,109, filed on Jun. 20, 2006, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
The present disclosure relates generally to laser ablation and more particularly to activation of the Coulomb explosion mechanism in the laser ablation of semiconductor materials by means of direct interband transitions.
BACKGROUND OF THE INVENTION
Laser ablation has proven a useful tool for micrometer scale machining of metal and dielectric materials. The laser ablation process is not completely understood, however, it generally can be divided into two types: a thermally activated ablation associated with nanosecond timescale laser pulses; and a non-thermal ablation associated with picosecond and femtosecond pulse lengths. The thermal vaporization is also known as “strong ablation,” since it results in greater rates of material removal and is the dominant mechanism at laser fluences well above the ablation threshold. The non-thermal ablation is also known as “gentle ablation,” since it occurs near the ablation threshold and tends to result in optimal surface quality with material removal controllable on the nanometer scale. For example, the gentle ablation does not produce a melt zone. As such, the gentle ablation mechanism is more desirable for precise control of the machining process than is thermal ablation. Gentle ablation is thought to occur through a physical mechanism analogous to the “Coulomb explosion” seen in gas clusters, wherein a laser pulse is used to rapidly evacuate electrons from a region of the gas such that the Coulombic repulsion of the positive ions then leads to rapid expansion. In solids, it is hypothesized Coulomb explosion is driven by positively charged near-surface layers which electrostaticly repel each other, possibly aided by the pull of ionizing electrons [Gamaly, 2002].
The key to activating this non-thermal, or “cold” ablation then lies in the electron dynamics. Work in the prior art has entailed modeling the electron dynamics with the Fokker-Planck equation. The production of electrons is due to two types of optical absorption: the sum over all interband optical absorptions including multi-photon absorptions; and the “avalanche” photoionization. Avalanche photoionization is due to free carrier absorption and therefore of primary importance in metals. It also can become dominant in dielectrics once the carrier density reaches a critical value. To see this point, it is useful to consider the differential equation conventionally taken to describe the carrier dynamics a laser field:
dN e /dt=Σα m I m +βN e I−N e /τ,
where N e is the carrier density, I is the laser intensity inside the sample, α m are the multi-photon absorption coefficients, β is the “avalanche” absorption coefficient, and τ is the phenomenological carrier relaxation time [Mero, 2005]. For purposes of understanding the carrier production during ultra-short laser pulses, the relaxation term may be neglected. The equation may then be viewed as an interpolation scheme—during the leading edge of the laser pulse, the carrier density is small and therefore the avalanche absorption will be negligible, resulting in a carrier density N e ≈∫Σα m I m dt, whereas later in the pulse, once the carrier density becomes significant, the avalanche term becomes dominant and the solution takes the exponential form N e ≈N o exp{βIt} [Gamaly, 2002]. For dielectric materials irradiated by a typical femtosecond laser wavelength of ˜800 nm, the linear optical absorption will be small. Therefore, the avalanche seeding process proceeds through multi-photon absorption, and hence requires strong laser intensity. Once the seed density is reached the avalanche absorption leads to very rapid ablation. Thus, the seed carrier density typically invoked as the ablation threshold density is the critical density at which the plasma becomes opaque. This condition occurs when ω p ≧ω, where ω p is the Drude plasma frequency and ω is the laser photon frequency. The plasma frequency and photon frequency are given by the relations ω p 2 =N e e 2 /ε o m*, and ω=2πc/λ, respectively, where e is the electronic charge, ε o is the vacuum permittivity (8.85×10 −12 C 2 /N·m 2 ), m* is the electron effective mass, c is the speed of light, and λ is the laser wavelength. The critical Drude plasma density is then: N cr =4m*ε o π 2 c 2 /e 2 λ 2 , and typically takes values of N cr ≈10 21 /cm 3 . Note this not the actual ablation density, but rather, the density which seeds the exponential avalanche process.
To estimate the charge density needed to induce ablation through the Coulomb explosion, it has been suggested ablation occurs whenever the electrostatic force due to the surface charge density exceeds the bonding force [Bulgakova, 2004]. The bonding stress may be estimated as a percentage of the Young's modulus, typically taken at ˜5-10%. This implies electric fields of ˜1-5×10 10 V/m are required to exceed the bonding force. The surface charge densities corresponding to such fields can be estimated from the Poisson relation: F=(2 eN e V/ε) 1/2 , where V is the built-in surface voltage (˜1V) and ε is the permittivity of the material (≈10ε o ). From this expression, it may be seen the surface charge densities required to produce such fields are greater than 1×10 22 /cm 3 . The threshold fractional ionization per atom required for Coulomb explosion of silicon has been estimated in the range 0.3-0.65, corresponding to charge densities of 1.5-3.5×10 22 /cm 3 [Stoian, 2004].
The Coulomb explosion mechanism has been clearly observed in laser ablation of dielectrics [Stoian, 2000]. It has also been postulated that low conductivity silicon behaves similarly to dielectrics, thus allowing Coulomb explosion [Roeterdink, 2003]. However, calculations have been performed suggesting the threshold charge density is not reached due to charge reneutralization [Bulgakova, 2004]. A fundamental advantage of the disclosure contained herein is the use of strong linear semiconductor absorption such that the conditions for Coulomb explosion are met without requirement for avalanche photoionization. This enables the use of a lower laser intensity to ablate material, hence providing enhanced control over material removal rates attained in the Coulomb explosion (CE) process. A further advantage may be obtained over the conventional CE machining process by the function of the static electric field to enhance the linear optical absorption. This dependence of the optical absorption on electric field has never been disclosed or utilized in the prior art of laser ablation. In particular, nearby to strong interband transitions, the optical absorption takes the form α(F)=α o +α 2 F 2 , where α o is the linear optical absorption at zero field, and α 2 is a third order non-linear optical absorption coefficient. α 2 itself depends on the electric field and in particular describes the redshifting of semiconductor interband transitions in a strong electric field [Keldysh, 1958]. The field dependence of α 2 may be used to moderate the laser absorption by an order of magnitude or more. Therefore, given selection of laser wavelength to coincide with strong optical absorptions such that avalanche photoionization is suppressed or takes secondary importance, the addition of a strong electric field may be utilized to further reduce the intensity required to generate the threshold carrier density.
Additionally, conventional laser ablation cannot be conveniently used for nanometer scale machining since it is limited by far field spot size focus limit, typically on the order of a micron. By the use of nanometer scale surface variations to provide nanometer scale variation of the electric field, ablation can be achieved on lateral scales smaller than the laser spot diameter.
Thus, while the prior art may be suitable for the particular purposes which they address, they are not as suitable for laser ablation of semiconductor materials. In these respects, the laser ablation technique according to the present disclosure substantially departs from the conventional concepts and designs of the prior art, and in so doing provides a technique primarily developed for the purpose of nanoscale laser machining of semiconductor materials.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known laser ablation methods in the prior art, the present disclosure provides a new Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures.
The Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures disclosed herein is capable of rapidly evacuating electrons from the focal region in a semiconductor material through the use of a femtosecond pulsed laser. This rapid evacuation results in the creation of positively charged near-surface layers which electrostaticly repel each other. Once the local binding force is exceeded, lattice ions undergo Coulomb explosion, resulting in the ablation of material. Selection of the laser wavelength to coincide with strong linear optical absorption provides efficient electron generation, effecting a substantial reduction in the ablation threshold intensity. The application of a strong static electric field allows the laser pulse to control the carrier density at or very near the ablation threshold. This allows maximal control over the ablation rate. The use of this field enhanced optical absorption is available in all semiconductor materials and provides a large enhancement of the absorption coefficient through an electric field induced redshift of the optical absorption. In these respects, the present disclosure provides a new Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures that has many of the advantages of the conventional laser ablation art mentioned heretofore and many novel features that result in a new Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art of laser ablation, either alone or in any combination thereof.
To attain this, the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures generally comprises a semiconductor material with an exposed surface, a femtosecond pulsed laser system, and an optical system for delivery of the laser beam onto the sample surface effective to induce Coulomb explosion of near-surface layers. The Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures also comprises methods and instrumentation for analysis of ablated ions such as those commonly found in Laser-Induced Breakdown Spectroscopy (LIBS), and/or Field Ion Microscopy (FIM). The Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures further comprises methods and instrumentation to apply a strong electric field to the surface of the semiconductor structure. The semiconductor structure may comprise planar semiconductor surfaces subject to strong electrical fields, or comprise surfaces subject to very strong electrical fields such as those found in conventional field ionization microscopes and atom probes, or may consist of nanoscale patterned structures producing nanometer scale electric field variations. The electric field is held effectively static during the laser pulse. With selection of the laser wavelength at or near strong optical absorption features of the semiconductor under process, the external field is used to enhance and control the optical absorption of said semiconductor material. The pulsed laser is a commercially available femtosecond laser system operating in the VIS-UV, with mount. The laser beam is collimated and directed onto the sample surface using a focusing lens arrangement. The optical system consists of a number of optical elements positioned to provide for the propagation of light from the laser source, and onto the sample surface.
The semiconductor materials that are the subject of the present disclosure may be any semiconductor materials, and may include, but are not limited to Group II-VI semiconductor materials or Group III-V semiconductor materials. In certain embodiments such materials may include silicon, carbon, germanium, silicon carbide, silicon germanium, boron, nitrogen, phosphorus, arsenic, or any combinations thereof, or they may include gallium arsenide, aluminum arsenide, gallium nitride, aluminum nitride, indium nitride, gallium phosphide, indium phosphide, indium arsenide, or any combinations thereof.
In this respect, before explaining at least one embodiment of the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures in detail, it is to be understood that the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description. The disclosure 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 the description and should not be regarded as limiting. Advantages of the electric field ablation technique will become obvious to the reader and it is intended that these objects and advantages are within the scope of the disclosure. There has thus been outlined the more important features of the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures so that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the disclosure that will be described hereinafter.
DETAILED DESCRIPTION
The following discusses use of the new technique and Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures for laser ablation of silicon semiconductor structures. It is understood that the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures of the present description may be used to perform material removal on any semiconductor structure, the discussion of silicon semiconductor structures considered to be exemplary only and in no way limiting in scope.
As discussed in the background, the activation of the Coulomb explosion mechanism in laser ablation is predicated on the efficient and rapid evacuation of electrons. In the prior art activation of Coulomb explosion in typical dielectrics, a seed carrier density is first created though multi-photon absorption in an intense laser field, followed by the onset of avalanche photoionization. The avalanche photoionization term is due to free carrier absorption and is therefore also operative in metals, although no seed stage is necessary. In the disclosure contained herein, the wavelength of the laser is selected to maximize the linear optical absorption such that the avalanche process becomes secondary or unnecessary. In order to understand this, consider the exemplary case of an approximately 400 nm wavelength femtosecond laser applied to the ablation of silicon. At this wavelength, well above the band edge of silicon, the linear absorption, coefficient is substantial and any multi-photon absorption may be neglected. Neglecting the carrier relaxation term, the equation which describes carrier production in a laser field becomes:
dN e /dt =[α( F )+α D ( N e )]× I,
where α(F) is the linear optical absorption coefficient, which depends on the electric field F, and α D (N e ) is the Drude carrier absorption, which depends on the carrier density. Note from this expression the formal connection between the Drude absorption and the avalanche absorption coefficient may be identified. The semiconductor optical absorption will dominate the carrier generation process provided α(F)≧α D (N e ). At 400 nm wavelength, the Drude absorption is well approximated by α D (N e )≅1/ncτ×N e e 2 /ε o m*ω 2 , where n is the index of refraction at the laser wavelength and τ is the plasma relaxation time. The condition α(F)≧α D (N e ) implies N e ≦ncτm*ω 2 ε o α(F)/e 2 . Taking n≈5.6, τ≈200 fs, m*≈0.3 m e , λ≈400 nm, and α(F)≈1×10 6 /cm (constant), the condition α(F)≧α D (N e ) is satisfied for carrier densities N e ≦7×10 25 /cm 3 . This carrier density exceeds, by several orders of magnitude, the threshold density at which material is expected to undergo ablation due to Coulomb explosion. Hence, femtosecond Coulomb explosion of Si with 400 nm wavelength does not invoke or require the avalanche photoionization mechanism. Equivalently stated, the short absorption depth of Si at 400 nm wavelength would require a plasma density ˜10 25 /cm 3 in order to attain comparable plasma skin depths. In practice, this never occurs.
Without the avalanche photoionization term, the solution to the differential equation at the end of the laser pulse becomes: N e ≈α(F)×I×τ p , where τ p is the laser pulse width. Assuming values of α(F)≈1×10 6 /cm, τ p ≈150 fs, and N th ≈1×10 23 /cm 3 , where N th is the approximate Coulomb explosion threshold, a threshold intensity of I th ≈3.3×10 11 W/cm 2 may be estimated. This is well below the ˜10 13 -10 14 W/cm 2 thresholds commonly seen for avalanche photoionization. For pulse lengths up to the plasma relaxation time τ, a longer laser pulse requires proportionally less intensity, since it is the laser fluence which governs the final carrier density. The presence of a relaxation term will suppress the induced carrier density by a factor of ˜exp{−τ p /τ}. For Si and the carrier densities under discussion herein, relaxation times are commonly estimated to be in the range of ˜20-200 fs, corresponding to Si mobilities μ≈10 2 -10 3 cm 2 /V·s.
An instructive counterpoint to this example is obtained when the activation of Coulomb explosion in silicon through the conventional avalanche photoionization is considered. In an exemplary case, consider an approximately 800 nm wavelength laser applied to the conventional avalanche photoionization activation of Coulomb explosion in silicon. This wavelength is above the band edge of silicon, so multi-photon absorptions may again be neglected. The linear absorption must develop a seed plasma density of N e ≈10 21 /cm 3 within approximately the first half of the pulse. Using N e ≈α×I×τ p ÷2, with α≈1×10 3 /cm and τ p ≈200 fs, the estimated intensity to seed the avalanche I≈2.5×10 12 W/cm 2 , or greater. An analogous estimate of the intensity required to seed the avalanche, for the case of 400 nm radiation of silicon, results in I≈5×10 9 W/cm 2 . However, as discussed, this estimate is purely hypothetical since the linear optical absorption will continue to dominate the avalanche photoionization even well beyond the Coulomb explosion threshold density.
Another key advantage inherent to the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures is the ability to use an externally applied electric field to enhance the linear optical absorption. Nearby to strong features in the optical absorption spectra of a semiconductor material, the field dependence of the optical absorption coefficient will be large. In particular, the optical absorption of semiconductors and dielectrics undergoes significant redshifting in strong electric fields. This effect is known as the Franz-Keldysh effect [Keldysh, 1958], and may be explained as follows. Since the strong electric field tilts the semiconductor bandstructure spatially, electrons may tunnel from the valence band to the conduction band. Thus, at photon energies just below strong absorption features, the redshift of the absorption is due to photon-stimulated tunneling [Yu & Cardona, 2001]. The dependence of the absorption coefficient on electric field F is given by:
α( F )= KF 2 exp{− C/F},
where K and C are constants which depend on the “zero field” absorption, the effective electronic mass, and the difference in laser wavelength from the strong absorption feature. The “zero field” absorption is the optical absorption of the material wherein no electric field is applied. The expression above describes the redshifting of an optical absorption edge in the presence of a strong electric field [Keldysh, 1958]. The 400 nanometer wavelength laser is nearby to such an absorption edge in silicon, which occurs at a wavelength of approximately 375 nanometers. As an externally applied field approaches 10 7 V/cm, the silicon optical absorption coefficient increases about an order of magnitude from 10 5 /cm to 10 6 /cm. Thus, an externally applied electric field may be used to enhance and control the optical absorption coefficient.
It is therefore instructive to understand the ablation threshold for Coulomb explosion in the case of electric fields F ˜10 6 -10 7 V/m. For the laser pulse lengths under consideration herein, the electrons will thermally equilibrate but will not have time to transfer their energy to the lattice via collisions or thermal diffusion. The kinetic energy the electron attains from the field is given by ΔK=m*v S 2 /2, where v S is the saturation velocity (ΔK is on the order ˜10 meV, so it does not add substantial energy to the electron) [Yu & Cardona, 2001,]. The equation for the average change in electron temperature T e (or energy) due to laser absorption is given by:
c e ( T e ) N e ×∂T e /∂t=−∂S/∂x; S =(1 −R ) I o ×exp{−2 x/δ},
where c e is the specific heat of conduction electrons, and S is the absorbed energy flux as a function of depth (R is the reflectivity and I o is the incident intensity) [Chichkov, 1996]. Near the laser ablation threshold T e ≈E F , and c e ≈ 3/2. The average change in electron energy then may be expressed: T e ≈ 4/3×(1−R)Iτ p /δN at ×exp{−2x/δ}. The threshold fluence for ablation is conventionally determined by the requirement the electron energy T e reach, within a surface layer x<<δ, a value equal to the sum of the atomic binding energy and the electron ionization energy, i.e. T e ≧E b +I p . This is the threshold condition for energetic electrons to escape the solid and produce a strong charge separation field which then results in the Coulomb explosion of the surface layers [Gamaly, 2002]. Solving the relation T e ≧E b +I p for the fluence I th τ p , yields the threshold dependence on the static field:
(1 −R ) I th τ p ≈3/8 ×N at /α( F )×( E b +I p ).
For Si at 400 nm, the reflectivity is roughly 50%. The Si binding energy is E b ≈4.62 eV/atom, and the ionization potential is I p ≈1.12 eV. The predicted threshold fluence is then I th τ p ≈20 mJ/cm 2 . For a pulse length of approximately 200 fs, this corresponds to a pulse intensity of approximately 10 11 W/cm 2 . This estimate agrees with the earlier estimate from use of the linear semiconductor absorption to generate threshold carrier densities. It is instructive to compare this to the expression for threshold derived for avalanche activated ablation. For a plasma skin layer, we have 1−R≈2 ωδ/c, which is justified at critical density. The threshold fluence then becomes I th τ p ≈3/8×λN at /2π×(E b +I p ). From this, it is seen the ablation threshold in the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures is reduced by a factor ≈2π/λ·α(F) relative to the conventionally used avalanche ablation mechanism. For the exemplary case of ablation of silicon using 400 nm radiation herein, this results in a more than six (6) times reduction in the threshold intensity. Using the relation α=4πk/λ, where k is the imaginary part of the complex index of refraction, known as the extinction coefficient, it may be seen the ablation process will proceed through semiconductor linear optical absorption, and not the avalanche (Drude) absorption, provided k≧½. Also note in the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures, k depends on the applied electric field and therefore field induced shifts of the optical absorption may be used to effect reductions in ablation threshold.
In order to estimate the ablation rates attained in the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures, we note that due to the exponential decrease of the electron energy into the surface, the ablation depth is of the order of the absorption depth and exhibits a logarithmic dependence on fluence. The ablation depth may therefore be written L ab ˜δ/2×ln{I/I th }. The number of particles ablated per unit area per unit time can be estimated as j˜L ab N at /τ p ˜δ/2×N at /τ p ×ln{I/I th }. For 400 nm irradiation of silicon using a femtosecond laser pulse, the ablation rate is estimated ˜1.67×10 29 /cm 2 ·s×ln{I/I th }. For strong fields ˜10 7 V/m, we obtained an estimate of I th ˜5×10 11 W/cm 2 . Assuming an operational intensity such that I/I th ≈2, we find j˜10 29 /cm 2 ·s. The number of ablated ions per laser pulse is L ab ×N at ×S, where S is the surface area available for ablation. In the exemplary planar configuration, S is the focal area≈π×10 −8 cm 2 (S≈π ω 2 , where ω ˜1 micron). Then the number of ablated atoms per laser pulse is ˜10 8 -10 9 . Similarly, in a typical field emission tip application, the ablation rate ramps from zero at threshold to j ˜10 29 /cm 2 ·s at twice threshold. However the tip surface area is S≈2πr 2 , where r≈50 nm, such that S≈1.6×10 −10 cm 2 , which implies a reduction in the number of atoms ablated per pulse to approximately 10 6 . Such large efficiencies of atom yield near threshold are a well above the rates seen in conventional field ion microscopy.
Therefore, as disclosed herein, the Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures provides a new and remarkable capability to effect and control laser ablation, and in so doing, substantially departs from the conventional concepts and designs of the prior art.
As to a further discussion of the manner of usage and operation of the present disclosure, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those described in the specification are intended to be encompassed by the present disclosure.
Therefore, the foregoing is considered as illustrative only of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure.
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A new technique and Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures in semiconductor materials is disclosed. The Method of Direct Coulomb Explosion in Laser Ablation of Semiconductor Structures provides activation of the “Coulomb explosion” mechanism in a manner which does not invoke or require the conventional avalanche photoionization mechanism, but rather utilizes direct interband absorption to generate the Coulomb explosion threshold charge densities. This approach minimizes the laser intensity necessary for material removal and provides optimal machining quality. The technique generally comprises use of a femtosecond pulsed laser to rapidly evacuate electrons from a near surface region of a semiconductor or dielectric structure, and wherein the wavelength of the laser beam is chosen such that interband optical absorption dominates the carrier production throughout the laser pulse. The further application of a strong electric field to the semiconductor or dielectric structure provides enhancement of the absorption coefficient through a field induced redshift of the optical absorption. The use of this electric field controlled optical absorption is available in all semiconductor materials and allows precise control of the ablation rate. When used in conjunction with nanoscale semiconductor or dielectric structures, the application of a strong electric field provides for laser ablation on sub-micron lateral scales.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Patent Application No. 61/783,176 filed on Mar. 14, 2013 entitled METHODS AND SYSTEMS FOR MINI-SPLIT LIQUID DESICCANT AIR CONDITIONING, which is hereby incorporated by reference.
BACKGROUND
[0002] The present application relates generally to the use of liquid desiccants to dehumidify and cool, or heat and humidify an air stream entering a space. More specifically, the application relates to the replacement of conventional mini-split air conditioning units with (membrane based) liquid desiccant air conditioning system to accomplish the same heating and cooling capabilities as those conventional mini-split air conditioners.
[0003] Desiccant dehumidification systems—both liquid and solid desiccants—have been used parallel to conventional vapor compression HVAC equipment to help reduce humidity in spaces, particularly in spaces that require large amounts of outdoor air or that have large humidity loads inside the building space itself. (ASHRAE 2012 Handbook of HVAC Systems and Equipment, Chapter 24, p. 24.10). Humid climates, such as for example Miami, Fla. require a lot of energy to properly treat (dehumidify and cool) the fresh air that is required for a space's occupant comfort. Desiccant dehumidification systems—both solid and liquid—have been used for many years and are generally quite efficient at removing moisture from the air stream. However, liquid desiccant systems generally use concentrated salt solutions such as ionic solutions of LiCl, LiBr or CaCl 2 and water. Such brines are strongly corrosive, even in small quantities, so numerous attempts have been made over the years to prevent desiccant carry-over to the air stream that is to be treated. In recent years efforts have begun to eliminate the risk of desiccant carry-over by employing micro-porous membranes to contain the desiccant. These membrane based liquid desiccant systems have been primarily applied to unitary rooftop units for commercial buildings. However, residential and small commercial buildings often use mini-split air conditioners wherein the condenser is located outside and the evaporator cooling coil is installed in the room or space than needs to be cooled, and unitary rooftop units are not an appropriate choice for servicing those spaces.
[0004] Liquid desiccant systems generally have two separate functions. The conditioning side of the system provides conditioning of air to the required conditions, which are typically set using thermostats or humidistats. The regeneration side of the system provides a reconditioning function of the liquid desiccant so that it can be re-used on the conditioning side. Liquid desiccant is typically pumped between the two sides, and a control system helps to ensure that the liquid desiccant is properly balanced between the two sides as conditions necessitate and that excess heat and moisture are properly dealt with without leading to over-concentrating or under-concentrating the desiccant.
[0005] In many smaller buildings a small evaporator coil is hung high up on a wall or covered by a painting as for example the LG LAN126HNP Art Cool Picture frame. A condenser is installed outside and high pressure refrigerant lines connect the two components. Furthermore a drain line for condensate is installed to remove moisture that is condensed on the evaporator coil to the outside. A liquid desiccant system can significantly reduce electricity consumption and can be easier to install without the need for high pressure refrigerant lines that need to be installed on site.
[0006] Mini-split systems typically take 100% room air through the evaporator coil and fresh air only reaches the room through ventilation and infiltration from other sources. This often can result in high humidity and cool temperatures in the space since the evaporator coil is not very efficient for removing moisture. Rather, the evaporator coil is better suited for sensible cooling. On days where only a small amount of cooling is required the building can reach unacceptable levels of humidity since not enough natural heat is available to balance the large amount of sensible cooling.
[0007] There thus remains a need to provide a retrofitable cooling system for small buildings with high humidity loads, wherein the cooling and dehumidification of indoor air can be accommodated at low capital and energy costs.
BRIEF SUMMARY
[0008] Provided herein are methods and systems used for the efficient cooling and dehumidification of an air stream especially in small commercial or residential buildings using a mini-split liquid desiccant air conditioning system. In accordance with one or more embodiments, the liquid desiccant flows down the face of a support plate as a falling film. In accordance with one or more embodiments, the desiccant is contained by a microporous membrane and the air stream is directed in a primarily vertical orientation over the surface of the membrane and whereby both latent and sensible heat are absorbed from the air stream into the liquid desiccant. In accordance with one or more embodiments, the support plate is filled with a heat transfer fluid that ideally is flowing in a direction counter to the air stream. In accordance with one or more embodiments, the system comprises a conditioner that removes latent and sensible heat through the liquid desiccant into the heat transfer fluid and a regenerator that rejects the latent and sensible heat from the heat transfer fluid to the environment. In accordance with one or more embodiments, the heat transfer fluid in the conditioner is cooled by a refrigerant compressor or an external source of cold heat transfer fluid. In accordance with one or more embodiments, the regenerator is heated by a refrigerant compressor or an external source of hot heat transfer fluid. In accordance with one or more embodiments, the refrigerant compressor is reversible to provide heated heat transfer fluid to the conditioner and cold heat transfer fluid to the regenerator and the conditioned air is heat and humidified and the regenerated air is cooled and dehumidified. In accordance with one or more embodiments, the conditioner is mounted against a wall in a space and the regenerator is mounted outside of the building. In accordance with one or more embodiments, the regenerator supplies liquid desiccant to the conditioner through a heat exchanger. In one or more embodiments, the heat exchanger comprises two desiccant lines that are bonded together to provide a thermal contact. In one or more embodiments, the conditioner receives 100% room air. In one or more embodiments, the regenerator receives 100% outside air. In one or more embodiments, the conditioner and evaporator are mounted behind a flat screen TV or flat screen monitor or some similar device.
[0009] In accordance with one or more embodiments a liquid desiccant membrane system employs an indirect evaporator to generate a cold heat transfer fluid wherein the cold heat transfer fluid is used to cool a liquid desiccant conditioner. Furthermore in one or more embodiments, the indirect evaporator receives a portion of the air stream that was earlier treated by the conditioner. In accordance with one or more embodiments, the air stream between the conditioner and indirect evaporator is adjustable through some convenient means, e.g., through a set of adjustable louvers or through a fan with adjustable fan speed. In one or more embodiments, the water supplied to the indirect evaporator is potable water. In one or more embodiments, the water is seawater. In one or more embodiments, the water is waste water. In one or more embodiments, the indirect evaporator uses a membrane to prevent carry-over of non-desirable elements from the seawater or waste water. In one or more embodiments, the water in the indirect evaporator is not cycled back to the top of the indirect evaporator such as would happen in a cooling tower, but between 20% and 80% of the water is evaporated and the remainder is discarded. In one or more embodiments, the indirect evaporator is mounted directly behind or directly next to the conditioner. In one or more embodiments, the conditioner and evaporator are mounted behind a flat screen TV or flat screen monitor or some similar device. In one or more embodiments, the exhaust air from the indirect evaporator is exhausted out of the building space. In one or more embodiments, the liquid desiccant is pumped to a regenerator mounted outside the space through a heat exchanger. In one or more embodiments, the heat exchanger comprises two lines that are thermally bonded together to provide a heat exchange function. In one or more embodiments, the regenerator receives heat from a heat source. In one or more embodiments, the heat source is a solar heat source. In one or more embodiments, the heat source is a gas-fired water heater. In one or more embodiments, the heat source is a steam pipe. In one or more embodiments, the heat source is waste heat from an industrial process or some other convenient heat source. In one or more embodiments, the heat source can be switched to provide heat to the conditioner for winter heating operation. In one or more embodiments, the heat source also provides heat to the indirect evaporator. In one or more embodiments, the indirect evaporator can be directed to provide humid warm air to the space rather than exhausting the air to the outside.
[0010] In accordance with one or more embodiments, the indirect evaporator is used to provide heated, humidified air to a supply air stream to a space while a conditioner is simultaneously used to provide heated, humidified air to the same space. This allows the system to provide heated, humidified air to a space in winter conditions. The conditioner is heated and is desorbing water vapor from a desiccant and the indirect evaporator can be heated as well and is desorbing water vapor from liquid water. In combination the indirect evaporator and conditioner provide heated humidified air to the building space for winter heating conditions.
[0011] In no way is the description of the applications intended to limit the disclosure to these applications. Many construction variations can be envisioned to combine the various elements mentioned above each with its own advantages and disadvantages. The present disclosure in no way is limited to a particular set or combination of such elements.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 illustrates an exemplary 3-way liquid desiccant air conditioning system using a chiller or external heating or cooling sources.
[0013] FIG. 2 shows an exemplary flexibly configurable membrane module that incorporates 3-way liquid desiccant plates.
[0014] FIG. 3 illustrates an exemplary single membrane plate in the liquid desiccant membrane module of FIG. 2 .
[0015] FIG. 4 shows a schematic of a conventional mini-split air conditioning system.
[0016] FIG. 5A shows a schematic of an exemplary chiller assisted mini-split liquid desiccant air conditioning system in a summer cooling mode in accordance with one or more embodiments.
[0017] FIG. 5B shows a schematic of an exemplary chiller assisted mini-split liquid desiccant air conditioning system in a winter heating mode in accordance with one or more embodiments.
[0018] FIG. 6 shows an alternate embodiment of a mini-split liquid desiccant air conditioning system using an indirect evaporative cooler and an external heat source in accordance with one or more embodiments.
[0019] FIG. 7 shows the liquid desiccant mini-split system of FIG. 6 configured for operation in a winter heating mode in accordance with one or more embodiments.
[0020] FIG. 8 is a perspective view of an exemplary liquid desiccant mini-split system similar to FIG. 5A .
[0021] FIG. 9A illustrates a cut-away rear-view of the system of FIG. 8 .
[0022] FIG. 9B illustrates a cut-away front-view of the system of FIG. 8 .
[0023] FIG. 10 shows a three dimensional view of a liquid desiccant mini-split system of FIG. 6 in accordance with one or more embodiments.
[0024] FIG. 11 shows a cut-away view of the system of FIG. 10 in accordance with one or more embodiments.
[0025] FIG. 12 illustrates an exemplary liquid desiccant supply and return structure comprising two bonded plastic tubes creating a heat exchange effect in accordance with one or more embodiments.
DETAILED DESCRIPTION
[0026] FIG. 1 depicts a new type of liquid desiccant system as described in more detail in U.S. Patent Application Publication No. US 20120125020, which is incorporated by reference herein. A conditioner 101 comprises a set of plate structures that are internally hollow. A cold heat transfer fluid is generated in cold source 107 and entered into the plates. Liquid desiccant solution at 114 is brought onto the outer surface of the plates and runs down the outer surface of each of the plates. The liquid desiccant runs behind a thin membrane that is located between the air flow and the surface of the plates. Outside air 103 is now blown through the set of wavy plates. The liquid desiccant on the surface of the plates attracts the water vapor in the air flow and the cooling water inside the plates helps to inhibit the air temperature from rising. The treated air 104 is put into a building space.
[0027] The liquid desiccant is collected at the bottom of the wavy plates at 111 and is transported through a heat exchanger 113 to the top of the regenerator 102 to point 115 where the liquid desiccant is distributed across the wavy plates of the regenerator. Return air or optionally outside air 105 is blown across the regenerator plate and water vapor is transported from the liquid desiccant into the leaving air stream 106 . An optional heat source 108 provides the driving force for the regeneration. The hot transfer fluid 110 from the heat source can be put inside the wavy plates of the regenerator similar to the cold heat transfer fluid on the conditioner. Again, the liquid desiccant is collected at the bottom of the wavy plates 102 without the need for either a collection pan or bath so that also on the regenerator the air flow can be horizontal or vertical. An optional heat pump 116 can be used to provide cooling and heating of the liquid desiccant. It is also possible to connect a heat pump between the cold source 107 and the hot source 108 , which is thus pumping heat from the cooling fluids rather than the desiccant.
[0028] FIG. 2 describes a 3-way heat exchanger as described in further detail in U.S. patent application Ser. No. 13/915,199 filed on Jun. 11, 2013, Ser. No. 13/915,222 filed on Jun. 11, 2013, and Ser. No. 13/915,262 filed on Jun. 11, 2013, which are all incorporated by reference herein. A liquid desiccant enters the structure through ports 304 and is directed behind a series of membranes as described in FIG. 1 . The liquid desiccant is collected and removed through ports 305 . A cooling or heating fluid is provided through ports 306 and runs counter to the air stream 301 inside the hollow plate structures, again as described in FIG. 1 and in more detail in FIG. 3 . The cooling or heating fluids exit through ports 307 . The treated air 302 is directed to a space in a building or is exhausted as the case may be.
[0029] FIG. 3 describes a 3-way heat exchanger as described in more detail in U.S. Provisional Patent Application Ser. No. 61/771,340 filed on Mar. 1, 2013, which is incorporated by reference herein. The air stream 251 flows counter to a cooling fluid stream 254 . Membranes 252 contain a liquid desiccant 253 that is falling along the wall 255 that contain a heat transfer fluid 254 . Water vapor 256 entrained in the air stream is able to transition the membrane 252 and is absorbed into the liquid desiccant 253 . The heat of condensation of water 258 that is released during the absorption is conducted through the wall 255 into the heat transfer fluid 254 . Sensible heat 257 from the air stream is also conducted through the membrane 252 , liquid desiccant 253 and wall 255 into the heat transfer fluid 254 .
[0030] FIG. 4 illustrates a schematic diagram of a conventional mini-split air conditioning system as is frequently installed on buildings. The unit comprises a set of indoor components that generate cool, dehumidified air and a set of outdoor components that release heat to the environment. The indoor components comprise a cooling (evaporator) coil 401 through which a fan 407 blows air 408 from the room. The cooling coil cools the air and condenses water vapor on the coil which is collected in drain pan 418 and ducted to the outside 419 . The resulting cooler, drier air 409 is circulated into the space and provides occupant comfort. The cooling coil 401 receives liquid refrigerant at pressures of typically 50-200 psi through line 412 , which has already been expanded to a low temperature and pressure by expansion valve 406 . The pressure of the refrigerant in line 412 is typically 300-600 psi. The cold liquid refrigerant 410 enters the cooling coil 401 where it picks up heat from the air stream 408 . The heat from the air stream evaporates the liquid refrigerant in the coil and the resulting gas is transported through line 404 to the outdoor components and more specifically to the compressor 402 where it is re-compressed to a high pressure of typically 300-600 psi. In some instances the system can have multiple cooling coils 410 , fans 407 and expansion valves 406 , for example a cooling coil assembly could be located in various rooms that need to be cooled.
[0031] Besides the compressor 402 , the outdoor components comprise a condenser coil 403 and a condenser fan 417 . The fan 417 blows outside air 415 through the condenser coil 403 where it picks up heat from the compressor 402 which is rejected by air stream 416 . The compressor 402 creates hot compressed refrigerant in line 411 . The heat of compression is rejected in the condenser coil 403 . In some instances the system can have multiple compressors or multiple condenser coils and fans. The primary electrical energy consuming components are the compressor through electrical line 413 , the condenser fan electrical motor through supply line 414 and the evaporator fan motor through line 405 . In general the compressor uses close to 80% of the electricity required to operate the system, with the condenser and evaporator fans taking about 10% of the electricity each.
[0032] FIG. 5A illustrates a schematic representation of a liquid desiccant air conditioner system. A 3-way conditioner 503 (which is similar to the conditioner 101 of FIG. 1 ) receives an air stream 501 from a room (“RA”). Fan 502 moves the air 501 through the conditioner 503 wherein the air is cooled and dehumidified. The resulting cool, dry air 504 (“SA”) is supplied to the room for occupant comfort. The 3-way conditioner 503 receives a concentrated desiccant 527 in the manner explained under FIGS. 1-3 . It is preferable to use a membrane on the 3-way conditioner 503 to ensure that the desiccant is generally fully contained and is unable to get distributed into the air stream 504 . The diluted desiccant 528 , which contains the captured water vapor is transported to the outside regenerator 522 . Furthermore the chilled water 509 is provided by pump 508 , enters the conditioner module 503 where it picks up heat from the air as well as latent heat released by the capture of water vapor in the desiccant 527 . The warmer water 506 is also brought outside to the heat exchanger 507 on the chiller system 530 . It is worth noting that unlike the mini-split system of FIG. 4 , which has high pressure between 50 and 600 psi, the lines between the indoor and outdoor system of FIG. 5A are all low pressure water and liquid desiccant lines. This allows the lines to be inexpensive plastics rather than refrigerant lines in FIG. 4 , which are typically copper and need to be braised in order to withstand the high refrigerant pressures. It is also worth noting that the system of FIG. 5A does not require a condensate drain line like line 419 in FIG. 4 . Rather, any moisture that is condensed into the desiccant is removed as part of the desiccant itself. This also eliminates problems with mold growth in standing water that can occur in the conventional mini-split systems of FIG. 4 .
[0033] The liquid desiccant 528 leaves the conditioner 503 and is moved through the optional heat exchanger 526 to the regenerator 522 by pump 525 . If the desiccant lines 527 and 528 are relatively long they can be thermally connected to each other, which eliminates the need for heat exchanger 526 .
[0034] The chiller system 530 comprises a water to refrigerant evaporator heat exchanger 507 which cools the circulating cooling fluid 506 . The liquid, cold refrigerant 517 evaporates in the heat exchanger 507 thereby absorbing the thermal energy from the cooling fluid 506 . The gaseous refrigerant 510 is now re-compressed by compressor 511 . The compressor 511 ejects hot refrigerant gas 513 , which is liquefied in the condenser heat exchanger 515 . The liquid refrigerant 514 then enters expansion valve 516 , where it rapidly cools and exits at a lower pressure. It is worth noting that the chiller system 530 can be made very compact since the high pressure lines with refrigerant ( 510 , 513 , 514 and 517 ) only have to run very short distances. Furthermore, since the entire refrigerant system is located outside of the space that is to be conditioned, it is possible to utilize refrigerants that normally cannot be used in indoor environments such as by way of example, CO 2 , Ammonia and Propane. These refrigerants are sometimes preferable over the commonly used R410A, R407A, R134A or R1234YF refrigerants, but they are undesirable indoor because of flammability or suffocation or inhaling risks. By keeping all of the refrigerants outside, these risks are essentially eliminated. The condenser heat exchanger 515 now releases heat to another cooling fluid loop 519 which brings hot heat transfer fluid 518 to the regenerator 522 . Circulating pump 520 brings the heat transfer fluid back to the condenser 515 . The 3-way regenerator 522 thus receives a dilute liquid desiccant 528 and hot heat transfer fluid 518 . A fan 524 brings outside air 523 (“OA”) through the regenerator 522 . The outside air picks up heat and moisture from the heat transfer fluid 518 and desiccant 528 which results in hot humid exhaust air (“EA”) 521 .
[0035] The compressor 511 receives electrical power 512 and typically accounts for 80% of electrical power consumption of the system. The fan 502 and fan 524 also receive electrical power 505 and 529 respectively and account for most of the remaining power consumption. Pumps 508 , 520 and 525 have relatively low power consumption. The compressor 511 will operate more efficiently than the compressor 402 in FIG. 4 for several reasons: the evaporator 507 in FIG. 5A will typically operate at higher temperature than the evaporator 401 in FIG. 4 because the liquid desiccant will condense water at much higher temperature without needing to reach saturation levels in the air stream. Furthermore the condenser 515 in FIG. 5A will operate at lower temperatures than the condenser 403 in FIG. 4 because of the evaporation occurring on the regenerator 522 which effectively keeps the condenser 515 cooler. As a result the system of FIG. 5A will use less electricity than the system of FIG. 4 for similar compressor isoentropic efficiencies.
[0036] FIG. 5B shows essentially the same system as FIG. 5A except that the compressor 511 's refrigerant direction has been reversed as indicated by the arrows on refrigerant lines 514 and 510 . Reversing the direction of refrigerant flow can be achieved by a 4-way reversing valve (not shown) or other convenient means. It is also possible to instead of reversing the refrigerant flow to direct the hot heat transfer fluid 518 to the conditioner 503 and the cold heat transfer fluid 506 to the regenerator 522 . This will in effect provide heat to the conditioner which will now create hot, humid air 504 for the space for operation in winter mode. In effect the system is now working as a heat pump, pumping heat from the outside air 523 to the space supply air 504 . However unlike the system of FIG. 4 , which is oftentimes also reversible, there is much less of a risk of the coil freezing because the desiccant 525 usually has much lower crystallization limit than water vapor. In the system of FIG. 4 , the air stream 523 contains water vapor and if the condenser coil 403 gets too cold, this moisture will condense on the surfaces and create ice formation on those surfaces. The same moisture in the regenerator of FIG. 5B will condense in the liquid desiccant which—when managed properly will not crystallize until −60° C. for some desiccants such as LiCl and water.
[0037] FIG. 6 illustrates an alternate embodiment of a mini-split liquid desiccant system. Similar to FIG. 5A , a 3-way liquid desiccant conditioner 503 receives an air stream 501 (“RA”) moved by fan 502 through the conditioner 503 . However unlike the case of FIG. 5A , a portion 601 of the supply air stream 504 (“SA”) is directed towards an indirect evaporative cooling module 602 through sets of louvers 610 and 611 . Air stream 601 is usually between 0 and 40% of the flow of air stream 504 . The dry air stream 601 is now directed through the 3-way indirect evaporative cooling module 602 which is constructed similarly to the 3-way conditioner module 503 , except that instead of using a desiccant behind a membrane, the module now has a water film behind such membrane supplied by water source 607 . This water film can be potable water, non-potable water, seawater or waste water or any other convenient water containing substance that is mostly water. The water film evaporates in the dry air stream 601 creating a cooling effect in the heat transfer fluid 604 which is then circulated to the conditioner module as cold heat transfer fluid 605 by pump 603 . The cold water 605 then cools the conditioner module 503 , which in turn creates cooler drier air 504 , which then results in an even stronger cooling effect in the indirect evaporative module 602 . As a result the supply air 504 will ultimately be both dry and cold and is supplied to the space for occupant comfort. Conditioner module 503 also receives a concentrated liquid desiccant 527 that absorbs moisture from the air stream 501 . Dilute liquid desiccant 528 is then returned to the regenerator 522 similar to FIG. 5A . It is of course possible to locate the indirect evaporative cooler 602 outside of the space rather than inside, but for thermal reasons it is probably better to mount the indirect evaporator 602 in close proximity to the conditioner 503 . The indirect evaporative cooling module 602 does not evaporate all of the water (typically 50 to 80%) and thus a drain 608 is employed. The exhaust air stream 606 (“EA 1 ”) from the module evaporative cooling module 602 is brought to the outside since it is warm and very humid.
[0038] As in FIG. 5A , the concentrated liquid desiccant 527 and dilute liquid desiccant 528 pass through a heat exchanger 526 by pump 525 . As before one can thermally connect the lines 527 and 528 which eliminates the need for heat exchanger 526 . The 3-way regenerator 522 as before receives an outdoor air stream 523 through fan 524 . And as before a hot heat transfer fluid 518 is applied to the 3-way regenerator module 522 by pump 520 . However unlike the system of FIG. 5A , there is no heat from a compressor to use in the regenerator 522 , so an external heat source 609 needs to be provided. This heat source can be a gas water heater, a solar module, a solar thermal/PV hybrid module (a PVT module), it can be heat from a steam loop or other convenient source of heat or hot water. In order to prevent over-concentration of the desiccant 528 , a supplemental heat dump 614 can be employed which can temporarily absorb heat from the heat source 609 . An additional fan 613 and air stream 612 are then necessary as well. Of course other forms of heat dumps can be devised and may not always be required. The heat source 609 ensures that the excess water is evaporated from the desiccant 528 so that it can be re-used on the conditioner 503 . As a result the exhaust stream 521 (“EA 2 ”) comprises hot, humid air. It is worth noting that again no high pressure lines are needed between the indoor and outside components of the system. A single water line for water supply is needed and a drain line for the removal of excess water. However a compressor and heat exchanger are no longer required in this embodiment. As a result this system will use significantly less electricity than the system of FIG. 4 and the system of FIG. 5A . The major consumption of electricity are now the fans 502 and 524 through electrical supply lines 505 and 529 respectively and the liquid pumps 603 , 520 and 525 . However these devices consume considerably less power than the compressor 402 in FIG. 4 .
[0039] FIG. 7 illustrates the system of FIG. 6 reconfigured slightly to allow for operation in winter heating mode. The heat source 609 now provides hot heat transfer fluid to the conditioner module 503 through lines 701 . As a result the supply air to the space 504 will be warm and humid. It is also possible to provide hot heat transfer fluid 703 to the indirect evaporative cooler 602 and to direct the hot, humid exhaust air 702 to the space rather than to the outside. This increases the available heating and humidification capacity of the system since both the conditioner 503 and the indirect evaporative “cooler” 602 (or “heater” may be a better moniker) are operating to provide the same hot humid air and this can be handy since heating capacity in winter typically needs to be larger than cooling capacity in summer.
[0040] FIG. 8 shows an embodiment of the system of FIG. 5A . The air intake 801 allows for air from space 805 to enter the conditioner unit 503 (not shown). The air supply exits from roster 803 into the space. A flat screen television 802 or painting, or monitor or any other suitable device can be used to visually hide the conditioner 503 . An external wall 804 would be a logical place to mount the conditioner system. A regenerator and chiller system 807 can be mounted in a convenient outside location 806 . Desiccant supply and return lines 809 and cold heat transfer fluid supply and return lines 808 connect the two sides of the system.
[0041] FIG. 9A shows a cut-away view of the rear side of the system in FIG. 8 . The regenerator module 522 receives liquid desiccant from lines 809 . A compressor 511 an expansion valve 516 and two refrigerant to liquid heat exchangers 507 and 515 are also shown. Other components have not been shown for convenience.
[0042] FIG. 9B shows a cut-away view of the front side of the system in FIG. 8 . The flat screen TV 802 has been omitted to allow a view of the conditioner module 503 .
[0043] FIG. 10 shows an aspect of an embodiment of the system of FIG. 6 . The system has an air intake 801 and a supply roster 803 similar to the system of FIG. 8 . As in FIG. 8 , a TV 802 or something similar can be used to cover the conditioner module 503 . The unit can be mounted to wall 804 and provide conditioning of the space 805 . The system also has an exhaust 606 that penetrates the wall 804 . On the outside 806 , the regenerator module 902 provides concentrated liquid desiccant to the conditioner section (not shown) through desiccant supply and return lines 809 . A water supply line 901 is also shown. A source of hot heat transfer fluid can be the solar PVT module 903 which provides hot water through line 905 which after being cooled through the regenerator returns heat transfer fluid to the PVT module 903 through line 904 . An integrated hot water storage tank 906 can provide both a hot water buffer as well as a ballast for the PVT module 903 .
[0044] FIG. 11 shows a cut-away view of the system of FIG. 10 . The conditioner module 503 can be clearly seen as can the indirect evaporator module 602 . Inside the regenerator module 902 one can see the regenerator module 522 as well as the optional heat dump 614 and fan 612 .
[0045] FIG. 12 illustrates a structure 809 for the supply and return of the liquid desiccant to the indoor conditioning unit. The structure comprises a polymer material such as for example an extruded High Density Polypropylene or High Density Polyethylene material the comprises two passages 1201 and 1202 for the supply and return of desiccant respectively. The wall 1203 between the two passages could be manufactured from a thermally conductive polymer, but in many cases that may not be necessary because the length of the structure 809 is by itself sufficient to provide adequate heat exchange capacity between the supply and return liquids.
[0046] Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present disclosure to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Additionally, elements and components described herein may be further divided into additional components or joined together to form fewer components for performing the same functions. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting.
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A split liquid desiccant air conditioning system is disclosed for treating an air stream flowing into a space in a building. The split liquid desiccant air-conditioning system is switchable between operating in a warm weather operation mode and a cold weather operation mode.
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BACKGROUND OF THE INVENTION
This invention relates to mounting arrangements and units for use therein.
The invention is especially concerned with mounting arrangements for electrical equipment.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a mounting arrangement comprises a rack formed by two spaced series of projections that define a plurality of guideways side by side, in combination with units each of which is adapted to be slidable into an individual one of said guideways and which includes means for locking that unit in its respective guideway by a clamping action effected in conjunction with both series of projections.
A plurality of said units may be coupled by resilient means to form an integral assembly, the resilient means being adapted to maintain the relative disposition of the units in the assembly upon removal from said mounting arrangement.
The locking means may involve a wedge-lock action by which a portion of the unit associated with each series of projections is urged into direct face-to-face abutment with a projection. In this respect, and according to another aspect of the present invention, a unit for use in a mounting arrangement includes a mechanism which is selectively actuable for clamping the unit in the arrangement, the mechanism comprising a first member mounted for movement longitudinally of the unit upon actuation of said mechanism, and a second member that is arranged to be urged sideways from the unit to abut a surface of the mounting arrangement along a substantial portion of (for example by abutment at a plurality of spaced positions along) the length of the unit in response to said longitudinal movement of the first member.
According to a further aspect of the present invention a unit for use in a mounting arrangement, comprises a frame having a plurality of elongate portions defining therebetween one or more windows for receiving items to be mounted in the plane of the frame. The items mounted in the windows of the frame may be electrical-circuit modules and electrical interconnection between different ones of the modules in the frame may be established by electrical connections that bridge cross-pieces of the frame structure.
BRIEF DESCRIPTION OF THE DRAWINGS
A mounting arrangement for electrical equipment, according to the present invention, will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a part of the mounting arrangement, showing a hinged lid of the arrangement raised and revealing one of a multiplicity of racks for receiving individual units of the electrical equipment; and
FIG. 2 is a partially exploded view of an assembly of two of the units of electrical equipment shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The mounting arrangement to be described is of especial advantage in providing for the mounting of electronic equipment in aircraft, both as regards the rigidity of mounting provided to enable the equipment to withstand vibration and dynamic forces generally in such enviroment, but also in regard to the dissipation of heat from the equipment and electrical screening of the equipment.
Referring to FIG. 1, the electrical equipment is totally enclosed within a metal cabinet 1 with the individual units 2 of the equipment mounted in racks one above the other. Each rack is defined in the space between two horizontal metal-plates 3, and the units 2 contained in it are accessible from the front of the cabinet 1 by unlocking and raising a hinged lid 4 individual to the rack. The units 2 are received in the rack within individual guideways formed by aligned upper and lower channels 5 that are machined from the opposed faces of the plates 3 to run fromt the front towards the rear of the cabinet 1. Each unit 2 is slid rearwardly into its guideway and is then locked in place by turn-screws 6 at top and bottom. This locking of the unit 2 in the rack, clamps it firmly against the projections defining the upper and lower channels 5 so as to ensure that the unit is retained in the rack with good thermal (and, if desired, electrical) connection to both plates 3 as well as rigidity of mounting.
Electrical connection with each unit 2 is made via one or more plug or socket connectors which are carried at the rear of the unit and which mate with corresponding connectors mounted on the plates 3 towards the rear of the cabinet 1. The connectors come together into their mating relationship so as thereby to establish the electrical connection automatically, as the unit continues to be slid rearwardly in completion of its insertion into the rack. The locking of the unit 2 in the rack using the turn-screws 6, ensures that the established electrical connection is maintained against any vibration to which the equipment may be subjected in use.
Any unit 2 may be removed from the cabinet 1 for maintenance, repair or replacement, simply by unlocking and raising the lid 4 of the relevant rack, twisting the two turn-screws 6 of the unit to unlock it from the rack, and then withdrawing the unit from its guideway. As the unit is withdrawn so the connectors at its rear are released from one enother, quickly breaking electrical connection to the unit.
The units 2 are of a standard rectangular format based on, for example, a height of some 8 inches, a length of 10 inches and a unit-width of 17 millimeters. Where, however, a unit wider than this is required, for example to accomodate switches, knobs, clamps or display devices, then a multiple of this unit-width may be used as in the case of each of the two double-units 2A illustrated in FIG. 1. Each double-unit 2A is of an overall width equal to double the unit-width plus the projection-width (for example, 3 millimeters), the unit being of the standard width at top and bottom to slide into the upper and lower channels of only one guideway but elsewhere being of the double width.
Two or more standard units 2 may be linked to one another so that they can be inserted and withdrawn from the rack together. For example, two units may be coupled together side by side as in the case of the unit-assembly 2B illustrated in FIG. 1, the two standard units 2 occupying individual guideways and being locked, top and bottom, in these independently of one another. Interconnection of the two units 2 in the assembly 2B is achieved by means of two resilient couplings 8 that are clamped to the two units, one at the front of the assembly and the other at the rear. More units may be involved as illustrated in FIG. 1 by the assembly 2C which comprises four standard units 2 linked one to another by couplings 8 in the same way as the units of assembly 2B. The fact that in both assemblies 2B and 2C each unit 2 is still individually clamped in the rack ensures that each unit 2 has its own independent thermal paths to the plates 3. Thus the same high degree of heat dissipation with mechanical rigidity can be achieved for each unit irrespective of the linking together.
Provision may be made for blowing air or passing other coolant between, and possibly through, the units 2 within the cabinet 1, and apertures may be provided in the upper and lower plates 3 of each rack to facilitate this.
The separate clamping of each unit 2 in the rack also enables good electrical connection to be provided, when required, for screening against interference and like purposes.
The construction of the individual units 2 will now be described in greater detail with reference to FIG. 2.
Referring to FIG. 2, each unit has a rectangular metal-frame 11 that is divided by cross-pieces 12 into four separate windows each of which is occupied by the ceramic substrate 13 of an individual electrical-circuit module 14. The electrical circuit components of each module 14 are carried by the substrate 13 as discrete and integratedcircuit elements 15 with the electrical interconnections of the circuit provided in metal-layer form (not illustrated) on the substrate surfaces. Interconnection between the circuits of the different modules 14 are provided by surface-mounted conductors 16 bridging the cross-pieces 12, and between the circuits and the connectors 17 at the rear of the unit by sheaves of conductors 18.
The substrates 13, which are clamped in the windows of the frame 11 so as to ensure good thermal connection and rigid mounting, may be of a multilayer form in accordance with the circuit requirements and the packing density that is required or can be tolerated. Just four substrates 13 may be provided all inserted from the same side of the frame 11, but up to eight, four inserted from each side, may be accomodated in the specific unit illustrated. Although printed-circuits on epoxy-laminated boards may be used in place of the described modules 14, ceramic substrates are preferred in view of their better thermal conductivity. Covers (shown in FIG. 1) may be fitted to one or both sides of the frame 11 to enclose the modules 14 in the unit 2.
Each unit 2 is locked in its guideway by the action of the two turn-screws 6 on wedge-lock mechanisms 19 that lie in channels 20 along the top and bottom respectively of the frame 11. Each mechanism 19 includes a metal bar 21 which lies in the respective channel 20 and which has three spaced metal-blocks 22 on one side and a wedge-shaped cam 23 on the other. The cam 23 is opposed by a corresponding cam 24 on a metal bar 25 which is mounted within the channel 20 and which is engaged by the respective turn-screw 6 to move longitudinally of the frame 11 when the screw 6 is twisted. Twisting of the screw 6 to lock the unit in its guideway moves the bar 25 rearwardly of the unit 2 to urge the cam 24 against the cam 23 and thereby urge the bar 21 sideways to cause the blocks 22 to project through slots 26 in one side-wall 27 of the channel 20. The blocks 22 (which in modification may be combined into a single block) abut one side of the guideway-channel 5 of the relevant plate 3 (FIG. 1) to urge the other side-wall 28 of the channel 16 hard against the other side of the guideway-channel 5, and thus hold the frame 11 firmly to that plate 3 with good thermal contact for dissipation of heat from the unit. The clamping pressure on the bar 21 is released to enable the unit 2 to be withdrawn, when the turn-screw 6 is twisted in the opposite sense moving the bar 25 forwardly of the unit along the channel 20.
A quick-release fastener which is turned through 180 degrees to lock the frame 11 in place may be used in place of the screw 6.
The couplings 8 used for linking standard units 2 to one another at front and rear, each involves a resilientmetal strip 31 which bends back on itself to form a U-shape portion 32 for insertion between the frames 11 of the two units 2. The two flange portions 33 of each strip 31 on either side of the portion 32, are clamped to the frames 11 respectively, beneath metal fillet-pieces 34. The portion 32 acts in the manner of bellows providing sufficient deflection to allow for mechanical-tolerance variations in the mounting of the linked units 2, yet having sufficient stiffness to ensure that the assembly can be handled as one without damage.
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A rack for mounting electronic equipment comprises two spaced plates each having a series of aligned channels. Each item of electronic equipment is carried by a frame which is located in the guideway defined by an opposed pair of channels, and the frame is individually clamped in each channel. Large items of equipment are held in several frames interconnected by resilient metal strips, but each frame is still individually locked in its respective pair of channels. Thus each frame has an independent thermal path to each plate, with predictable, uniform characteristics; in addition, the entire assembly is resistant to dynamic loads. The plates and/or the frames may be force-ventilated.
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FIELD OF THE INVENTION
The present invention relates to aza adamantane derivatives that have the ability to inhibit 11-β-hydroxysteroid dehydrogenase type 1 (11β-HSD-1) and which are therefore useful in the treatment of certain disorders that can be prevented or treated by inhibition of this enzyme. In addition the invention relates to the compounds, methods for their preparation, pharmaceutical compositions containing the compounds and the uses of these compounds in the treatment of certain disorders. It is expected that the compounds of the invention will find application in the treatment of conditions such as non-insulin dependent type 2 diabetes mellitus (NIDDM), insulin resistance, obesity, impaired fasting glucose, impaired glucose tolerance, lipid disorders such as dyslipidemia, hypertension and as well as other diseases and conditions.
BACKGROUND OF THE INVENTION
Glucocorticoids are stress hormones with regulatory effects on carbohydrate, protein and lipid metabolism. Cortisol (or hydrocortisone in rodent) is the most important human glucocorticoid. 11-beta hydroxyl steroid dehydrogenase or 11 beta-HSD1 (11β-HSD-1) is a member of the short chain dehydrogenase super-family of enzymes which converts functionally inert cortisone to active cortisol locally, in a pre-receptor manner. Given that the enzyme is abundantly expressed in metabolically important tissues, such as adipose, muscle, and liver, that become resistant to insulin action in Type 2 Diabetes, inhibition of 11β-HSD-1 offers the potential to restore the glucose lowering action of insulin in these tissues without impacting the central HPA. Another important 11-beta hydroxyl steroid dehydrogenase, namely Type 2 11-beta-HSD (11β-HSD-2), which converts cortisol into cortisone, is a unidirectional dehydrogenase mainly located in kidney and protects minerallocorticoid receptors from illicit activation by glucocorticoids.
Multiple lines of evidence indicate that 11β-HSD-1-mediated intracellular cortisol production may have a pathogenic role in Obesity, Type 2 Diabetes and its co-morbidities.
In humans, treatment with non-specific inhibitor carbenoxolone improves insulin sensitivity in lean healthy volunteers and people with type2 diabetes (Walker B R et al (1995)). Likewise, 11β-HSD-1 activity was decreased in liver and increased in the adipose tissue of obese individuate. Similarly 11β-HSD-1 mRNA was found to be increased in both visceral and subcutaneous adipose tissue of obese patients (Desbriere R et al (2006)) and was positively related to BMI and central obesity in Pima Indians, Caucasians and Chinese youth (Lindsay R S et al (2003), Lee Z S et al (1999)). Adipose tissue 11β-HSD-1 and Hexose-6-Phosphate Dehydrogenase gene expressions have also been shown to increase in patients with type 2 diabetes mellitus (Uçkaya G et al (2008)). In human skeletal muscle 11β-HSD-1 expression was found to be positively associated with insulin resistance (Whorwood C B et al (2002)). Increased 11β-HSD-1 expression was also seen in diabetic myotubes (Abdallah B M et al (2005)).
Various studies have been conducted in rodent models to substantiate the role of 11β-HSD-1 in diabetes and obesity. For example, over-expression of 11β-HSD-1 specifically in adipose tissue causes development of metabolic syndrome (glucose intolerance, obesity, dyslipidemia and hypertension) in mice (Masuzaki H et al (2001)). Conversely, when 11β-HSD-1 gene was knocked out, the resulting mice showed resistance to diet induced obesity and improvement of the accompanying dysregulation of glucose and lipid metabolism (Kotelevtsev Y et al (1997), Morton N M et al (2001), Morton N M et al (2004)). In addition, treatment of diabetic mouse models with specific inhibitors of 11β-HSD-1 caused a decrease in glucose output from the liver and overall increase in insulin sensitivity (Alberts P et al (2003)).
The results of the preclinical and early clinical studies suggest that the treatment with a selective and potent inhibitor of 11β-HSD-1 will be an efficacious therapy for type 2 diabetes, obesity and metabolic syndrome.
The role of 11β-HSD-1 as an important regulator of liver glucocorticoid level and thus of hepatic glucose production is well substantiated. Hepatic insulin sensitivity was improved in healthy human volunteers treated with the non-specific 11β-HSD-1 inhibitor carbenoxolone (Walker B R (1995)). Many in vitro and in vivo (animal model) studies showed that the mRNA levels and activities of two key enzymes (PEPCK and G6PC) in gluconeogenesis and glycogenolysis were reduced by reducing 11β-HSD-1 activity. Data from these models also confirm that inhibition of 11β-HSD-1 will not cause hypoglycemia, as predicted since the basal levels of PEPCK and G6Pase are regulated independently of glucocorticoids (Kotelevtsev Y (1997)).
In the pancreas cortisol is shown to inhibit glucose induced insulin secretion as well as increase stress induced beta cell apoptosis. Inhibition of 11β-HSD-1 by carbenoxolone in isolated murine pancreatic beta-cells improves glucose-stimulated insulin secretion (Davani B et al (2000)). Recently, it was shown that 11β-HSD-1 within alpha cells regulates glucagon secretion and in addition may act in a paracrine manner to limit insulin secretion from beta cells (Swali A et al (2008)). Levels of 11β-HSD-1 in islets from ob/ob mice were shown to be positively regulated by glucocorticoids and were lowered by a selective 11β-HSD-1 inhibitor and a glucocorticoid receptor antagonist. Increased levels of 11β-HSD-1 were associated with impaired GSIS (Ortsater H et al (2005)). In Zuker diabetic rats, troglitazone treatment improved metabolic abnormalities with a 40% decline in expression of 11β-HSD-1 in the islets (Duplomb L et al (2004)). Cortisol inhibition may lead to an increase in the insulin gene transcription and a normalization of first phase insulin secretion (Shinozuka Y et al (2001)).
In human skeletal muscle 11β-HSD-1 expression is positively associated insulin resistance and increased expression of 11β-HSD-1 was also reported in type 2 diabetic myotubes (Abdallah B M et al (2005)). Recently the contribution of cortisol in muscle pathology is being considered for modulating its action. Very recently it has been demonstrated that targeted reduction or pharmacological inhibition of 11β-HSD-1 in primary human skeletal muscle prevents the effect of cortisone on glucose metabolism and palmitate oxidation (Salehzadeh F et al (2009)). Over activity of cortisol in muscle leads to muscle atrophy, fibre type switch and poor utilization of glucose due to insulin resistance. Cortisol might have a direct role in reducing muscle glucose uptake.
Obesity is an important factor in Metabolic syndrome as well as in the majority (>80%) of type 2 diabetics, and omental (visceral) fat appears to be of central importance. 11β-HSD-1 activity is increased in the both visceral and subcutaneous adipose tissue of obese individual (Lindsay R S et al (2003)). Cortisol activity in adipose is known to increase the adipogenic program. Inhibition of 11β-HSD-1 activity in pre-adipocytes has been shown to decrease the rate of differentiation into adipocytes (Bader T et al (2002)). This is predicted to result in diminished expansion (possibly reduction) of the omental fat depot, i.e., reduced central obesity (Bujalska I J et al (1997) and (2006)). Intra-adipose cortisol levels have been associated with adipose hypertrophy, independent of obesity (Michailidou Z et al (2006)).
Cortisol in coordination with adrenergic signalling is also known to increase lipolysis which leads to increase in plasma free fatty acid concentrations which, in turn, is the primary cause of many deleterious effects of obesity (TomLinson J W et al (2007)).
Adrenalectomy attenuates the effect of fasting to increase both food intake and hypothalamic neuropeptide Y expression. This supports the role of glucocorticoids in promoting food intake and suggests that inhibition of 11β-HSD-1 in the brain might increase satiety and therefore reduce food intake (Woods S C (1998)). Inhibition of 11β-HSD-1 by a small molecule inhibitor also decreased food intake and weight gain in diet induced obese mice (Wang S J Y et al (2006)).
The effects discussed above therefore suggest that an effective 11β-HSD-1 inhibitor would have activity as an anti-obesity agent.
Cortisol in excess can also trigger triglyceride formation and VLDL secretion in liver, which can contribute to hyperlipidemia and associated dyslipidemia. It has been shown that 11β-HSD-1−/− transgenic mice have markedly lower plasma triglyceride levels and increased HDL cholesterol levels indicating a potential atheroprotective phenotype (Morton N M et al (2001)). In a diet-induced obese mouse model, a non-selective inhibitor of 11β-HSD-1 reduced plasma free fatty acid as well as triacylglycerol (Wang S J et al (2006)). Over-expression of 11β-HSD-1 in liver increased liver triglyceride and serum free fatty acids with the up regulation of hepatic lipogenic genes (Paterson J M et al (2004). It has been illustrated that inhibition of 11β-HSD-1 improves triglyceridemia by reducing hepatic VLDL-TG secretion, with a shift in the pattern of TG-derived fatty acid uptake toward oxidative tissues, in which lipid accumulation is prevented by increased lipid oxidation (Berthiaume M et al (2007)).
Atherosclerotic mouse model (APOE −/−) which are susceptible to atheroma when fed high fat diet, are protected against development of atherosclerosis when treated with 11β-HSD-1 inhibitors (Hermanowski-Vostaka A et al, (2005)).
Inhibition of 11β-HSD-1 in mature adipocytes is expected to attenuate secretion of the plasminogen activator inhibitor 1 (PAI-1)—an independent cardiovascular risk factor (Halleux C M et al (1999)). Furthermore, there is a clear correlation between glucocorticoid activity and cardiovascular risk factor suggesting that a reduction of the glucocorticoid effects would be beneficial (Walker B R et al (1998), Fraser R et al (1999)).
The association between hypertension and insulin resistance might be explained by increased activity of cortisol. Recent data show that the intensity of dermal vasoconstriction after topical application of glucocorticoids is increased in patients with essential hypertension (Walker B R et al (1998)). Glucocorticoid was shown to increase the expression of angiotensin receptor in vascular cell and thus potentiating the renin-angiotensin pathway (Ullian M E et al (1996)), (Sato A et al (1994)). Role of cortisol in NO signalling and hence vasoconstriction has been proved recently (Liu Y et al (2009)). These findings render 11β-HSD-1 a potential target for controlling hypertension and improving blood-flow in target tissues.
In the past decade, concern on glucocorticoid-induced osteoporosis has increased with the widespread use of exogenous glucocorticoids (GC). GC-induced osteoporosis is the most common and serious side-effect for patients receiving GC. Loss of bone mineral density (BMD) is greatest in the first few months of GC use. Mature bone-forming cells (osteoblasts) are considered to be the principal site of action of GC in the skeleton. The whole differentiation of mesenchymal stem cell toward the osteoblast lineage has been proven to be sensitive to GC as well as collagen synthesis (Kim C H et al (1999)). The effects of GC on this process are different according to the stage of differentiation of bone cell precursors. The presence of intact GC signalling is crucial for normal bone development and physiology, as opposed to the detrimental effect of high dose exposure (Pierotti S et al (2008), Cooper M S et al (2000)). Other data suggest a role of 11β-HSD-1 in providing sufficiently high levels of active glucocorticoid in osteoclasts, and thus in augmenting bone resorption (Cooper M S et al (2000)). The negative effect on bone nodule formation could be blocked by the non-specific inhibitor carbenoxolone suggesting an important role of 11β-HSD-1 in the glucocorticoid effect (Bellows C G et al (1998)).
Stress and glucocorticoids influence cognitive function (de Quervain D J et al (1998)). The enzyme 11β-HSD-1 controls the level of glucocorticoid action in the brain also known to contributes to neurotoxicity (Rajan V et al (1996)). It has been also suggested that inhibiting 11β-HSD-1 in the brain may result in reduced anxiety (Tronche F et al (1999)). Thus, taken together, the hypothesis is that inhibition of 11β-HSD-1 in the human brain would prevent reactivation of cortisone into cortisol and protect against deleterious glucocorticoid-mediated effects on neuronal survival and other aspects of neuronal function, including cognitive impairment, depression, and increased appetite.
Recent data suggest that the levels of the glucocorticoid target receptors and the 11β-HSD-1 enzymes determine the susceptibility to glaucoma (Stokes, J. et al. (2000)). Ingestion of carbenoxolone, a non-specific inhibitor of 11β-HSD-1, was shown to reduce the intraocular pressure by 20% in normal subjects. There are evidences that 11β-HSD-1 isozyme may modulate steroid-regulated sodium transport across the NPE, thereby influencing intra ocular pressure (IOP). 11β-HSD-1 is suggested to have a role in aqueous production, rather than drainage, but it is presently unknown if this is by interfering with activation of the glucocorticoid or the mineralocorticoid receptor, or both (Rauz S et al (2001; 2003)).
The multitude of glucocorticoid action is exemplified in patients with prolonged increase in plasma glucocorticoids, so called “Cushing's syndrome”. These patients have prolonged increase in plasma glucocorticoids and exhibit impaired glucose tolerance, type 2 diabetes, central obesity, and osteoporosis. These patients also have impaired wound healing and brittle skin. Administration of glucocorticoid receptor agonist (RU38486) in Cushing's syndrome patients reverses the features of metabolic syndrome (Neiman L K et al (1985)).
Glucocorticoids have been shown to increase risk of infection and delay healing of open wounds. Patients treated with glucocorticoids have 2-5-fold increased risk of complications when undergoing surgery. Glucocorticoids influence wound healing by interfering with production or action of cytokines and growth factors like IGF, TGF-beta, EGF, KGF and PDGF (Beer H D et al (2000)). TGF-beta reverses the glucocorticoid-induced wound-healing deficit in rats by PDGF regulation in macrophages (Pierce G F et al (1989)). It has also been shown that glucocorticoids decrease collagen synthesis in rat and mouse skin in vivo and in rat and human fibroblasts (Oishi Y et al, 2002).
Glucocorticoids have also been implicated in conditions as diverse aspolycystic Ovaries Syndrome, infertility, memory dydsfunction, sleep disorders, myopathy (Endocrinology. 2011 January; 152(1):93-102. Epub 2010 Nov. 24. PMID: 21106871) and muscular dystrophy. As such the ability to target enzymes that have an impact on glucocorticoid levels is expected to provide promise for the treatment of these conditions.
Based on patent literature and company press releases, there are many compound tested for 11β-HSD-1 inhibition in the different stages of drug discovery pipeline.
Incyte Corporation's INCB13739 has proceeded furthest to phase IIb stage of clinical trial. The results of phase IIa trial for type 2 diabetes (28-days, placebo-controlled, two-step hyperinsulinemic clamp studies) showed that it was safe and well tolerated without any serious side effects and hypoglycemia.
Though this molecule significantly improved hepatic insulin sensitivity there was no appreciable improvement in plasma glucose levels. The molecule appeared to be having positive effects on risk factors for cardiovascular disease including reduction of LDL, total cholesterol and triglycerides as well as more modest increases in HDL. INCB13739 is currently being studied in a dose ranging phase IIb trials in T2D patients whose glucose levels are not controlled by metformin monotherapy.
In the pre-clinical stage, Incyte's lead inhibitor INCB13739 was tested in rhesus monkey and was shown to inhibit adipose 11β-HSD-1 (INCB013739, a selective inhibitor of 11β-Hydroxysteroid Dehydrogenase Type 1 (11βHSD1) improves insulin sensitivity and lowers plasma cholesterol over 28 days in patients with type 2 diabetes mellitus.
The evidence therefore strongly suggests that compounds that are inhibitors of 11β-Hydroxysteroid Dehydrogenase would be useful in the treatment of a number of clinical conditions associated with the expression of this enzyme. In addition it would be desirable if the inhibitors were selective inhibitors so as not to interfere with the functioning of closely related enzymes such as 11β-HSD-2 which is known to provide a protective effect in the body.
OBJECTS OF INVENTION
The principal object of the invention is to provide compounds that are inhibitors of 11β-Hydroxysteroid Dehydrogenase. These compounds would be expected to be useful in the treatment of 11β-Hydroxysteroid Dehydrogenase related conditions as discussed above.
A further object is to provide a pharmaceutical composition containing a compound that is an inhibitor of 11β-Hydroxysteroid Dehydrogenase and a pharmaceutically acceptable excipient, diluent or carrier.
A further object is to provide a method of prevention or treatment of a condition associated with 11β-Hydroxysteroid Dehydrogenase activity in a mammal.
STATEMENT OF INVENTION
The present invention provides compounds of Formula (I):
wherein:
each R 1 , R 1α and R 2 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , OCH 3 , CH 2 OH, CH 2 CO 2 H, CH 2 CH 2 CO 2 H, CH 2 NH 2 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 2 -C 12 alkenyloxy, optionally substituted C 2 -C 12 alkynyloxy, optionally substituted C 2 -C 10 heteroalkyloxy, optionally substituted C 3 -C 12 cycloalkyloxy, optionally substituted C 3 -C 12 cycloalkenyloxy, optionally substituted C 2 -C 12 heterocycloalkyloxy, optionally substituted C 2 -C 12 heterocycloalkenyloxy, optionally substituted C 6 -C 18 aryloxy, optionally substituted C 1 -C 18 heteroaryloxy, optionally substituted C 1 -C 12 alkylamino, SR 3 , SO 3 H, SO 2 NR 3 R 4 , SO 2 R 3 , SONR 3 R 4 , SOR 3 , COR 3 , COOH, COOR 3 , CONR 3 R 4 , NR 3 COR 4 , NR 3 COOR 4 , NR 3 SO 2 R 4 , NR 3 CONR 3 R 4 , and NR 3 R 4 ;
Ar is an optionally substituted C 1 -C 18 heteroaryl group or an optionally substituted C 2 -C 12 heterocycloalkyl group;
A is selected from the group consisting of S, SO, SO 2 , O, and —CR a R b —;
B is a group of the formula —(CR c R d ) n —;
wherein each R a , R b , R c and R d is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, SR 3 , SO 3 H, SO 2 NR 3 R 4 , SO 2 R 3 , SONR 3 R 4 , SOR 3 , COR 3 , COOH, COOR 3 , CONR 3 R 4 , NR 3 COR4 3 , NR 3 COOR 4 , NR 3 SO 2 R 4 , NR 3 CONR 3 R 4 , NR 3 R 4 ;
or any two R a , R b , R c and R d on the same carbon atom when taken together may form a substituent of the formula:
wherein each R 3 and R 4 is independently selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
R 5 is selected from the group consisting of O, S, and NR 6 ;
R 6 is selected from the group consisting of H, OR 7 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 1 -C 12 haloalkyloxy, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
R 7 is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl;
or any two or more R a , R b , R c and R d may join together to form a multiple bond between adjacent carbon atoms such as a double or triple bond, or a cyclic moiety connecting the carbon atoms to which they are attached;
n is an integer selected from the group consisting of 0, 1, 2, 3, and 4;
a is an integer selected from the group consisting of 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10;
or a pharmaceutically acceptable salt, N-oxide, or prodrug thereof.
As with any group of structurally related compounds which possess a particular utility, certain embodiments of variables of the compounds of the Formula (I), are particularly useful in their end use application.
In some embodiments A is S. In some embodiments A is SO. In some embodiments A is SO 2 . In some embodiments A is O. In some embodiments A is CR a R b .
In some embodiments where A is CR a R b , R a and R b are each independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 . In some embodiments R a is H. In some embodiments R b is H. In some embodiments R a and R b are different such that the carbon is a chiral carbon. In some embodiments one of R a and R b is H and the other is an optionally substituted alkyl.
In some embodiments R b is H and R a is optionally substituted alkyl. In some embodiments R b is H and R a is selected from the group consisting of methyl, ethyl, propyl, isopropyl and butyl.
B is a group of the formula —(CR c R d ) n —. In some embodiments n is 0. In some embodiments n is 1. In some embodiments n is 2.
In some embodiments R c and R d are each independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 . In some embodiments both R c and R d are H such that B is CH 2 .
In some embodiments any two or more R a , R b , R c and R d may join together to form a multiple bond between adjacent carbon atoms such as a double or triple bond, or a cyclic moiety connecting the carbon atoms to which they are attached.
In some embodiments two of R a , R b , R c and R d on adjacent carbon atoms are joined to form a double bond. In some embodiments four of R a , R b , R c and R d on adjacent carbon atoms are joined to form a triple bond.
In some embodiments one of R a and R b and one or R c and R d when taken together with the carbon atoms to which they are attached form a cyclic moiety. Examples of cyclic moieties that may be formed include cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
In some embodiments n=2 and one of R a and R b and one or R c and R d on the carbon atom two carbons removed (on the beta carbon) when taken together with the carbon atoms to which they are attached and the alpha carbon atom form a cyclic moiety. Examples of cyclic moieties that may be formed include cyclobutyl, cyclopentyl and cyclohexyl.
In some embodiments A is CR a R b and B is CH 2 , this provides compounds of formula (II):
wherein R 1 , R 1α , R a , R b , R 2 and Ar, are as defined above.
The group Ar may be any optionally substituted C 1 -C 18 heteroaryl moiety. Suitable heteroaryl groups include thiophene, benzothiophene, benzofuran, benzimidazole, benzoxazole, benzothiazole, benzisothiazole, naphtho[2,3-b]thiophene, furan, isoindolizine, xantholene, phenoxatine, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, tetrazole, indole, isoindole, 1H-indazole, purine, quinoline, isoquinoline, phthalazine, naphthyridine, quinoxaline, cinnoline, carbazole, phenanthridine, acridine, phenazine, thiazole, isothiazole, phenothiazine, oxazole, isooxazole, furazane, phenoxazine, pyridyl, quinolyl, isoquinolinyl, indolyl, and thienyl. In each instance where there is the possibility of multiple sites of substitution on the heteroaryl ring all possible attachment points are contemplated. Merely by way of example if the heteroaryl is a pyridyl moiety it may be a 2-pyridyly, a 3-pyridyl or a 4-pyridyl.
In some embodiments Ar is a group of the formula 3:
wherein each V 1 , V 2 , V 3 , V 4 , V 5 and V 6 is independently selected from the group consisting of N and CR 8 ;
U is selected from the group consisting of NR 9 , O, S and CR 9 2 ,
wherein each R 8 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, SH, NH 2 , CF 3 , OCF 3 , optionally substituted C 1 -C 12 alkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 3 -C 12 cycloalkenyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 2 -C 12 heterocycloalkenyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, optionally substituted C 1 -C 12 alkyloxy, optionally substituted C 2 -C 12 alkenyloxy, optionally substituted C 2 -C 12 alkynyloxy, optionally substituted C 2 -C 10 heteroalkyloxy, optionally substituted C 3 -C 2 cycloalkyloxy, optionally substituted C 3 -C 12 cycloalkenyloxy, optionally substituted C 2 -C 12 heterocycloalkyloxy, optionally substituted C 2 -C 12 heterocycloalkenyloxy, optionally substituted C 6 -C 18 aryloxy, optionally substituted C 1 -C 1 heteroaryloxy, optionally substituted C 1 -C 12 alkylamino, SR 10 , SO 3 H, SO 2 NR 10 R 11 , SO 2 R 10 , OSO 2 R 10 , SONR 10 R 11 , SOR 10 , COR 10 , COOH, COOR 10 , CONR 10 R 11 , NR 10 COR 11 , NR 10 COOR 11 , NR 10 SO 2 R 11 , NR 10 CONR 10 R 11 , and NR 10 R 11 ;
wherein R 9 is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 12 alkenyl, optionally substituted C 2 -C 12 alkynyl, optionally substituted C 2 -C 12 heteroalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 2 -C 12 heterocycloalkyl, optionally substituted C 6 -C 18 aryl, optionally substituted C 1 -C 18 heteroaryl, SO 3 H, SO 2 NR 10 R 11 , SO 2 R 10 , SONR 10 R 11 , SOR 10 , COR 10 , COOH, COOR 10 , and CONR 10 R 11 ;
wherein each R 10 and R 11 is independently selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 2 -C 10 heteroalkyl, optionally substituted C 1 -C 12 haloalkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl.
In some embodiments Ar is selected from the group consisting of:
wherein R 8 and R 9 is as defined above;
e is an integer selected from the group consisting of 0, 1, 2, 3 and 4;
f is an integer selected the group consisting of 0, 1, 2, and 3.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3a), this provides compounds of formula (IVa):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3b), this provides compounds of formula (IVb):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and f, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3c), this provides compounds of formula (IVc):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3d), this provides compounds of formula (IVd):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 and e, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3e), this provides compounds of formula (IVe):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 and e, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3f), this provides compounds of formula (IVf):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 , R 9 and e, are as defined above.
In some embodiments A is CR a R b , B is CH 2 and Ar is a group of formula (3 g), this provides compounds of formula (IVg):
wherein R 1 , R 1α , R a , R b , R 2 , R 8 , and e, are as defined above.
In some embodiments e is 1. In some embodiments e is 2. In some embodiments e is 3. In some embodiments e is 4. In circumstances where e is 1 the R 8 group may be located at either the 4, 5, 6, or 7 position on the six membered ring. In some embodiments where e is 1 the R 8 substituent is located at the 4 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 5 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 6 position on the ring. In some embodiments where e is 1 the R 8 substituent is located at the 7 position on the ring.
In some embodiments f is 1. In some embodiments f is 2. In some embodiments f is 3. In some embodiments where f is 1 the R 8 substituent is located at the 4 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 5 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 6 position on the ring. In some embodiments where f is 1 the R 8 substituent is located at the 7 position on the ring.
In some embodiments of the compounds described above each R 1 is independently selected from the group consisting of H, OH, F, Cl, Br, CH 3 , CH 2 CO 2 H, CH 2 CH 2 CO 2 H, CO 2 H, CONH 2 , CH 2 OH, CH 2 NH 2 , CN, OCH 3 , Ocyclopropyl, and OCHF 2 . In some embodiments one R 1 is H and the other R 1 is OH. In some embodiments both R 1 are H.
In some embodiments of the compounds described above each R 1α is independently selected from the group consisting of H, OH, F, Cl, Br, CO 2 H, CONH 2 , CH 2 OH, CN, OCH 3 , and OCHF 2 . In some embodiments one R 1α is H and the other R 1α is OH. In some embodiments both R 1α are H.
In some embodiments each R 2 is independently selected from the group consisting of H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , Cl, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3
In some embodiments a is 0. In some embodiments a is 1. In some embodiments a is 2. In some embodiments a is 3. In some embodiments a is 4. In some embodiments a is 5. In some embodiments a is 6. In some embodiments a is 7. In some embodiments a is 8. In some embodiments a is 9. In some embodiments a is 10.
In some embodiments of the compounds of the invention containing an R 3 group, the R 3 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 3 is H. in some embodiments R 3 is methyl.
In some embodiments of the compounds of the invention containing an R 4 group, the R 4 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 4 is H. in some embodiments R 4 is methyl.
In some embodiments of the compounds of the invention containing an R 5 group, the R 5 group is selected from O and S. In some embodiments R 5 is O. in some embodiments R 5 is S.
In some embodiments of the compounds of the invention containing an R 6 group, the R 6 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 6 is H. in some embodiments R 6 is methyl.
In some embodiments of the compounds of the invention containing an R 7 group, the R 7 group is selected from H and C 1 -C 12 alkyl. In some embodiments R 7 is H. in some embodiments R 7 is methyl.
R 8 may be selected from a wide range of possible substituents as discussed above. In some embodiments each R 8 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 1 -C 12 alkoxyl, and C 1 -C 12 haloalkoxyl. Exemplary R 8 substituents include H, CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , cyclopropyl, I, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH(CH 3 ) 2 , OCH 2 CH 2 CH 3 , OSO 2 CF 3 , CF 3 , and OCF 3 .
R 9 may be selected from a wide range of possible substituents as discussed above. In some embodiments each R 9 is independently selected from the group consisting of H, halogen, OH, NO 2 , CN, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 1 -C 12 alkoxyl, and C 1 -C 12 haloalkoxyl. Exemplary R 9 substituents include CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , CH(CH 3 ) 2 , (CH 2 ) 3 CH 3 , I, Br, F, I, OH, NO 2 , NH 2 , CN, SO 3 H, OCH 3 , OCH 2 CH 2 CH 3 , CF 3 , and OCF 3 .
Many if not all of the variables discussed above may be optionally substituted. If the variable is optionally substituted then in some embodiments each optional substituent is independently selected from the group consisting of halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, cycloalkylalkyl, heterocycloalkylalkyl, heteroarylalkyl, arylalkyl, cycloalkylalkenyl, heterocycloalkylalkenyl, arylalkenyl, heteroarylalkenyl, cycloalkylheteroalkyl, heterocycloalkylheteroalkyl, arylheteroalkyl, heteroarylheteroalkyl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxycycloalkyl, alkyloxyheterocycloalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkyloxycarbonyl, alkylaminocarbonyl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, phenoxy, benzyloxy, heteroaryloxy, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonylamino, sulfinylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, sulfinyl, alkylsulfinyl, arylsulfinyl, aminosulfinylaminoalkyl, —C(═O)OH, —C(═O)R e , —C(═O)OR e , C(═O)NR e R f , C(═NOH)R e , C(═NR e )NR f R g , NR e R f , NR e C(═O)R f , NR e C(═O)OR f , NR e C(═O)NR f R g , NR e C(═NR f )NR g R h , NR e SO 2 R f , —SR e , SO 2 NR e R f , —OR e , OC(═O)NR e R f , OC(═O)R e and acyl,
wherein R e , R f , R g and R h are each independently selected from the group consisting of H, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 10 heteroalkyl, C 3 -C 12 cycloalkyl, C 3 -C 12 cycloalkenyl, C 1 -C 12 heterocycloalkyl, C 1 -C 12 heterocycloalkenyl, C 6 -C 18 aryl, C 1 -C 18 heteroaryl, and acyl, or any two or more of R a , R b , R c and R d , when taken together with the atoms to which they are attached form a heterocyclic ring system with 3 to 12 ring atoms.
In some embodiments each optional substituent is independently selected from the group consisting of: F, Cl, Br, ═O, ═S, —CN, —NO 2 , alkyl, alkenyl, heteroalkyl, haloalkyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, hydroxy, hydroxyalkyl, alkoxy, alkylamino, aminoalkyl, acylamino, phenoxy, alkoxyalkyl, benzyloxy, alkylsulfonyl, arylsulfonyl, aminosulfonyl, —C(O)OR a , COOH, SH, and acyl.
In some embodiments each optional substituent is independently selected from the group consisting of: F, Br, Cl, ═O, ═S, —CN methyl, trifluoro-methyl, ethyl, 2,2,2-trifluoroethyl, isopropyl, propyl, 2-ethyl-propyl, 3,3-dimethyl-propyl, butyl, isobutyl, 3,3-dimethyl-butyl, 2-ethyl-butyl, pentyl, 2-methyl-pentyl, pent-4-enyl, hexyl, heptyl, octyl, phenyl, NH 2 , —NO 2 , phenoxy, hydroxy, methoxy, trifluoro-methoxy, ethoxy, and methylenedioxy.
Alternatively, two optional substituents on the same moiety when taken together may be joined to form a fused cyclic substituent attached to the moiety that is optionally substituted. Accordingly the term optionally substituted includes a fused ring such as a cycloalkyl ring, a heterocycloalkyl ring, an aryl ring or a heteroaryl ring.
In addition to compounds of formula I, the embodiments disclosed are also directed to pharmaceutically acceptable salts, pharmaceutically acceptable N-oxides, pharmaceutically acceptable prodrugs, and pharmaceutically active metabolites of such compounds, and pharmaceutically acceptable salts of such metabolites.
The invention also relates to pharmaceutical compositions including a compound of the invention and a pharmaceutically acceptable carrier, diluent or excipient.
In a further aspect the present invention provides a method of prevention or treatment of a condition in a mammal, the method comprising administering an effective amount of a compound of the invention. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
In yet an even further aspect the invention provides the use of a compound of the invention in the preparation of a medicament for the treatment of a condition in a mammal. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
In yet an even further aspect the invention provides the use of a compound of the invention in the treatment of a condition in a mammal. In one embodiment the condition is a condition that can be treated by inhibition of 11β-HSD1.
In some embodiments the condition is selected from the group consisting of is selected from the group consisting of diabetes, hyperglycemia, low glucose tolerance, hyperinsulinemia, hyperlipidemia, hypertriglyceridemia, hypercholesterolemia, dyslipidemia, obesity, abdominal obesity, glaucoma, hypertension, atherosclerosis and its sequelae, retinopathy and other ocular disorders, nephropathy, neuropathy, myopathy, osteoporosis, osteoarthritis, dementia, depression, neurodegenerative disease, psychiatric disorders, Polycystic ovaries syndrome, infertility, Cushing's Disease, Cushing's syndrome, viral diseases, and inflammatory diseases.
In some embodiments the condition is diabetes. In some embodiments the condition is type II diabetes.
In some embodiments the compound is administered in combination with an adjuvant. In some embodiments the adjuvant is selected from the group consisting of dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha.-glucosidase inhibitors; (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists; and combinations thereof.
In one other embodiment the compound is administered as a substitute for monotherapy or combination therapy, in an event of failure of treatment by an agent selected from the group consisting of dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha.-glucosidase inhibitors; (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists; and combinations thereof.
In one embodiment the insulin sensitizing agent is selected from the group consisting of (i) PPAR-gamma-agonists, (ii) PPAR-alpha-agonists, (iii) PPAR-alpha/gamma-dual agonists, (iv) biguanides, and combinations thereof.
These and other teachings of the invention are set forth herein.
DETAILED DESCRIPTION OF THE INVENTION
In this specification a number of terms are used which are well known to a skilled addressee. Nevertheless for the purposes of clarity a number of terms will be defined.
As used herein, the term “unsubstituted” means that there is no substituent or that the only substituents are hydrogen.
The term “optionally substituted” as used throughout the specification denotes that the group may or may not be further substituted or fused (so as to form a condensed polycyclic system), with one or more non-hydrogen substituent groups. In certain embodiments the substituent groups are one or more groups independently selected from the group consisting of halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, cycloalkylalkyl, heterocycloalkylalkyl, heteroarylalkyl, arylalkyl, cycloalkylalkenyl, heterocycloalkylalkenyl, arylalkenyl, heteroarylalkenyl, cycloalkylheteroalkyl, heterocycloalkylheteroalkyl, arylheteroalkyl, heteroarylheteroalkyl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxycycloalkyl, alkyloxyheterocycloalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkyloxycarbonyl, alkylaminocarbonyl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, phenoxy, benzyloxy, heteroaryloxy, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonylamino, sulfinylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, sulfinyl, alkylsulfinyl, arylsulfinyl, aminosulfinylaminoalkyl, —C(═O)OH, —C(═O)R e , —C(═O)OR e , C(═O)NR e R f , C(═NOH)R e , C(═NR e )NR f R g , NR e R f , NR e C(═O)R f , NR e C(═O)OR f , NR e C(═O)NR f R g , NR e C(═NR f )NR g R h , NR e SO 2 R f , —SR e , SO 2 NR e R f , —OR e , OC(═O)NR e R f , OC(═O)R e and acyl,
wherein R e , R f , R g and R h are each independently selected from the group consisting of H, C 1 -C 12 alkyl, C 1 -C 12 haloalkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 10 heteroalkyl, C 3 -C 12 cycloalkyl, C 3 -C 12 cycloalkenyl, C 1 -C 12 heterocycloalkyl, C 1 -C 12 heterocycloalkenyl, C 6 -C 18 aryl, C 1 -C 18 heteroaryl, and acyl, or any two or more of R a , R b , R c and R d , when taken together with the atoms to which they are attached form a heterocyclic ring system with 3 to 12 ring atoms.
In some embodiments each optional substituent is independently selected from the group consisting of: halogen, ═O, ═S, —CN, —NO 2 , —CF 3 , —OCF 3 , alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, heteroalkyl, cycloalkyl, cycloalkenyl, heterocycloalkyl, heterocycloalkenyl, aryl, heteroaryl, hydroxy, hydroxyalkyl, alkyloxy, alkyloxyalkyl, alkyloxyaryl, alkyloxyheteroaryl, alkenyloxy, alkynyloxy, cycloalkyloxy, cycloalkenyloxy, heterocycloalkyloxy, heterocycloalkenyloxy, aryloxy, heteroaryloxy, arylalkyl, heteroarylalkyl, arylalkyloxy, amino, alkylamino, acylamino, aminoalkyl, arylamino, sulfonyl, alkylsulfonyl, arylsulfonyl, aminosulfonyl, aminoalkyl, —COOH, —SH, and acyl.
Examples of particularly suitable optional substituents include F, Cl, Br, I, CH 3 , CH 2 CH 3 , OH, OCH 3 , CF 3 , OCF 3 , NO 2 , NH 2 , and CN.
In the definitions of a number of substituents below it is stated that “the group may be a terminal group or a bridging group”. This is intended to signify that the use of the term is intended to encompass the situation where the group is a linker between two other portions of the molecule as well as where it is a terminal moiety. Using the term alkyl as an example, some publications would use the term “alkylene” for a bridging group and hence in these other publications there is a distinction between the terms “alkyl” (terminal group) and “alkylene” (bridging group). In the present application no such distinction is made and most groups may be either a bridging group or a terminal group.
“Acyl” means an R—C(═O)— group in which the R group may be an alkyl, cycloalkyl, heterocycloalkyl, aryl or heteroaryl group as defined herein. Examples of acyl include acetyl and benzoyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
“Acylamino” means an R—C(═O)—NH— group in which the R group may be an alkyl, cycloalkyl, heterocycloalkyl, aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
“Alkenyl” as a group or part of a group denotes an aliphatic hydrocarbon group containing at least one carbon-carbon double bond and which may be straight or branched preferably having 2-12 carbon atoms, more preferably 2-10 carbon atoms, most preferably 2-6 carbon atoms, in the normal chain. The group may contain a plurality of double bonds in the normal chain and the orientation about each is independently E or Z. The alkenyl group is preferably a 1-alkenyl group. Exemplary alkenyl groups include, but are not limited to, ethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl and nonenyl. The group may be a terminal group or a bridging group.
“Alkenyloxy” refers to an alkenyl-O— group in which alkenyl is as defined herein. Preferred alkenyloxy groups are C 1 -C 6 alkenyloxy groups. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Alkyl” as a group or part of a group refers to a straight or branched aliphatic hydrocarbon group, preferably a C 1 -C 12 alkyl, more preferably a C 1 -C 10 alkyl, most preferably C 1 -C 6 unless otherwise noted. Examples of suitable straight and branched C 1 -C 6 alkyl substituents include methyl, ethyl, n-propyl, 2-propyl, n-butyl, sec-butyl, t-butyl, hexyl, and the like. The group may be a terminal group or a bridging group.
“Alkylamino” includes both mono-alkylamino and dialkylamino, unless specified. “Mono-alkylamino” means an Alkyl-NH— group, in which alkyl is as defined herein. “Dialkylamino” means a (alkyl) 2 N— group, in which each alkyl may be the same or different and are each as defined herein for alkyl. The alkyl group is preferably a C 1 -C 6 alkyl group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
“Alkylaminocarbonyl” refers to a group of the formula (Alkyl) x (H) y NC(═O)— in which alkyl is as defined herein, x is 1 or 2, and the sum of X+Y=2. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
“Alkyloxy” refers to an alkyl-O— group in which alkyl is as defined herein. Preferably the alkyloxy is a C 1 -C 6 alkyloxy. Examples include, but are not limited to, methoxy and ethoxy. The group may be a terminal group or a bridging group.
“Alkyloxyalkyl” refers to an alkyloxy-alkyl- group in which the alkyloxy and alkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Alkyloxyaryl” refers to an alkyloxy-aryl- group in which the alkyloxy and aryl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the aryl group.
“Alkyloxycarbonyl” refers to an alkyl-O—C(═O)— group in which alkyl is as defined herein. The alkyl group is preferably a C 1 -C 6 alkyl group. Examples include, but are not limited to, methoxycarbonyl and ethoxycarbonyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the carbonyl carbon.
“Alkyloxycycloalkyl” refers to an alkyloxy-cycloalkyl- group in which the alkyloxy and cycloalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the cycloalkyl group.
“Alkyloxyheteroaryl” refers to an alkyloxy-heteroaryl- group in which the alkyloxy and heteroaryl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroaryl group.
“Alkyloxyheterocycloalkyl” refers to an alkyloxy-heterocycloalkyl- group in which the alkyloxy and heterocycloalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heterocycloalkyl group.
“Alkylsulfinyl” means an alkyl-S—(═O)— group in which alkyl is as defined herein. The alkyl group is preferably a C 1 -C 6 alkyl group. Exemplary alkylsulfinyl groups include, but not limited to, methylsulfinyl and ethylsulfinyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
“Alkylsulfonyl” refers to an alkyl-S(═O) 2 — group in which alkyl is as defined above. The alkyl group is preferably a C 1 -C 6 alkyl group. Examples include, but not limited to methylsulfonyl and ethylsulfonyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
“Alkynyl” as a group or part of a group means an aliphatic hydrocarbon group containing a carbon-carbon triple bond and which may be straight or branched preferably having from 2-12 carbon atoms, more preferably 2-10 carbon atoms, more preferably 2-6 carbon atoms in the normal chain. Exemplary structures include, but are not limited to, ethynyl and propynyl. The group may be a terminal group or a bridging group.
“Alkynyloxy” refers to an alkynyl-O— group in which alkynyl is as defined herein. Preferred alkynyloxy groups are C 1 -C 6 alkynyloxy groups. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Aminoalkyl” means an NH 2 -alkyl- group in which the alkyl group is as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Aminosulfonyl” means an NH 2 —S(═O) 2 — group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
“Aryl” as a group or part of a group denotes (i) an optionally substituted monocyclic, or fused polycyclic, aromatic carbocycle (ring structure having ring atoms that are all carbon) preferably having from 5 to 12 atoms per ring. Examples of aryl groups include phenyl, naphthyl, and the like; (ii) an optionally substituted partially saturated bicyclic aromatic carbocyclic moiety in which a phenyl and a C 5-7 cycloalkyl or C 5-7 cycloalkenyl group are fused together to form a cyclic structure, such as tetrahydronaphthyl, indenyl or indanyl. The group may be a terminal group or a bridging group. Typically an aryl group is a C 6 -C 18 aryl group.
“Arylalkenyl” means an aryl-alkenyl- group in which the aryl and alkenyl are as defined herein. Exemplary arylalkenyl groups include phenylallyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
“Arylalkyl” means an aryl-alkyl- group in which the aryl and alkyl moieties are as defined herein. Preferred arylalkyl groups contain a C 1-5 alkyl moiety. Exemplary arylalkyl groups include benzyl, phenethyl, 1-naphthalenemethyl and 2-naphthalenemethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Arylalkyloxy” refers to an aryl-alkyl-O— group in which the alkyl and aryl are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Arylamino” includes both mono-arylamino and di-arylamino unless specified. Mono-arylamino means a group of formula arylNH—, in which aryl is as defined herein. Di-arylamino means a group of formula (aryl) 2 N— where each aryl may be the same or different and are each as defined herein for aryl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
“Arylheteroalkyl” means an aryl-heteroalkyl- group in which the aryl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
“Aryloxy” refers to an aryl-O— group in which the aryl is as defined herein. Preferably the aryloxy is a C 6 -C 18 aryloxy, more preferably a C 6 -C 10 aryloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Arylsulfonyl” means an aryl-S(═O) 2 — group in which the aryl group is as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
A “bond” is a linkage between atoms in a compound or molecule. The bond may be a single bond, a double bond, or a triple bond.
“Cycloalkenyl” means a non-aromatic monocyclic or multicyclic ring system containing at least one carbon-carbon double bond and preferably having from 5-10 carbon atoms per ring. Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl. The cycloalkenyl group may be substituted by one or more substituent groups. A cycloalkenyl group typically is a C 3 -C 12 alkenyl group. The group may be a terminal group or a bridging group.
“Cycloalkyl” refers to a saturated monocyclic or fused or spiro polycyclic, carbocycle preferably containing from 3 to 9 carbons per ring, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like, unless otherwise specified. It includes monocyclic systems such as cyclopropyl and cyclohexyl, bicyclic systems such as decalin, and polycyclic systems such as adamantane. A cycloalkyl group typically is a C 3 -C 12 alkyl group. The group may be a terminal group or a bridging group.
“Cycloalkylalkyl” means a cycloalkyl-alkyl- group in which the cycloalkyl and alkyl moieties are as defined herein. Exemplary monocycloalkylalkyl groups include cyclopropylmethyl, cyclopentylmethyl, cyclohexylmethyl and cycloheptylmethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Cycloalkylalkenyl” means a cycloalkyl-alkenyl- group in which the cycloalkyl and alkenyl moieties are as defined herein. The group, may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
“Cycloalkylheteroalkyl” means a cycloalkyl-heteroalkyl- group in which the cycloalkyl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
“Cycloalkyloxy” refers to a cycloalkyl-O— group in which cycloalkyl is as defined herein. Preferably the cycloalkyloxy is a C 1 -C 6 cycloalkyloxy. Examples include, but are not limited to, cyclopropanoxy and cyclobutanoxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Cycloalkenyloxy” refers to a cycloalkenyl-O— group in which the cycloalkenyl is as defined herein. Preferably the cycloalkenyloxy is a C 1 -C 6 cycloalkenyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
Failure of treatment can be defined as condition in which a non-fasting blood glucose level of less than 200 mg/dl and a blood glucose level during fasting (deprived of food for at least 8 hr) of less than 126 mg/dl are retained after administration of the agent in its recommended dose.
“Haloalkyl” refers to an alkyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom selected from the group consisting of fluorine, chlorine, bromine and iodine. A haloalkyl group typically has the formula C n H (2n+1-m) X m wherein each X is independently selected from the group consisting of F, Cl, Br and I. In groups of this type n is typically from 1 to 10, more preferably from 1 to 6, most preferably 1 to 3. m is typically 1 to 6, more preferably 1 to 3. Examples of haloalkyl include fluoromethyl, difluoromethyl and trifluoromethyl.
“Haloalkenyl” refers to an alkenyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom independently selected from the group consisting of F, Cl, Br and I.
“Haloalkynyl” refers to an alkynyl group as defined herein in which one or more of the hydrogen atoms has been replaced with a halogen atom independently selected from the group consisting of F, Cl, Br and I.
“Halogen” represents chlorine, fluorine, bromine or iodine.
“Heteroalkyl” refers to a straight- or branched-chain alkyl group preferably having from 2 to 12 carbons, more preferably 2 to 6 carbons in the chain, in which one or more of the carbon atoms (and any associated hydrogen atoms) are each independently replaced by a heteroatomic group selected from S, O, P and NR′ where R′ is selected from the group consisting of H, optionally substituted C 1 -C 12 alkyl, optionally substituted C 3 -C 12 cycloalkyl, optionally substituted C 6 -C 18 aryl, and optionally substituted C 1 -C 18 heteroaryl. Exemplary heteroalkyls include alkyl ethers, secondary and tertiary alkyl amines, amides, alkyl sulfides, and the like. Examples of heteroalkyl also include hydroxyC 1 -C 6 alkyl, C 1 -C 6 alkyloxyC 1 -C 6 alkyl, aminoC 1 -C 6 alkyl, C 1 -C 6 alkylaminoC 1 -C 6 alkyl, and di(C 1 -C 6 alkyl)aminoC 1 -C 6 alkyl. The group may be a terminal group or a bridging group.
“Heteroalkyloxy” refers to a heteroalkyl-O— group in which heteroalkyl is as defined herein. Preferably the heteroalkyloxy is a C 2 -C 6 heteroalkyloxy. The group may be a terminal group or a bridging group.
“Heteroaryl” either alone or part of a group refers to groups containing an aromatic ring (preferably a 5 or 6 membered aromatic ring) having one or more heteroatoms as ring atoms in the aromatic ring with the remainder of the ring atoms being carbon atoms. Suitable heteroatoms include nitrogen, oxygen and sulphur. Examples of heteroaryl include thiophene, benzothiophene, benzofuran, benzimidazole, benzoxazole, benzothiazole, benzisothiazole, naphtho[2,3-b]thiophene, furan, isoindolizine, xantholene, phenoxatine, pyrrole, imidazole, pyrazole, pyridine, pyrazine, pyrimidine, pyridazine, tetrazole, indole, isoindole, 1H-indazole, purine, quinoline, isoquinoline, phthalazine, naphthyridine, quinoxaline, cinnoline, carbazole, phenanthridine, acridine, phenazine, thiazole, isothiazole, phenothiazine, oxazole, isooxazole, furazane, phenoxazine, 2-, 3- or 4-pyridyl, 2-, 3-, 4-, 5-, or 8-quinolyl, 1-, 3-, 4-, or 5-isoquinolinyl 1-, 2-, or 3-indolyl, and 2-, or 3-thienyl. A heteroaryl group is typically a C 1 -C 18 heteroaryl group. The group may be a terminal group or a bridging group.
“Heteroarylalkyl” means a heteroaryl-alkyl group in which the heteroaryl and alkyl moieties are as defined herein. Preferred heteroarylalkyl groups contain a lower alkyl moiety. Exemplary heteroarylalkyl groups include pyridylmethyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Heteroarylalkenyl” means a heteroaryl-alkenyl- group in which the heteroaryl and alkenyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
“Heteroarylheteroalkyl” means a heteroaryl-heteroalkyl- group in which the heteroaryl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
“Heteroaryloxy” refers to a heteroaryl-O— group in which the heteroaryl is as defined herein. Preferably the heteroaryloxy is a C 1 -C 18 heteroaryloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Heterocyclic” refers to saturated, partially unsaturated or fully unsaturated monocyclic, bicyclic or polycyclic ring system containing at least one heteroatom selected from the group consisting of nitrogen, sulfur and oxygen as a ring atom. Examples of heterocyclic moieties include heterocycloalkyl, heterocycloalkenyl and heteroaryl.
“Heterocycloalkenyl” refers to a heterocycloalkyl group as defined herein but containing at least one double bond. A heterocycloalkenyl group typically is a C 2 -C 12 heterocycloalkenyl group. The group may be a terminal group or a bridging group.
“Heterocycloalkyl” refers to a saturated monocyclic, bicyclic, or polycyclic ring containing at least one heteroatom selected from nitrogen, sulfur, oxygen, preferably from 1 to 3 heteroatoms in at least one ring. Each ring is preferably from 3 to 10 membered, more preferably 4 to 7 membered. Examples of suitable heterocycloalkyl substituents include pyrrolidyl, tetrahydrofuryl, tetrahydrothiofuranyl, piperidyl, piperazyl, tetrahydropyranyl, morphilino, 1,3-diazapane, 1,4-diazapane, 1,4-oxazepane, and 1,4-oxathiapane. A heterocycloalkyl group typically is a C 2 -C 12 heterocycloalkyl group. The group may be a terminal group or a bridging group.
“Heterocycloalkylalkyl” refers to a heterocycloalkyl-alkyl- group in which the heterocycloalkyl and alkyl moieties are as defined herein. Exemplary heterocycloalkylalkyl groups include (2-tetrahydrofuryl)methyl, (2-tetrahydrothiofuranyl)methyl. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkyl group.
“Heterocycloalkylalkenyl” refers to a heterocycloalkyl-alkenyl- group in which the heterocycloalkyl and alkenyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the alkenyl group.
“Heterocycloalkylheteroalkyl” means a heterocycloalkyl-heteroalkyl- group in which the heterocycloalkyl and heteroalkyl moieties are as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the heteroalkyl group.
“Heterocycloalkyloxy” refers to a heterocycloalkyl-O— group in which the heterocycloalkyl is as defined herein. Preferably the heterocycloalkyloxy is a C 1 -C 6 heterocycloalkyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Heterocycloalkenyloxy” refers to a heterocycloalkenyl-O— group in which heterocycloalkenyl is as defined herein. Preferably the Heterocycloalkenyloxy is a C 1 -C 6 heterocycloalkenyloxy. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the oxygen atom.
“Hydroxyalkyl” refers to an alkyl group as defined herein in which one or more of the hydrogen atoms has been replaced with an OH group. A hydroxyalkyl group typically has the formula C n H (2n+1-x) (OH) x . In groups of this type n is typically from 1 to 10, more preferably from 1 to 6, most preferably 1 to 3. x is typically 1 to 6, more preferably 1 to 3.
“Sulfinyl” means an R—S(═O)— group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
“Sulfinylamino” means an R—S(═O)—NH— group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
“Sulfonyl” means an R—S(═O) 2 — group in which the R group may be OH, alkyl, cycloalkyl, heterocycloalkyl; aryl or heteroaryl group as defined herein. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the sulfur atom.
“Sulfonylamino” means an R—S(═O) 2 —NH— group. The group may be a terminal group or a bridging group. If the group is a terminal group it is bonded to the remainder of the molecule through the nitrogen atom.
It is understood that included in the family of compounds of Formula (I) are isomeric forms including diastereoisomers, enantiomers, tautomers, and geometrical isomers in “E” or “Z” configurational isomer or a mixture of E and Z isomers. It is also understood that some isomeric forms such as diastereomers, enantiomers, and geometrical isomers can be separated by physical and/or chemical methods and by those skilled in the art. For those compounds where there is the possibility of geometric isomerism the applicant has drawn the isomer that the compound is thought to be although it will be appreciated that the other isomer may be the correct structural assignment.
Some of the compounds of the disclosed embodiments may exist as single stereoisomers, racemates, and/or mixtures of enantiomers and/or diastereomers. All such single stereoisomers, racemates and mixtures thereof, are intended to be within the scope of the subject matter described and claimed.
Additionally, Formula (I) is intended to cover, where applicable, solvated as well as unsolvated forms of the compounds. Thus, each formula includes compounds having the indicated structure, including the hydrated as well as the non-hydrated forms.
The term “pharmaceutically acceptable salts” refers to salts that retain the desired biological activity of the above-identified compounds, and include pharmaceutically acceptable acid addition salts and base addition salts. Suitable pharmaceutically acceptable acid addition salts of compounds of Formula (I) may be prepared from an inorganic acid or from an organic acid. Examples of such inorganic acids are hydrochloric, sulfuric, and phosphoric acid. Appropriate organic acids may be selected from aliphatic, cycloaliphatic, aromatic, heterocyclic carboxylic and sulfonic classes of organic acids, examples of which are formic, acetic, propanoic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, fumaric, maleic, alkyl sulfonic, arylsulfonic. Additional information on pharmaceutically acceptable salts can be found in Remington's Pharmaceutical Sciences, 19th Edition, Mack Publishing Co., Easton, Pa. 1995. In the case of agents that are solids, it is understood by those skilled in the art that the inventive compounds, agents and salts may exist in different crystalline or polymorphic forms, all of which are intended to be within the scope of the present invention and specified formulae.
“Prodrug” means a compound that undergoes conversion to a compound of formula (I) within a biological system, usually by metabolic means (e.g. by hydrolysis, reduction or oxidation). For example an ester prodrug of a compound of formula (I) containing a hydroxyl group may be convertible by hydrolysis in vivo to the parent molecule. Suitable esters of compounds of formula (I) containing a hydroxyl group, are for example acetates, citrates, lactates, tartrates, malonates, oxalates, salicylates, propionates, succinates, fumarates, maleates, methylene-bis-β-hydroxynaphthoates, gestisates, isethionates, di-p-toluoyltartrates, methanesulphonates, ethanesulphonates, benzenesulphonates, p-toluenesulphonates, cyclohexylsulphamates and quinates. As another example an ester prodrug of a compound of formula (I) containing a carboxy group may be convertible by hydrolysis in vivo to the parent molecule. (Examples of ester prodrugs are those described by F. J. Leinweber, Drug Metab. Res., 18:379, 1987). Similarly, an acyl prodrug of a compound of formula (I) containing an amino group may be convertible by hydrolysis in vivo to the parent molecule (Many examples of prodrugs for these and other functional groups, including amines, are described in Prodrugs: Challenges and Rewards (Parts 1 and 2); Ed V. Stella, R. Borchardt, M. Hageman, R. Oliyai, H. Maag and J Tilley; Springer, 2007).
The term “therapeutically effective amount” or “effective amount” is an amount sufficient to effect beneficial or desired clinical results. An effective amount can be administered in one or more administrations. An effective amount is typically sufficient to palliate, ameliorate, stabilize, reverse, slow or delay the progression of the disease state.
Specific compounds of the invention include the following:
or pharmaceutically acceptable salt, isomer or prodrug thereof.
The compounds have the ability to inhibit 11β-HSD1. The ability to inhibit 11β-HSD1 may be a result of the compounds acting directly and solely on the 11β-HSD1 to modulate/potentiate biological activity. However, it is understood that the compounds may also act at least partially on other factors associated with 11β-HSD1 activity.
The inhibition of 11β-HSD1 may be carried out in any of a number of ways known in the art. For example if inhibition of 11β-HSD1 in vitro is desired an appropriate amount of the compound may be added to a solution containing the 11β-HSD1. In circumstances where it is desired to inhibit 11β-HSD1 in a mammal, the inhibition of the 11β-HSD1 typically involves administering the compound to a mammal containing the 11β-HSD1.
Accordingly the compounds may find a multiple number of applications in which their ability to inhibit 11β-HSD1 enzyme of the type mentioned above can be utilised.
Accordingly compounds of the invention would be expected to have useful therapeutic properties especially in relation to diabetes, hyperglycemia, low glucose tolerance, hyperinsulinemia, hyperlipidemia, hypertriglyceridemia, hypercholesterolemia, dyslipidemia, obesity, abdominal obesity, glaucoma, hypertension, atherosclerosis and its sequelae, retinopathy, nephropathy, neuropathy, osteoporosis, osteoarthritis, dementia, depression, neurodegenerative disease, psychiatric disorders, Cushing's Disease, Cushing's syndrome, virus diseases, and inflammatory diseases.
Administration of compounds within Formula (I) to humans can be by any of the accepted modes for enteral administration such, as oral or rectal, or by parenteral administration such as subcutaneous, intramuscular, intravenous and intradermal routes. Injection can be bolus or via constant or intermittent infusion. The active compound is typically included in a pharmaceutically acceptable carrier or diluent and in an amount sufficient to deliver to the patient a therapeutically effective dose. In various embodiments the activator compound may be selectively toxic or more toxic to rapidly proliferating cells, e.g. cancerous tumours, than to normal cells.
In using the compounds of the invention they can be administered in any form or mode which makes the compound bioavailable. One skilled in the art of preparing formulations can readily select the proper form and mode of administration depending upon the particular characteristics of the compound selected, the condition to be treated, the stage of the condition to be treated and other relevant circumstances. We refer the reader to Remingtons Pharmaceutical Sciences, 19 th edition, Mack Publishing Co. (1995) for further information.
The compounds of the present invention can be administered alone or in the form of a pharmaceutical composition in combination with a pharmaceutically acceptable carrier, diluent or excipient. The compounds of the invention, while effective themselves, are typically formulated and administered in the form of their pharmaceutically acceptable salts as these forms are typically more stable, more easily crystallised and have increased solubility.
The compounds are, however, typically used in the form of pharmaceutical compositions which are formulated depending on the desired mode of administration. As such in some embodiments the present invention provides a pharmaceutical composition including a compound of Formula (I) and a pharmaceutically acceptable carrier, diluent or excipient. The compositions are prepared in manners well known in the art.
The invention in other embodiments provides a pharmaceutical pack or kit comprising one or more containers filled with one or more of the ingredients of the pharmaceutical compositions of the invention. In such a pack or kit can be found a container having a unit dosage of the agent(s). The kits can include a composition comprising an effective agent either as concentrates (including lyophilized compositions), which can be diluted further prior to use or they can be provided at the concentration of use, where the vials may include one or more dosages. Conveniently, in the kits, single dosages can be provided in sterile vials so that the physician can employ the vials directly, where the vials will have the desired amount and concentration of agent(s). Associated with such container(s) can be various written materials such as instructions for use, or a notice in the form prescribed by a governmental agency regulating the manufacture, use or sale of pharmaceuticals or biological products, which notice reflects approval by the agency of manufacture, use or sale for human administration.
The compounds of the invention may be used or administered in combination with one or more additional drug(s) for the treatment of the disorder/diseases mentioned. The components can be administered in the same formulation or in separate formulations. If administered in separate formulations the compounds of the invention may be administered sequentially or simultaneously with the other drug(s).
In addition to being able to be administered in combination with one or more additional drugs, the compounds of the invention may be used in a combination therapy. When this is done the compounds are typically administered in combination with each other. Thus one or more of the compounds of the invention may be administered either simultaneously (as a combined preparation) or sequentially in order to achieve a desired effect. This is especially desirable where the therapeutic profile of each compound is different such that the combined effect of the two drugs provides an improved therapeutic result.
Pharmaceutical compositions of this invention for parenteral injection comprise pharmaceutically acceptable sterile aqueous or nonaqueous solutions, dispersions, suspensions or emulsions as well as sterile powders for reconstitution into sterile injectable solutions or dispersions just prior to use. Examples of suitable aqueous and nonaqueous carriers, diluents, solvents or vehicles include water, ethanol, polyols (such as glycerol, propylene glycol, polyethylene glycol, and the like), and suitable mixtures thereof, vegetable oils (such as olive oil), and injectable organic esters such as ethyl oleate. Proper fluidity can be maintained, for example, by the use of coating materials such as lecithin, by the maintenance of the required particle size in the case of dispersions, and by the use of surfactants.
These compositions may also contain adjuvants such as preservative, wetting agents, emulsifying agents, and dispersing agents. Prevention of the action of micro-organisms may be ensured by the inclusion of various antibacterial and antifungal agents, for example, paraben, chlorobutanol, phenol sorbic acid, and the like. It may also be desirable to include isotonic agents such as sugars, sodium chloride, and the like. Prolonged absorption of the injectable pharmaceutical form may be brought about by the inclusion of agents that delay absorption such as aluminium monostearate and gelatin.
If desired, and for more effective distribution, the compounds can be incorporated into slow release or targeted delivery systems such as polymer matrices, liposomes, and microspheres.
The injectable formulations can be sterilized, for example, by filtration through a bacterial-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions that can be dissolved or dispersed in sterile water or other sterile injectable medium just prior to use.
Solid dosage forms for oral administration include capsules, tablets, pills, powders, and granules. In such solid dosage forms, the active compound is mixed with at least one inert, pharmaceutically acceptable excipient or carrier such as sodium citrate or dicalcium phosphate and/or a) fillers or extenders such as starches, lactose, sucrose, glucose, mannitol, and silicic acid, b) binders such as, for example, carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidone, sucrose, and acacia, c) humectants such as glycerol, d) disintegrating agents such as agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate, e) solution retarding agents such as paraffin, f) absorption accelerators such as quaternary ammonium compounds, g) wetting agents such as, for example, cetyl alcohol and glycerol monostearate, h) absorbents such as kaolin and bentonite clay, and i) lubricants such as talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof. In the case of capsules, tablets and pills, the dosage form may also comprise buffering agents.
Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like.
The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings and other coatings well known in the pharmaceutical formulating art. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner. Examples of embedding compositions which can be used include polymeric substances and waxes.
The active compounds can also be in microencapsulated form, if appropriate, with one or more of the above-mentioned excipients.
Liquid dosage forms for oral administration include pharmaceutically acceptable emulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art such as, for example, water or other solvents, solubilizing agents and emulsifiers such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethyl formamide, oils (in particular, cottonseed, groundnut, corn, germ, olive, castor, and sesame oils), glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof.
Besides inert diluents, the oral compositions can also include adjuvants such as wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents.
Suspensions, in addition to the active compounds, may contain suspending agents as, for example, ethoxylated isostearyl alcohols, polyoxyethylene sorbitol and sorbitan esters, microcrystalline cellulose, aluminium metahydroxide, bentonite, agar-agar, and tragacanth, and mixtures thereof.
Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of this invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at room temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
Dosage forms for topical administration of a compound of this invention include powders, patches, sprays, ointments and inhalants. The active compound is mixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives, buffers, or propellants which may be required.
The amount of compound administered will preferably treat and reduce or alleviate the condition. A therapeutically effective amount can be readily determined by an attending diagnostician by the use of conventional techniques and by observing results obtained under analogous circumstances. In determining the therapeutically effective amount a number of factors are to be considered including but not limited to, the species of animal, its size, age and general health, the specific condition involved, the severity of the condition, the response of the patient to treatment, the particular compound administered, the mode of administration, the bioavailability of the preparation administered, the dose regime selected, the use of other medications and other relevant circumstances.
A preferred dosage will be a range from about 0.01 to 300 mg per kilogram of body weight per day. A more preferred dosage will be in the range from 0.1 to 100 mg per kilogram of body weight per day, more preferably from 0.2 to 80 mg per kilogram of body weight per day, even more preferably 0.2 to 50 mg per kilogram of body weight per day. A suitable dose can be administered in multiple sub-doses per day.
The compound of the invention may also be administered in combination with (or simultaneously or sequentially with) an adjuvant to increase compound performance. Suitable adjuvants may include (a) dipeptidyl peptidase-IV (DP-IV) inhibitors; (b) insulin sensitizing agents; (iv) biguanides; (c) insulin and insulin mimetics; (d) sulfonylureas and other insulin secretagogues; (e) alpha-glucosidase inhibitors; and (f) GLP-1, GLP-1 analogs, and GLP-1 receptor agonists. The adjuvants may be part of the same composition, or the adjuvants may be administered separately (either simultaneously or sequentially). The order of the administration of the composition and the adjuvant will generally known to the medical practitioner involved and may be varied.
Synthesis of Compounds of the Invention
The agents of the various embodiments may be prepared using the reaction routes and synthesis schemes as described below, employing the techniques available in the art using starting materials that are readily available. The preparation of particular compounds of the embodiments is described in detail in the following examples, but the artisan will recognize that the chemical reactions described may be readily adapted to prepare a number of other agents of the various embodiments. For example, the synthesis of non-exemplified compounds may be successfully performed by modifications apparent to those skilled in the art, e.g. by appropriately protecting interfering groups, by changing to other suitable reagents known in the art, or by making routine modifications of reaction conditions. A list of suitable protecting groups in organic synthesis can be found in T. W. Greene's Protective Groups in Organic Synthesis, 3 rd Edition, John Wiley & Sons, 1991. Alternatively, other reactions disclosed herein or known in the art will be recognized as having applicability for preparing other compounds of the various embodiments.
Reagents useful for synthesizing compounds may be obtained or prepared according to techniques known in the art.
The symbols, abbreviations and conventions in the processes, schemes, and examples are consistent with those used in the contemporary scientific literature. Specifically but not meant as limiting, the following abbreviations may be used in the examples and throughout the specification.
g (grams) L (liters) Hz (Hertz) mol (moles) RT (room temperature) min (minutes) MeOH (methanol) CHCl 3 (chloroform) DCM (dichloromethane) DMSO (dimethylsulfoxide) EtOAc (ethyl acetate) mg (milligrams) mL (milliliters) psi (pounds per square inch) mM (millimolar) MHz (megahertz) h (hours) TLC (thin layer chromatography) EtOH (ethanol) CDCl 3 (deuterated chloroform) HCl (hydrochloric acid) DMF (N,N-dimethylformamide) THF (tetrahydrofuran) K 2 CO 3 (potassium carbonate) Na 2 SO 4 (sodium sulfate) RM (Reaction Mixture)
Unless otherwise indicated, all temperatures are expressed in ° C. (degree centigrade). All reactions conducted at room temperature unless otherwise mentioned.
All the solvents and reagents used are commercially available and purchased from Sigma Aldrich, Fluka, Acros, Spectrochem, Alfa Aesar, Avra, Qualigens, Merck, Rankem and Leonid Chemicals.
1 H NMR spectra were recorded on a Bruker AV 300. Chemical shifts are expressed in parts per million (ppm, δ units). Coupling constants are in units of hertz (Hz). Splitting patterns describe apparent multiplicities and are designated as s (singlet), d (doublet), t (triplet), q (quartet), m (multiplet), or br (broad).
Mass spectra were obtained on single quadruple 6120 LCMS from Agilent technologies, using either atmospheric chemical ionization (APCI) or Electrospray ionization (ESI) or in the combination of these two sources.
All samples were run on SHIMADZU system with an LC-20 AD pump, SPD-M20A diode array detector, SIL-20A auto sampler.
SYNTHETIC SCHEME 1
One scheme for making certain compounds of the invention is shown in scheme 1 below.
Synthesis of 4-oxotricyclo[3.3.1.1 3,7 ]dec-2-yl methanesulfonate (Intermediate-1)
A 1000 mL RB flask fitted with magnetic stirrer was charged with methanesulfonic acid (416.0 g, 4328.8 mmol) and Starting Material-1 (50.0 g, 333 mmol). To this sodium azide (23.0 g, 351 mmol) was added portion wise for 2 hours. Then reaction mixture was stirred at 20-25° C. for 3 days. Upon completion of the reaction (reaction monitored by TLC), reaction mixture was quenched with ice-water (3000 mL) and extracted with ethyl acetate (1000×3 mL). The organic layer was washed with brine solution, dried over anhydrous sodium sulfate and concentrated to give title Intermediate-1 (54.0 g, yield=66%).
Synthesis of bicyclo[3.3.1]non-6-ene-3-carboxylic acid (Intermediate-2)
A 2000 mL RB flask fitted with magnetic stirrer was charged with 1200 mL of ethanol and Intermediate-1 (54.0 g, 221.3 mmol). Potassium hydroxide (84.0 g, 150 mmol) was further added to this reaction mixture followed by addition of 950 mL of water. The reaction mixture was stirred at 110° C. for 12 hours. After completion of the reaction (reaction was monitored by TLC), reaction mixture was concentrated under vacuum. The resulted crude material was acidified with 1N HCl (pH=2) and extracted with ethyl acetate (250×3 mL). The organic layer was washed with brine solution, dried over anhydrous sodium sulfate and concentrated to give Intermediate-2 (32.0 g, yield=88%).
Synthesis of methyl bicyclo[3.3.1]non-6-en-3-ylcarbamate (Intermediate-3)
A 500 mL RB flask fitted with magnetic stirrer under nitrogen atmosphere charged with toluene (100 mL), Intermediate-2 (16.0 g, 96 mmol) and DPPA (28.8 g, 105 mmol). Reaction mixture was cooled to 0° C., and then triethylamine (15.4 g, 143.9 mmol) was added. The reaction mixture was stirred at room temperature for 1 hour. Then reaction mixture was heated at 80° C. for 8 h and 12 h at room temperature. To this 100 mL of methanol was added and refluxed for 12 hours. After the reaction, it was concentrated under vacuum. Obtained Crude was extracted with ethyl acetate. The organic layer was washed with 1N HCl, Saturated NaHCO 3 solution, brine solution and was then dried over anhydrous sodium sulfate and concentrated. Crude material was purified by silica gel column chromatography eluting with 6% of EtOAc in to give Intermediate-3 (8.0 g, yield=42%).
Synthesis of methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-4)
A 100 mL RB flask fitted with magnetic stirrer was charged with 50 mL of dichloromethane and Intermediate-4 (5.0 g, 25.6 mmol). To this reaction mixture, triflouromethane sulfonic acid (19.2 g, 125.2 mmol) was added at 0° C. The reaction mixture was then stirred at room temperature for 12 hours. After completion of reaction, the reaction mixture was quenched with water and extracted with dichloromethane. The organic layer was washed with saturated sodium bicarbonate solution, brine solution and the reaction mass was dried over anhydrous sodium sulfate and was concentrated to give Intermediate-4 (4.3 g, yield=86%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane (Intermediate-5)
A 50 mL pressurized seal tube fitted with magnetic stirrer was charged with Intermediate-4 (3.0 g, 15 mmol) in HCl containing 1,4-Dioxane (20 mL). Then the reaction mixture was stirred at 90° C. for 8 hours. After completion of the reaction (reaction was monitored by LCMS) it was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-5 (3.0 g, yield=100%).
Synthesis of tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-6)
A 250 mL RB fitted with magnetic stirrer was charged with Intermediate 5 (3.0 g, 21.6 mmol), concentrated nitric acid (30 mL), and H 2 SO 4 (5 mL). The reaction mixture was stirred at 80° C. for 12 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was quenched with water and basified with sodium carbonate. The aqueous layer was washed with DCM (100 mL) and resulting aqueous layer was diluted with THF (200 mL) and cooled to 0° C. The pH of the mixture was adjusted to basic using Triethyl amine (5 mL). To this reaction mixture Boc-anhydride (6.0 g, 27.52 mmol) was added. The resulting mixture was stirred at room temperature for 12 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was extracted with Ethyl acetate (100 mL×3). Combined organic layer was washed with water and brine and the reaction mass was dried over sodium sulfate. Organic layer was concentrated to obtain a crude intermediate which was then purified by silica gel column chromatography eluting with 40% of EtOAc to give Intermediate-6 (2.5 g, yield=50%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decan-5-ol (Intermediate-7)
A 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-6 (5.5 g, 21.5 mmol) in DCM (30 mL). The reaction mixture thus formed was cooled to 0° C. to which trifluoroacetic acid (7.4 g, 65.2 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-7 (3.4 g, yield=100%).
Synthesis of methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylate, intermediate-8
To 2-azatricyclo[3.3.1.1 3,7 ]decan-5-ol (Intermediate-7) (1.5 g, 5.9 mmol, 1 eq), 98% formic acid (9 ml) was added drop wise with vigorous gas evolution for over 30 minutes to a rapidly stirred 30% oleum (36 ml) heated to 60° C. Upon completion of this addition, 99% formic acid (9 ml) was slowly added for the next 30 minutes. The reaction mixture was stirred for another 1 hr at 60° C. (monitored by LCMS). The reaction mixture thus formed was then slowly poured into vigorously stirred methanol (75 ml) cooled to 00° C. The mixture was allowed to slowly warm to room temperature while stirring the reaction mixture for 4-5 hrs. The mixture was then concentrated under vacuum. The residue was poured into ice (30 g) and basified with saturated Na 2 CO 3 solution. The aqueous layer was extracted with 5% methanol in DCM (3×100 ml). Combined organic layer was washed with brine and dried over Na 2 SO 4 . The organic layer was finally concentrated to get intermediate-8, (550 mg, 50% yield) as an oily mass.
Synthesis of 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, intermediate-9
Methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylate, Intermediate-8 (0.32 g, 1.6 mmol) was added into THF (5 mL) and cooled to 0° C. Triethyl amine (1.3 mL) was added to the reaction mixture followed by addition of Boc-anhydride (0.5 g, 1.96 mmol). The resulting mixture was stirred at room temperature for 6 hours. Upon completion of the reaction (reaction was monitored by LC-MS) reaction mixture was extracted with Ethyl acetate (100 mL×3). Combined organic layer was washed with water and brine and was dried over sodium sulfate. Organic layer was concentrated to give crude intermediate-9, which was purified by silica gel column chromatography eluting with 15% of EtOAc to give Intermediate-9 (0.32 g, yield=66%).
Synthesis of 2-(tert-butoxycarbonyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid, Intermediate-10
To a 0° C. cooled stirred solution of 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, intermediate-9 (0.16 g, 0.5 mmol) dissolved in methanol (3 ml), THF (1 ml) and water (1 ml), LiOH (50 mg, 2 mmol) was added and the resulting reaction mass was stirred at room temperature for 6 hrs. Upon completion of the reaction (reaction monitored by TLC), the solvent present in the reaction mixture was completely removed under vacuum and the crude residue was acidified with saturated citric acid solution and extracted with ethyl acetate (3×15 ml). The organic layer was then washed with brine solution and dried over sodium sulfate and was finally concentrated under vacuum to get intermediate-10 as an oily mass, 0.16 g (95%).
Synthesis of tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11
A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of acetonitrile and 2-(tert-butoxycarbonyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid, Intermediate-10 (0.16 g, 0.56 mmol). Under N 2 atm, pyridine (60 mg, 0.6 mmol) and Boc-anhydride (0.148 g, 0.6 mmol) was added to the reaction mixture and was stirred for 1 hr. After 1 hr, ammonium bicarbonate solid (75 mg, 0.9 mmol) was added and the reaction mixture was stirred at room temperature for 12 hours. After completion of the reaction (reaction was monitored by TLC), reaction mixture was concentrated under vacuum. The resulted crude material was extracted with ethyl acetate (25 ml×3). The organic layer was washed with ammonium chloride solution and saturated sodium bi carbonate solution. It was then dried over anhydrous sodium sulfate and concentrated to give Intermediate-11, as an oily mass (0.14 g, yield=87%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide, Intermediate-12
To a 100 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11 (0.1 g, 0.0357 mmol) in DCM (5 mL). The reaction mixture was cooled to 0° C. and trifluoroacetic acetic anhydride (0.21 g, 0.17 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-12 (0.09 g, yield=90%).
Synthesis of tert-butyl 5-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-13
A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of DCM and tert-butyl 5-carbamoyl-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-11 (0.8 g, 2.8 mmol). Under N 2 atm, triethyl amine (1.15 g, 11.4 mmol) and trifluoroacetic anhydride (2.4 g, 11.4 mmol) was added and stirred for 6 hr. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with KHSO4 solution and extracted with DCM (50 ml×3). The organic layer was washed with saturated sodium bi carbonate solution followed by brine solution. Finally the reaction mixture was dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-13, which was subjected to column chromatogram (10% EtOAc in PE) as a off-white solid (0.5 g, yield=70%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile, Intermediate-14
A 50 mL RB flask fitted with magnetic stirrer was charged with tert-butyl 5-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-13 (0.5 g, 1.98 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (1.1 g, 9.54 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by the process of trituration with mixture of hexane:ether (1:1) to give Intermediate-14 (0.5 g, yield=97%).
Synthesis of tert-butyl 5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-15
A 50 mL RB flask fitted with magnetic stirrer was charged with 5 mL of THF, 2-tert-butyl 5-methyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,5-dicarboxylate, Intermediate-9 (0.15 g, 0.5 mmol) and cooled to 0° C. Under N 2 atm, LAH was added portion wise (30 mg, 0.8 mmol) and stirred for 2 hr. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with ethyl acetate and washed with water followed by 1N HCl solution. The organic layer was washed with brine solution. Finally the organic layer was dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-15, as an oily mass (0.12 g, yield=88%).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]dec-5-ylmethanol, Intermediate-16
To a 50 mL RB flask fitted with magnetic stirrer tert-butyl 5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-15 (0.12 g, 0.45 mmol) in DCM (5 mL) was added. The reaction mixture was cooled to 00° C. followed by addition of trifluoroacetic acid (0.26 g, 2.2 mmol). This mixture was stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-16 (0.12 g, yield=97%) as an oily mass.
Synthesis of tert-butyl 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-17
A 15 mL seal tube fitted with magnetic stirrer was charged with 5 mL of THF, tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-6 (0.15 g, 0.5 mmol). Potassium hydride (47 mg, 1.1 mmol) was added to this mixture at 0° C., under N 2 atm. The reaction mixture was then stirred at room temperature for 30 minutes. Methyl iodide was slowly added (0.12 g, 0.8 mmol) at 0° C. and the resulting reaction mass was refluxed at 60° C. under sealed condition for 12 hrs. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with cold water and extracted with ethyl acetate (25 ml×3). The organic layer was washed with sodium chloride solution, was dried over anhydrous sodium sulfate and was concentrated to give crude Intermediate-17, which was subjected to column chromatogram (22% EtOAc in PE) to obtain an oily mass (0.1 g, yield=70%).
Synthesis of 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane, Intermediate-18
To a 50 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-17 (0.1 g, 0.037 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (0.22 g, 1.8 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-18 (0.09 g, yield=95%) as an oily mass.
Synthesis of tert-butyl 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-19
A 15 mL seal tube fitted with magnetic stirrer was charged with 5 mL of THF, tert-butyl 5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-6 (50 mg, 0.2 mmol). To the tube, potassium hydride (20 mg, 0.5 mmol) was added at 0° C., under N 2 atm. The reaction mass was stirred at room temperature for 30 minutes. To this mixture, cyclopropyl methyl bromide (40 mg, 0.3 mmol) was slowly added at 0° C. and the resulting reaction mass was refluxed at 60° C. under sealed condition for 12 hrs. After completion of the reaction (reaction was monitored by TLC), reaction mixture was quenched with cold water and extracted with ethyl acetate (25 ml×3). The organic layer was washed with sodium chloride solution, dried over anhydrous sodium sulfate and concentrated to give crude Intermediate-17, which was subjected to column chromatogram (18% EtOAc in PE) to obtain an oily mass (50 mg, yield=80%).
Synthesis of 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane, Intermediate-20
To a 50 mL RB flask fitted with magnetic stirrer was charged tert-butyl 5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate, Intermediate-19 (50 mg, 0.016 mmol) in DCM (5 mL). Then reaction mixture was cooled to 0° C. and trifluoroacetic acid (0.099 g, 0.084 mmol) was added and stirred for 4 hours. After completion of the reaction (reaction was monitored by LCMS) the reaction mixture was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-20 (50 mg, yield=95%) as an oily mass.
Example 1
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl) propan-1-one (1)
Example 1
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (1)
Starting Material-2 (0.2 mmol) was added to Intermediate-5 (0.2 mmol) in dichloromethane (DCM), followed by the addition of 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochcloride (EDCl) (0.26 mmol) and 1-Hydroxybenztriazole (HOBt) (0.23 mmol). The reaction mixture was cooled to 0° C. and was maintained at the same temperature for 30 minutes. Further, Triethylamine (0.93 mmol) was added to the reaction mixture, and the resulting solution was stirred at room temperature for 15 hours. The reaction mass was then diluted with equal ratio of DCM and water, and was washed with 1N HCl solution followed by NaHCO 3 and brine solution. The organic layer was separated and dried over anhydrous sodium sulfate. The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (1) (9.5 mg, gummy material). 1 H NMR (300 MHz, CDCl3): δ 7.91 (brs, 1H), 7.54 (d, 1H), 7.28 (d, 1H), 7.12 (t, 1H), 7.02 (t, 1H), 6.98 (s, 1H), 4.82 (s, 1H), 3.92 (s, 1H), 3.06 (t, 2H), 2.61 (t, 2H), 1.97-1.98 (m, 2H), 1.60-1.75 (m, 10H). LC-MS (M+H) + =309.2; HPLC purity=92.94%.
Example 2
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (2)
Synthesis of 4-methyl-1H-indole (Intermediate-21)
A 100 mL RB flask fitted with magnetic stirrer and reflux condenser was charged with 60 mL of DMF. To the stirred solvent Starting Material-3 (5 g, 33 mmol) was added followed by Dimethyl formamide dimethyl acetal (13.1 mL, 99.2 mmol). To this Pyrrolidie (3.2 mL, 39.6 mmol) was added and the reaction mixture was heated at 120° C. under Nitrogen atmosphere for 21 hours. After completion of the reaction the mixture was cooled to room temperature and the solvent was removed under reduced pressure. The resulting crude mass was taken in ether (250 mL) and was washed with water (50 mL×3), saturated brine solution (50 mL) and the organic layer was dried over anhydrous sodium sulphate and concentrated. Resulted crude material was taken in Ethyl acetate (50 mL). To this 10% Pd/C (1.0 g, 10% w/w) was added and hydrogenated in a parr shaker for 2 hours. After completion of the reaction (reaction monitored by TLC), the mixture was filtered through celite bed. Filtrate was concentrated to give crude product, which was purified by column chromatography on silica gel (120 meshe) using Petroleum ether (60-80) and ethyl acetate as eluent to give Intermediate-21 (1.2 g).
Synthesis of 3-(4-methyl-1H-indol-3-yl)propanoic acid (Intermediate-22)
A 100 mL RB flask fitted with magnetic stirrer was charged with 2.5 mL of acetic acid. To the stirred solvent acetic anhydride 2.0 mL was added followed by addition of acrylic acid (1.8 mL, 27.4 mmol). To this stirred mixture Intermediate-21 (1.2 g, 9.15 mmol) was added and the reaction mixture was stirred at room temperature for 1 week. After completion of the reaction (reaction was monitored by TLC), reaction mass was basified using 5N NaOH (5 mL) and washed with Ethyl acetate (100 mL×2). The aqueous layer was acidified with concentrated HCl (3 ML) and was extracted using Ethyl acetate (100 mL×3). The combined ethyl acetate layer was washed with brine solution and was concentrated to give Intermediate-22 (350 mg).
Synthesis of Compound (2)
Compound (2) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (2). 1 H NMR (300 MHz, CDCl3): δ 7.94 (brs, 1H), 7.12 (d, 1H), 6.99 (t, 1H), 6.92 (s, 1H), 6.76 (d, 1H), 4.82 (s, 1H), 3.94 (s, 1H), 3.21 (t, 2H), 2.64 (s, 3H), 2.58 (t, 2H), 2.12-2.17 (m, 1H), 1.64-1.76 (m, 11H). LC-MS (M+H) + =323.2; HPLC purity: 71.84%.
Example 3
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,4-dimethyl-1H-indol-3-yl)propan-1-one (3)
Synthesis of Compound (3)
Compound (3) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (3). 1 H NMR (300 MHz, CDCl3): δ 6.98-7.05 (m, 2H), 6.75-6.78 (m, 2H), 4.82 (s, 1H), 3.93 (s, 1H), 3.63 (s, 3H), 3.16-3.22 (m, 2H), 2.64 (s, 3H), 2.55-2.61 (m, 2H), 1.97-2.01 (m, 2H), 1.75-1.79 (m, 2H), 1.70-1.72 (m, 3H), 1.59-1.65 (m, 5H). LC-MS (M+H) + =337.2; HPLC purity: 79.30%.
Example 4
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (4)
Synthesis of 4-fluoro-1H-indole-3-carbaldehyde (Intermediate-23)
To a 25 mL RB flask fitted with magnetic stirrer were added DMF (0.413 g) and POCl 3 (0.623 g, 4 mmol) at 0° C. under N 2 atmosphere and the resulting mixture was stirred for 30 minutes at same temperature. Then Starting Material-4 (500 mg, 3.7 mmol) in DMF was added to the mixture and stirred at 40° C. for 1 hour. After completion of the reaction the reaction mixture was cooled to 0° C., quenched with NaOH solution and was extracted with ethyl acetate. Organic layers were concentrated to give crude material, which was then purified by silica-gel column chromatography eluting with hexane:EtOAc to give Intermediate-23 (230 mg) as brown material. LC-MS (M+H) + =164.2.
Synthesis of ethyl (2E)-3-(4-fluoro-1H-indol-3-yl)prop-2-enoate (Intermediate-24)
To a 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-23 (0.23 g, 1.4 mmol), Ethyl Malonate (0.204 g, 1.5 mmol) and Piperdine (0.011 g, 0.13 mmol) in Pyridine (10 mL). Resulted reaction mixture was heated at 110° C. for 14 hours. After completion of the reaction, the reaction mixture was concentrated to obtain a crude material which was then dissolved in ethyl acetate and washed with water and brine. Organic layer was then concentrated to give crude material, which was purified by silica-gel column chromatography eluting with hexane:EtOAc to give Intermediate-24 (250 mg).
Synthesis of ethyl 3-(4-fluoro-1H-indol-3-yl)propanoate
(Intermediate-25)
Intermediate-24 (0.24 g, 1.0 mmol) was taken in EtOAc (10 mL) to which 10% Pd/C (50 mg) was added. The resulting reaction mass was stirred under H 2 atmosphere (30 psi) for 4 hours. The reaction mass was filtered through celite bed and concentrated to give Intermediate-25 (240 mg).
Synthesis of 3-(4-fluoro-1H-indol-3-yl)propanoic acid
(Intermediate-26)
Intermediate-25 (100 mg, 0.4 mmol) was taken in EtOH:THF:H 2 O (5 mL:5 mL:1 mL). To this NaOH (51 mg, 1.2 mmol) was added. Resulting reaction mixture was refluxed for 4 hours. After completion of reaction (reaction monitored by TLC), the reaction mixture was concentrated which was diluted with water, acidified (pH=1 to 2) with 1N HCl, extracted with EtOAc and concentrated to give Intermediate-26 (90 mg).
Synthesis of Compound (4)
Compound (4) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (4). 1 H NMR (300 MHz, CDCl3): δ 8.04 (s, 1H), 6.97-7.07 (m, 2H), 6.94 (s, 1H), 6.65-6.71 (m, 1H), 5.01 (s, 1H), 4.21 (s, 1H), 3.08-3.13 (t, 2H), 2.62-2.67 (t, 2H), 2.24 (s, 1H), 1.53-1.74 (m, 10H) + . LC-MS (M+H) + =343.12; HPLC purity: 95.20%.
Example 5
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(6-fluoro-1H-indol-3-yl)propan-1-one (5)
Synthesis of Compound (5)
Compound (5) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (5). 1 H NMR (300 MHz, CDCl3): δ 8.02 (brs, 1H), 7.41-7.46 (dd, 1H), 6.95-6.99 (m, 2H), 6.78-6.85 (m, 1H), 4.81 (s, 1H), 3.90 (s, 1H), 3.03-3.08 (t, 2H), 2.63-2.68 (t, 2H), 1.96-2.02 (m, 2H), 1.56-1.76 (m, 10H) + . LC-MS (M+H) + =327.3; HPLC purity: 95.25%.
Example 6
3-(5-fluoro-1H-indol-3-yl)-1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (6)
Synthesis of methyl 4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-27)
To a 100 mL RB flask fitted with magnetic stirrer was charged 25 mL of Dichloromethane. To this Intermediate-3 (0.5 g, 2.5 mmol), followed by m-CPBA (0.69 g, 4.0 mmol) were added at 0° C. Then reaction mixture was stirred at room temperature for 16 hours. After completion of the reaction, the reaction mixture was quenched using aqueous NaHCO 3 solution and was extracted with dichloromethane. Organic layer was concentrated to give Intermediate-27 (0.5 g).
Synthesis of 2-azatricyclo[3.3.1.1 3,7 ]decan-4-ol hydrogen chloride salt (Intermediate-28)
A 50 mL pressurized seal tube fitted with magnetic stirrer was charged with Intermediate-27 (0.2 g, 0.9 mmol) in HCl containing 1,4-Dioxane (20 mL). Then reaction mixture was stirred at 90° C. for 8 hours. After completion of the reaction (reaction was monitored by LCMS), it was concentrated followed by trituration with mixture of hexane:ether (1:1) to give Intermediate-28 (0.2 g).
Synthesis of Compound (6)
Compound (6) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (6). 1 H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.17-7.23 (d, 1H), 7.14-7.15 (d, 1H), 7.02 (s, 1H), 6.84-6.90 (m, 1H), 4.67-4.73 (d, 1H), 3.83 (brs, 0.5H), 3.68 (s, 1H), 3.35 (brs, 1H), 2.98-3.03 (t, 2H), 2.56-2.64 (m, 2H), 2.07-2.11 (m, 1H), 1.97 (m, 1H), 1.61-1.69 (m, 7H). LC-MS (M+H) + =343.1; HPLC purity: 95.88%.
Example 7
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-fluoro-1H-indol-3-yl)propan-1-one (7)
Synthesis of Compound (7)
Compound (7) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (7). 1 H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 722 (d, 1H), 7.16 (s, 1H), 7.03 (s, 1H), 6.86-6.87 (t, 1H), 4.81 (s, 1H), 3.91 (s, 1H), 2.99-3.04 (t, 2H), 2.57-2.62 (t, 2H), 1.92-1.98 (m, 2H), 1.58-1.75 (m, 10H). LC-MS (M+H) + =327.2; HPLC purity: 96.53%.
Example 8
3-(4-fluoro-1-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (8)
Synthesis of Compound (8)
Compound (8) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (8). 1 H NMR (300 MHz, CDCl3): δ 6.96-7.07 (m, 2H), 6.78 (s, 1H), 6.63-6.69 (m, 1H), 5.01 (s, 1H), 4.21 (s, 1H), 3.64 (s, 3H), 3.05-3.10 (t, 2H), 2.59-2.64 (t, 2H), 2.24 (s, 1H), 1.53-1.74 (m, 10H). LC-MS (M+H) + =357.1; HPLC purity: 89.95%.
Example 9
3-(5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (9)
Synthesis of Compound (9)
Compound (9) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (9). 1 H NMR. (300 MHz, CDCl3): δ 7.94 (brs, 1H), 7.19-7.22 (d, 1H), 7.15-7.16 (d, 1H), 7.02 (s, 1H), 6.83-6.90 (m, 1H), 5.02 (s, 1H), 4.01 (s, 1H), 2.99-3.04 (t, 2H), 2.57-2.62 (t, 2H), 2.26 (s, 1H), 1.61-1.97 (m, 10H). LC-MS (M+H) + =343.1; HPLC purity: 93.42%.
Example 10
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-methyl-3-(1-methyl-1H-indol-3-yl)butan-1-one (10)
Synthesis of methyl 1H-indol-3-ylacetate (Intermediate-29)
A 100 mL RB flask fitted with magnetic stirrer was charged with 15 mL of Methanol. To the stirred solvent Starting Material-5 (2.0 g, 11.41 mmol) was added. The resulting mixture was cooled to 0° C. and concentrated H 2 SO 4 (0.5 mL) was added. The reaction mixture was then stirred at room temperature for 1 hour. After completion of the reaction (reaction monitored by TLC), solvent from the reaction mass was removed under reduced pressure. The resulting crude mass was taken in Ethyl acetate (100 mL) and was washed with water (50 mL), Sodium bicarbonate solution (100 mL×2) and saturated brine solution (50 mL). The organic layer was then dried over anhydrous sodium sulphate. Then the solvent was removed under reduced pressure. The product Intermediate-29 was obtained as brown syrup. (2.1 g). LC-MS (M+H) + =190.2.
Synthesis of methyl 2-methyl-2-(1-methyl-1H-indol-3-yl)propanoate (Intermediate-30)
A 100 mL 3 neck RB flask fitted with magnetic stirrer was charged with 10 mL of dry THF. To the stirred solvent diisopropyl amine (401.12 mg, 3.964 mmol) was added and the resulting solution was cooled to −78° C. n-BuLi (2.5 mL, 3.964 mmol) was added and stirred for 1 hour at 0° C. The reaction mixture was again cooled to −78° C. to which Intermediate-29 (150 mg, 0.7928 mmol) was added. The reaction mixture was then stirred for 1 hour. This was followed by addition of Methyl Iodide. The resulting mass was then stirred at room temperature for 15 hours. After completion of the reaction (reaction monitored by TLC), the reaction mass was quenched with saturated ammonium chloride and was extracted using EtOAc (100 mL×3). The combined organic layers were washed with brine and dried after which the solvent was removed under reduced pressure. The resulting crude compound was purified by column chromatography on silica gel (120 meshes) using Petroleum ether (60-80) and ethyl acetate as eluent. The product Intermediate-30 was obtained as a brown syrup. (150 mg). LC-MS (M+H) + =232.2.
Synthesis of 2-methyl-2-(1-methyl-1H-indol-3-yl)propan-1-ol (Intermediate-31)
A 250 mL RB flask fitted with magnetic stirrer was charged with Lithium aluminum hydride (0.983 g, 25.951 mmol) and THF (20 mL) was added to it at 0° C. To this resulting suspension Intermediate-30 (2.0 g, 8.65 mmol) in THF (20 mL) was added and the resulting mixture was stirred at room temperature for 2 hours. After completion of the reaction, the reaction mixture was diluted with EtOAc (50 mL) and then quenched with Na 2 SO 4 (5 g). The resulting slurry was stirred at room temperature for 1 hour, filtered through celite and washed with ethyl acetate. The resulting filtrate was concentrated to give Intermediate-31 (0.9 g). 1 H NMR (300 MHz, DMSO-d6): δ 7.65-7.68 (d, 1H), 7.34-7.36 (d, 1H), 7.07-7.12 (t, 1H), 7.03 (s, 1H), 6.94-6.99 (t, 1H), 4.53-4.57 (t, 1H), 3.71 (s, 3H), 3.54-3.56 (d, 2H), 1.31 (s, 6H).
Synthesis of 2-methyl-2-(1-methyl-1H-indol-3-yl)propanal (Intermediate-32)
A 100 mL RB flask fitted with magnetic stirrer was charged with 30 mL DCM to which Pyridinium chloro chromate (2.466 g, 11.4419 mmol) was added followed by the addition of Intermediate-31 (1.55 g, 7.627 mmol) in 10 mL of DCM. The resulting mixture was stirred at room temperature for 2 hours. After completion of the reaction, the solvent from the reaction mass was removed under reduced pressure to yield the crude compound. Crude mass was purified by column chromatography using 60-120 silica gel and 9:1 Pet ether/ethyl acetate as eluent to give Intermediate-32 (0.79 g). 1 H NMR (300 MHz, DMSO-d6): δ 9.39 (s, 1H), 7.40-7.44 (t, 1H), 7.32 (s, 1H), 7.13-7.18 (t, 1H), 6.98-7.03 (t, 1H), 3.77 (s, 3H), 1.46 (s, H).
Synthesis of 3-[(3E)-4-methoxy-2-methylbut-3-en-2-yl]-1-methyl-1H-indole (Intermediate-33)
A 100 mL RB flask fitted with magnetic stirrer was charged with 20 mL of dry THF and Methoxy methyl triphenyl phosphonium chloride (2.566 g, 7.487 mmol) followed by Potassium tert butoxide (2.295 g, 20.451 mmol). The resulting mass was stirred at room temperature for 2 hours and then cooled to 0° C. Intermediate-32 (1.37 g, 6.807 mmol) in 10 mL of THF was added to the above reaction mass and was stirred at room temperature for 2 hours. After completion of the reaction the reaction mass was diluted with 10 mL of water and was extracted with ethyl acetate (100 mL×3). The combined organic layers were washed with brine solution and was dried over anhydrous sodium sulfate and concentrated to obtain the crude product. Crude product was purified by column chromatography using 60-120 silica gel and 6% of ethyl acetate in Pet ether as eluent to give Intermediate-33. Yield: 1.12 g (71.8%).
1 H NMR (300 MHz, CDCl3): δ 7.73-7.80 (m 1H), 7.33 (s, 1H), 7.16-7.21 (t, 1H), 7.03-7.08 (t, 1H), 6.81 (s, 1H), 5.79-6.34 (m, 1H), 4.58-5.15 (m, 1H), 3.73-3.74 (d, 3H), 3.49-3.53 (d, 3H), 1.55 (s, 6H).
Synthesis of 3-methyl-3-(1-methyl-1H-indol-3-yl)butanal (Intermediate-34)
A 100 mL RB flask fitted with magnetic stirrer was charged with 50.4 mL of 1,4 dioxane and 12.76 mL of water. To this Intermediate-33 (1.12 g, 4.884 mmol) was added followed by addition of p-toluene sulphonic acid (0.0424 g, 0.2232 mmol). The resulting mass was heated at 60° C. for 16 hours. After completion of the reaction, the reaction mixture was quenched with 10 mL of water and extracted with ethyl acetate (100 mL×3) and the combine organic layer was washed with saturated sodium bicarbonate solution followed by brine solution and was dried over anhydrous sodium sulfate and was concentrated to obtain the crude product. The crude product was purified by column chromatography using 60-120 silica gel and 8% of ethyl acetate in Pet ether as eluent to give Intermediate-34. 1 H NMR (300 MHz, DMSO-d6): δ 9.47-9.49 (t, 1H), 7.73-7.76 (d, 1H), 7.37-7.40 (d, 1H), 7.11-7.16 (t, 1H), 7.10 (s, 1H), 6.99-7.04 (t, 1H) 3.72 (s, 3H), 2.78 (s, 2H), 1.49 (s, 6H).
Synthesis of 3-methyl-3-(1-methyl-1H-indol-3-yl)butanoic acid (Intermediate-35)
A 50 mL RB flask fitted with magnetic stirrer was charged with 10 mL of THF and was cooled to −78° C. to which 2-methyl-2-butene (3 mL) was added and stirred for 15 minutes. Another 100 mL RB flask fitted with magnetic stirrer was charged with Intermediate-34 (557 mg, 2.59 mmol) and tert butanol (15 mL) and was stirred at room temperature and the above prepared THF solution was added to it. Then the resulting mass was cooled to 0° C. to which NaH 2 PO 4 (1.42 g) in water was added followed by addition of NaClO 2 (0.35 g) in water. The resulting mixture was stirred at 0° C. for 20 minutes and quenched with water. The pH of the reaction mixture was adjusted to 1-2 using 1N HCl and the product was extracted with ethyl acetate and concentrated to give Intermediate-35 (480 mg). 1 H NMR (300 MHz, DMSO-d6): δ 11.82 (s, 1H), 7.69-7.71 (d, 1H), 7.35-7.38 (d, 1H), 7.09-7.14 (t, 1H), 7.05 (s, 1H), 6.96-7.01 (t, 1H), 3.71 (s, 3H), 2.66 (s, 2H), 1.48 (s, 6H)
Synthesis of Compound (10)
Compound (10) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (10). 1 H NMR (300 MHz, DMSO-d6): δ 7.70-7.73 (d, 1H), 7.34-7.37 (d, 1H), 7.10 (t, 1H), 7.04 (s, 1H), 6.98-7.04 (t, 1H), 4.75 (brs, 1H), 4.54 (s, 1H), 3.99 (brs, 1H), 3.70 (s, 3H), 2.60-2.65 (dd, 2H), 2.02 (s, 1H), 1.28-1.62 (m, 16H) LC-MS (M+H) + =367.3; HPLC purity: 88.74%.
Example 11
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,3-benzothiazol-2-yl)propan-1-one (11)
Synthesis of 3-(1,3-benzothiazol-2-yl)propanoic acid (Intermediate-36)
Starting material-7 (3.97 mmol) in benzene was added drop wise to the solution of Starting Material-6 (3.97 mmol) in benzene. The resulting solution was heated to reflux for 2 hours. After 2 hours the reaction mass was cooled to room temperature and was extracted with 10% sodium hydroxide solution. The aqueous layer was acidified using Conc.HCl (3 ml) at 0° C. The resulting solids were filtered and dried at room temperature to get Intermediate-36 (660 mg).
Synthesis of Compound (11)
Compound (11) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (11). 1H NMR (300 MHz, CDCl3): δ 7.89-7.91 (d, 1H), 7.76-7.78 (d, 1H), 7.36-7.41 (t, 1H), 7.26-7.31 (t, 1H), 4.79 (s, 1H), 4.01 (s, 1H), 3.40-3.46 (t, 2H), 2.82-2.88 (t, 2H), 1.98-2.02 (m, 2H), 1.66-1.81 (m, 10H). LC-MS: (M+H)+=327.3; HPLC purity=94.43%.
Example 12
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (12)
Synthesis of Compound (12)
Compound (12) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (12). 1H NMR (300 MHz, CDCl3): δ 7.91-7.93 (d, 1H), 7.76-7.79 (d, 1H), 7.37-7.43 (t, 1H), 7.28-7.33 (t, 1H), 4.99 (s, 1H), 4.28 (s, 1H), 3.42-3.47 (t, 2H), 2.88-2.93 (t, 2H), 2.28 (brs, 1H), 1.51-1.79 (m, 10H). LC-MS: (M+H)+=343.1; HPLC purity=99.27%.
Example 13
3-(1,3-benzothiazol-2-yl)-1-[5-(difluoromethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]propan-1-one (13)
Synthesis of Compound (13)
To a stirred solution of (80 mg, 0.28 mmol) in MeCN (3 mL) was added CuI (88 mg, 0.046 mmol) and heated to 45° C. To this difluoro(fluorosulfonyl)acetic acid (23 mg, 0.46 mmol) was added. The resultant mixture is allowed to stir at the same temperature for 30 minutes. After completion of the reaction, the reaction mixture is quenched with water, extracted with EtOAc and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexane:EtOAc to give Compound (13) (40 mg) as dark yellow gummy material. 1H NMR (300 MHz, CDCl3): δ 7.87-7.89 (d, 1H), 7.76-7.78 (d, 1H), 7.35-7.40 (t, 1H), 7.26-7.31 (t, 1H), 5.97-6.48 (t, 1H), 5.03 (brs, 1H), 4.33 (brs, 1H), 3.39-3.44 (t, 2H), 2.85-2.89 (t, 2H), 2.33 (brs, 1H), 1.87-1.98 (m, 4H), 1.57-1.70 (m, 6H). LC-MS: (M+H)+=393.2; HPLC purity=89.63%.
Example 14
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (14)
Synthesis of 3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propanoic acid (Intermediate-37)
Intermediate-37 was synthesized by following the procedure used to make Intermediate-26 (Scheme 4).
Synthesis of Compound (14)
Compound (14) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (14). 1H NMR (300 MHz, CDCl3): δ 8.99 (brs, 1H), 8.22-8.21 (d, 1H), 7.9-7.88 (d, 1H), 7.07 (s, 1H), 7.03-6.99 (t, 1H), 4.81 (s, 1H), 3.92 (s, 1H), 3.07-3.02 (t, 2H), 2.62-2.57 (t, 2H), 1.97-1.98 (m, 3H), 1.76-1.56 (m, 11H). LC-MS: (M+H)+=310.2; HPLC purity=98.28%.
Example 15
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (15)
Synthesis of Compound (15)
Compound (15) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (15). 1H NMR (300 MHz, CDCl3): δ 9.02 (brs, 1H), 8.20-8.22 (d, 1H), 7.86-7.88 (d, 1H), 7.07 (brs, 1H), 6.99-7.03 (dd, 1H), 5.00 (bs, 1H), 4.10 (brs, 1H), 3.02-3.07 (t, 2H), 2.57-2.62 (t, 2H), 2.22 (brs, 1H), 1.45-1.73 (m, 10H). LC-MS: (M+H)+=326.1; HPLC purity=98.04%.
Example 16
3-(1H-benzotriazol-1-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (16)
Synthesis of ethyl 3-(1H-benzotriazol-1-yl)propanoate (Intermediate-38)
The starting material-8 (4.1 mmol) in dry THF (5 ml) was cooled to 0° C., followed by the addition of NaH (6.0 mmol). The reaction mixture was gradually warmed to room temperature and allowed to react for 20 minutes. The reaction mixture was again cooled to 0° C., followed by the drop wise addition of ethyl 3-bromopropanoate (4.6 mmol) in THF (2.5 ml). The reaction was allowed for 12 hours at room temperature. After 12 hours the reaction mixture was quenched with ice cooled water and extracted with ethyl acetate. The organic layer was dried over anhydrous MgSO 4 , and concentrated to obtain Intermediate-38 (70 mg). 1H NMR (300 MHz, CDCl3): δ 7.98-8.01 (1H, d), 7.55-7.58 (d, 1H), 7.41-7.46 (t, 1H), 7.28-7.33 (t, 1H), 4.82-4.87 (t, 2H), 4.00-4.07 (t, 2H), 3.00-3.05 (t, 2H), 1.08-1.1 (t, 3H).
Synthesis of 3-(1H-benzotriazol-1-yl)propanoic acid (Intermediate-39)
At 0° C., LiOH (1.5 mmol) in water (1 ml) was added to Intermediate-38 in the solvent THF:MeOH (1:1, 3 ml each). The reaction was allowed for 12 hours at room temperature. After 12 hours the reaction mixture was concentrated, further acidified with 1N HCl (pH=2). The reaction mixture was extracted with ethyl acetate. The organic layer was dried over anhydrous MgSO 4 , and evaporated under reduced pressure to obtain Intermediate-39 (60 mg). 1H NMR (300 MHz, CDCl3): δ 7.29-8.00 (4H, m), 4.82-4.87 (t, 2H), 3.09-3.14 (t, 2H).
Synthesis of Compound (16)
Compound (16) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (16). 1H NMR (300 MHz, CDCl3): δ 7.23-7.97 (m, 4H), 4.81-4.92 (m, 3H), 4.10 (brs, 1H), 3.01-3.05 (t, 2H), 2.21 (brs, 1H), 1.40-1.78 (m, 10H). LC-MS: (M+H)+=327.2; HPLC purity=98.35%.
Example 17
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (17)
Synthesis of 5-[1-(1H-indol-3-yl)ethyl]-2,2-dimethyl-1,3-dioxane-4,6-dione (Intermediate-40)
A 100 mL RB flask fitted with magnetic stirrer was charged with Starting Material-9 (4.0 g, 34 mmol), Starting Material-10 (4.92, 34 mmol) and Starting Material-11 (3 g, 68 mmol) in 75 mL of acetonitrile. The resulting solution was stirred at room temperature overnight. After completion of the reaction (reaction monitored by TLC), the solvent was removed under reduced pressure, and the resulting crude compound was purified by column chromatography on silica gel (230-400 mesh) using Petroleum ether (60-80) and ethyl acetate as eluent. The product (intermediate-40) was obtained as a brown liquid (2.51 g). LC-MS (M−H) + =286.
Synthesis of ethyl 3-(1H-indol-3-yl)butanoate (Intermediate-41)
A 100 mL RB flask fitted with magnetic stirrer was charged with intermediate-40 (2.5 g, 8.7 mmol) in 50 mL of pyridine and 8 ml of ethanol. To this mixture copper powder (0.4 g, 5 mol %) was added. Then the resulting reaction mass was refluxed at 110° C. for 3 hours. After completion of the reaction (reaction monitored by TLC), solvent was removed from the reaction mass and the reaction mass was diluted with 100 mL of ethyl acetate. This was followed by washing of the reaction mass with 50 mL 1.5N HCl (2×25 mL) and brine solution. Then the organic layer was dried over 10 g of anhydrous MgSO 4 . The solvent was removed under reduced pressure, and the resulting crude compound was purified by column chromatography on silica gel (230-400 mesh) using Petroleum ether (60-80) and ethyl acetate as eluent. The product (intermediate-41) was obtained as a brown liquid. (0.380 g). LC-MS (M+H) + ==232.
Synthesis of ethyl 3-(1H-indol-3-yl)butanoic acid (Intermediate-42)
A 50 mL RB flask fitted with magnetic stirrer was charged with 6 mL of methanol and 2 mL of water. To the stirred solvent intermediate-41 (0.145 g, 0.62 mmol) and KOH (0.098 g, 2.54 mmol) was added. Then the resulting reaction mass was refluxed at 70° C. for 3 hours. After completion of the reaction (reaction monitored by TLC), solvent was removed from the reaction mass and the reaction mass was diluted with 20 mL of water. The aqueous layer was washed with 20 mL of diethylether and was acidified by 1NHCl to pH 5.5. The product was then extracted with ethyl acetate and the solvent was removed under reduced pressure. The product (intermediate-42) was obtained as a brown liquid (0.115 g). The product obtained above was directly taken for next step without any purification.
Synthesis of Compound (17)
Compound (17) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (17). 1H NMR (300 MHz, CDCl3): δ 7.91 (brs, 1H), 7.60-7.63 (d, 1H), 7.27-7.30 (d, 1H), 7.09-7.13 (t, 1H), 7.01-7.03 (t, 1H), 6.96 (s, 1H), 4.80 (s, 1H), 3.93 (s, 1H), 3.54-3.61 (m, 1H), 2.72-2.79 (m, 1H), 2.45-2.50 (m, 1H), 2.10 (brs, 1H), 1.88-1.97 (m, 1H), 1.66-1.74 (m, 5H), 1.47-1.59 (m, 5H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=323.3; HPLC purity=90.83%.
Example 18
1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (18)
Synthesis of Compound (18)
Compound (18) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (18). 1H NMR (300 MHz, CDCl3): δ 7.92 (brs, 1H), 7.75-7.54 (m, 1H), 7.35-7.27 (m, 1H), 7.14-7.01 (m, 2H), 6.96 (brs, 1H), 4.73-4.64 (d, 1H), 3.89 (s, 1H), 3.67 (s, 1H), 3.37-3.60 (m, 1H), 2.67-2.79 (m, 1H), 2.59-2.46 (m, 1H), 2.08-1.86 (m, 3H), 1.75-1.60 (m, 5H), 1.53-1.44 (m, 2H), 1.38-1.42 (m, 3H). LC-MS: (M+H)+=339.2; HPLC purity=98.80%.
Example 19
1-(4-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (19)
Synthesis of Compound (19)
Compound (19) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (19). 1H NMR (300 MHz, CDCl3): δ 8.06-7.98 (d, 1H), 7.70-7.56 (d, 1H), 7.36-7.24 (m, 1H), 7.16-7.01 (m, 2H), 6.98-6.91 (d, 1H), 4.57-4.56 (d, 1H), 3.83-3.39 (m, 2H), 3.25-2.90 (m, 2H), 2.80-2.66 (m, 1H), 2.16-2.02 (m, 1H), 1.98-1.66 (m, 4H), 1.54-1.08 (m, 6H), 0.961-0.89 (d, 6H). LC-MS: (M+H)+=367.3; HPLC purity=98.74%.
Example 20
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (20)
Synthesis of Compound (20)
Compound (20) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (20). 1H NMR (300 MHz, CDCl3): δ 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=94.22%.
Example 21
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (21)
Synthesis of Compound (21) (Peak-1)
Racemate of Compound (20) was separated by using HPLC to give enantiomer Compound (21) (peak-1). 1H NMR (300 MHz, CDCl3): 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=98.2%, Chiral purity: (RT=19.9 min).
Example 22
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)butan-1-one (22)
Synthesis of Compound (22) (Peak-1)
Racemate of Compound (20) was separated by using HPLC to give enantiomer Compound (22) (peak-2). 1H NMR (300 MHz, CDCl3): 7.99 (brs, 1H), 7.59-7.62 (d, 1H), 7.27-7.29 (d, 1H), 7.08-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.96 (brs, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.56-3.61 (q, 1H), 2.73-2.78 (t, 1H), 2.43-2.50 (m, 1H), 1.94-1.97 (m, 1H), 1.42-1.68 (m, 10H), 1.40 (d, 3H). LC-MS: (M+H)+=339.2; HPLC purity=97.8%; Chiral purity: (RT=22.28 min).
Example 23
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (23)
Synthesis of Compound (23)
Compound (23) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain (23). 1H NMR (300 MHz, DMSO-d6): δ 10.77 (s, 1H), 7.50-7.53 (d, 1H), 7.28-7.31 (d, 1H), 7.07 (s, 1H), 6.99-7.04 (t, 1H), 6.90-6.95 (t, 1H), 4.67 (s, 1H), 4.55-4.62 (d, 1H), 4.26-4.29 (d, 1H), 3.22-3.26 (m, 1H), 2.65-2.67 (m, 2H), 1.98 (m, 2H), 1.55-1.62 (d, 5H), 1.36-1.48 (m, 3H), 1.15-1.19 (m, 1H), 1.01-1.06 (m, 1H), 0.77-0.87 (m, 6H). LC-MS: (M+H)+=367.2; HPLC purity=85.41%.
Example 24
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-4-methylpentan-1-one (24)
Synthesis of Compound (24)
Under N 2 atmosphere to a stirred solution of Compound (23) (0.035 g, 0.09 mmol), DAST (0.015 g, 0.09 mmol) was added at −78° C. The reaction mixture was stirred for 2 h at same temperature. After completion of the reaction (reaction monitored by TLC), reaction mass was quenched with NaHSO 3 Solution and extracted with DCM (3×25 mL). The organic layer was washed with saturated brine solution (15 mL), and concentrated to obtain the crude product. The crude product was loaded on Prep TLC plate (97:3. Chloroform:Methanol) and Compound (24) (12 mg) was collected as pale yellow solid. 1H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 7.57-7.59 (d, 1H), 7.25-7.30 (m, 1H), 6.99-7.12 (m, 2H), 6.93 (s, 1H), 4.95 (s, 1H), 4.09 (s, 1H), 3.12-3.21 (m, 1H), 2.72-2.82 (m, 1H) 2.63-2.67 (m, 1H), 2.08-2.25 (m, 3H), 1.72-1.79 (m, 2H), 1.61-1.69 (m, 7H), 0.96-0.98 (d, 3H). 0.71-0.81 (d, 3H). LC-MS: (M+H)+=369.1; HPLC purity=96.16%.
Example 25
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methylpentan-1-one (25)
Synthesis of Compound (25)
Compound (25) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (25). 1H NMR (300 MHz, CDCl3): δ 8.29-8.26 (d, 1H), 7.14-7.02 (m, 2H), 6.98 (s, 1H), 6.77-6.71 (t, 1H), 4.93 (s, 1H), 4.21 (s, 1H), 3.25 (m, 1H), 2.91-2.66 (m, 2H), 2.25 (s, 1H), 2.16-2.05 (m, 2H), 1.72-1.34 (m, 9H), 0.79-0.81 (d, 6H). LC-MS: (M+H)+=385.2; HPLC purity=98.37%.
Example 26
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (26)
Synthesis of Compound (26)
Compound (26) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (26). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.31 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=97.11%.
Example 27
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (27)
Synthesis of Compound (27) (Peak-1)
Racemate of Compound (26) was separated by using chiral HPLC to give enantiomer, Compound (27) (peak-1). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.31 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=99.60%; Column: Chiralpak IA. 4.6 mm×250 mm, mobile phase: Hexanes:EtOH (8:2), chiral purity=92.25% (RT=12.52 min).
Example 28
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (28)
Synthesis of Compound (28) (Peak-2)
Racemate of Compound (26) was separated by using chiral HPLC to give enantiomer, Compound (28) (peak-2). 1H NMR (300 MHz, CDCl3): δ 8.15 (brs, 1H), 7.00-7.09 (m, 3H), 6.67-6.73 (t, 1H), 4.99 (s, 1H), 4.25 (s, 1H), 3.59 (m, 1H), 2.90 (s, 1H), 2.63-2.70 (s, 1H), 2.26-2.3 (m, 2H), 1.85 (m, 3H), 1.60-1.72 (m, 6H), 1.35-1.40 (d, 3H). LC-MS: (M+H)+=357.2; HPLC purity=94.43%; Column: Chiralpak IA. 4.6 mm×250 mm, mobile phase: Hexanes:EtOH (8:2), Chiral purity=99.69% (RT=11.13 min).
Example 29
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (29)
Synthesis of Compound (29)
Compound (29) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (29). 1H NMR (300 MHz, CDCl3): δ8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=97.80%.
Example 30
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (30)
Synthesis of Compound (30) (Peak-1)
Racemate of Compound (29) was separated by using chiral HPLC to give enantiomer Compound (30) (peak-1). 1H NMR (300 MHz, CDCl3): δ8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=99.56%; Chiral purity=99.75% (RT=13.52 min, Column: Chiral pack IA, 4.6 mm×250 mm, mobile phase: MTBE:MeOH (98:02).
Example 31
3-(4-fluoro-1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (31)
Synthesis of Compound (31) (Peak-2)
Racemate of Compound (29) was separated by using chiral HPLC to give enantiomer Compound (31). 1H NMR (300 MHz, CDCl3): δ 8.06 (brs, 1H), 7.02-7.07 (m, 1H), 6.97-7.01 (m, 1H), 6.94-6.95 (d, 1H), 6.66-6.72 (dd, 1H), 4.26 (brs, 1H), 4.26 (brs, 1H), 3.5-3.6 (m, 1H), 3.05-3.12 (d, 3H), 2.8-2.89 (m, 1H), 2.41-2.48 (m, 1H), 2.17-2.23 (m, 1H), 1.48-1.72 (m, 10H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=95.79%; Chiral purity=99.88% (RT=16.37 min, Column: Chiral pack IA, 4.6 mm×250 mm, mobile phase: MTBE:MeOH (98:02).
Example 32
1-(5-chloro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-fluoro-1H-indol-3-yl)butan-1-one (32)
Synthesis of tert-butyl 5-chloro-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-43)
To a stirred solution of Intermediate-6 (70 mg, 0.19 mmol) in CCl4 (3 mL), SOCl2 (1.5 mL) was added and the reaction mixture was heated at 80° C. for 15 hours. After reaction was completed (reaction was monitored by LC-MS), reaction mass was concentrated to give Intermediate-43 (60 mg).
Synthesis of 5-chloro-2-azatricyclo[3.3.1.1 3,7 ]decane, trifluoroacetic acid salt (Intermediate-44)
Intermediate-44 was synthesized by following the procedure used to make Intermediate-20 (Scheme 1).
Synthesis of Compound (32)
Compound (32) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate as eluent to obtain Compound (32). 1H NMR (300 MHz, CDCl3): δ 8.02-8.06 (d, 1H), 7.01-7.09 (m, 2H), 6.94 (s, 1H), 6.67-6.73 (m, 1H), 4.95 (s, 1H), 4.20 (s, 1H), 3.54-3.61 (m, 1H), 2.79-2.88 (m, 1H), 2.40-2.49 (m, 1H), 2.12-2.26 (m, 4H), 1.81-2.02 (m, 3H), 1.5 (m, 4H), 1.36-1.43 (d, 3H). LC-MS: (M+H)+=376.1; HPLC purity=90.30%.
Example 33
1-[5-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]-3-(4-fluoro-1H-indol-3-yl)butan-1-one (33)
Synthesis of Compound (33)
Compound (33) was synthesized by using intermediate 20 and following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (33). 1H NMR (300 MHz, CDCl3): δ 8.07 (s, 1H), 6.97-7.07 (m, 2H), 6.95-6.94 (d, 1H), 6.66-6.72 (t, 1H), 4.97 (s, 1H), 4.25 (s, 1H), 3.53-3.60 (m, 1H), 3.00-3.12 (dd, 2H), 2.79-2.89 (m, 1H), 2.40-2.50 (m, 1H), 2.16-2.25 (d, 1H), 2.13-2.26 (d, 1H), 1.54-1.74 (m, 8H), 1.36-1.38 (d, 3H), 0.87-0.89 (m, 1H) 0.41-0.47 (m, 2H), 0.07 (m, 2H). LC-MS: (M+H)+=411.2; HPLC purity=96.10%.
Example 34
3-(1H-indol-3-yl)-1-(5-methoxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (34)
Synthesis of Compound (34)
Compound (34) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (34). 1H NMR (300 MHz, CDCl3): δ 7.95 (brs, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 1H) 7.07 (m, 2H), 6.95 (s, 1H), 4.99 (brs, 1H), 4.10 (brs, 1H), 3.50-3.67 (m, 1H), 3.00-3.12 (d, 3H), 2.74-2.82 (m, 1H), 2.42-2.52 (m, 1H), 2.15-2.12 (m, 1H), 1.46-1.72 (m, 6H), 1.36-1.38 (d, 3H), 0.99-1.46 (m, 4H). LC-MS: (M+H)+=353.2; HPLC purity=90.44%.
Example 35
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (35)
Synthesis of Compound (35)
Compound (35) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (35). 1H NMR (300 MHz, CDCl3): δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.01 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=93.64%.
Example 36
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (36)
Synthesis of Compound (36) (Peak-1)
Racemate of Compound (35) was separated by using chiral HPLC to give enantiomer Compound (36) (peak-1). 1H NMR (300 MHz, CDCl3) δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.01 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=91.31%; Chiral purity=98.36% (RT=17.89 min).
Example 37
3-(4-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (37)
Synthesis of Compound (37) (peak-2)
Racemate of Compound (35) was separated by using chiral HPLC to give enantiomer Compound (37) (peak-2). 1H NMR (300 MHz, CDCl3) δ 8.44 (brs, 1H), 7.01-7.19 (m, 1H), 6.95-7.011 (m, 3H), 4.99 (brs, 1H), 4.23 (brs, 1H), 3.99-4.06 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.50 (m, 1H), 1.34-2.22 (m, 14H). LC-MS: (M+H)+=373.2; HPLC purity=97.96%; Chiral purity=99.11% (RT=15.94 min).
Example 38
1-[6-(cyclopropylmethoxy)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]-3-(1H-indol-3-yl)butan-1-one (38)
Synthesis of Compound (38)
Compound (38) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (38). 1H NMR (300 MHz, CDCl3): δ 7.92 (brs, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 2H), 7.01-7.02 (m, 2H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.45-3.61 (m, 1H), 3.08-3.16 (dd, 2H), 2.55-2.64 (m, 2H), 2.09-2.36 (m, 2H), 1.61-1.82 (m, 9H), 1.41-1.43 (d, 3H), 0.86-0.89 (m, 1H), 0.41-0.47 (m, 2H), 0.07 (m, 2H). LC-MS: (M+H)+=393.3; HPLC purity=95.10%.
Example 39
3-(4-chloro-1H-indol-3-yl)-1-[5-(difluoromethoxy)-2-azatricyclo[3.3.1.1 7 ]dec-2-yl]butan-1-one (39)
Synthesis of Compound (39)
Compound (39) was synthesized by following the procedure used to make and Compound (1) (Scheme 2) and Compound (13) (Scheme 8). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate as eluent to obtain Compound (39). 1H NMR (300 MHz, CDCl3): δ 8.22 (brs, 1H), 7.06 (brs, 2H), 6.99-7.01 (m, 2H), 5.9-6.4 (t, 1H), 5.03 (brs, 1H), 4.26 (brs, 1H), 4.03-4.04 (m, 1H), 2.83-2.87 (m, 1H), 2.49-2.57 (m, 1H), 2.28 (brs, 1H), 1.93 (m, 1H), 1.62-2.01 (m, 10H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=423.2; HPLC purity=92.19%.
Example 40
3-(4-bromo-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (40)
Synthesis of Compound (40)
Compound (40) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (40). 1H NMR (300 MHz, DMSO-d6): δ 11.21 (brs, 1H), 7.32-7.36 (m, 2H), 7.14-7.17 (d, 1H), 6.92-6.97 (t, 1H), 4.80 (brs, 1H), 4.66 (s, 1H), 4.33 (brs, 1H), 3.99-4.06 (m, 1H), 2.50-2.55 (m, 1H), 2.19 (brs, 1H), 1.69 (brs, 2H), 1.62-2.01 (m, 8H), 1.38-1.41 (d, 3H). LC-MS: (M+H)+=418.1; HPLC purity=92.77%.
Example 41
3-(4-cyclopropyl-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (41)
Synthesis of Compound (41)
Compound (41) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (41). 1H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.01-7.1 (d, 1H), 6.97-7.02 (m, 2H, 6.66-6.68 (d, 1H), 5.03 (brs, 1H), 4.19 (brs, 2H), 2.77-2.83 (m, 1H), 2.35-2.44 (m, 2H), 2.24 (brs, 1H), 1.75 (brs, 2H), 1.57-1.66 (m, 8H), 1.36-1.38 (d, 3H), 0.73-0.94 (m, 4H). LC-MS: (M+H)+=379.2; HPLC purity=97.64%.
Example 42
3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indole-4-carbonitrile (42)
Synthesis of Compound (42)
Compound (42) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (42). 1H NMR (300 MHz, CDCl3): δ8.97 (s, 1H), 7.47-7.50 (d, 1H), 7.38-7.40 (d, 1H), 7.18 (m, 1H), 7.07-7.13 (m, 1H), 4.95 (s, 1H), 4.30 (s, 1H), 3.86-3.93 (m, 1H), 2.81-2.91 (m, 1H), 2.56-2.66 (m, 1H), 2.23 (s, 1H), 1.57-1.74 (m, 10H), 1.39-1.41 (d, 3H). LC-MS: (M+H)+=364.2; HPLC purity=97.36%.
Example 41
3-(4-cyclopropyl-1H-indol-3-yl)-1-5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (41)
Synthesis of Compound (41)
Compound (41) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (41). 1H NMR (300 MHz, CDCl3): δ 7.97 (brs, 1H), 7.01-7.1 (d, 1H), 6.97-7.02 (m, 2H, 6.66-6.68 (d, 1H), 5.03 (brs, 1H), 4.19 (brs, 2H), 2.77-2.83 (m, 1H), 2.35-2.44 (m, 2H), 2.24 (brs, 1H), 1.75 (brs, 2H), 1.57-1.66 (m, 8H), 1.36-1.38 (d, 3H), 0.73-0.94 (m, 4H). LC-MS: (M+H)+=379.2; HPLC purity=97.64%.
Example 42
3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indole-4-carbonitrile (42)
Synthesis of Compound (42)
Compound (42) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (42). 1H NMR (300 MHz, CDCl3): δ8.97 (s, 1H), 7.47-7.50 (d, 1H), 7.38-7.40 (d, 1H), 7.18 (m, 1H), 7.07-7.13 (m, 1H), 4.95 (s, 1H), 4.30 (s, 1H), 3.86-3.93 (m, 1H), 2.81-2.91 (m, 1H), 2.56-2.66 (m, 1H), 2.23 (s, 1H), 1.57-1.74 (m, 10H), 1.39-1.41 (d, 3H). LC-MS: (M+H)+=364.2; HPLC purity=97.36%.
Example 43
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-carboxylic acid (43)
Synthesis of Compound (43)
Compound (43) was synthesized by following the procedure used to make Intermediate-26 (Scheme 4). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (43). 1H NMR (300 MHz, CDCl3): δ 12.25 (s, 1H), 11.20 (s, 1H), 7.29-7.31 (m, 2H), 6.96-7.04 (m, 2H), 4.78 (s, 1H), 4.28 (s, 1H), 3.92-3.99 (m, 1H), 2.55-2.76 (m, 2H), 2.11 (s, 1H), 1.59-1.89 (m, 10H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=401.1; HPLC purity=89.33%.
Example 44
3-[4-(4-chlorophenoxy)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (44)
Synthesis of Compound (44)
Compound (44) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (44). 1H NMR (300 MHz, CDCl3): δ 8.12 (s, 1H), 7.21-7.24 (m, 2H), 7.04-7.07 (m, 2H), 6.94-7.01 (m, 2H), 6.92-6.93 (m, 1H), 6.40-6.43 (d, 1H), 4.94 (s, 1H), 4.11 (s, 1H), 3.57-3.63 (m, 1H), 2.78-2.85 (m, 1H), 2.32-2.42 (m, 1H), 2.16 (s, 1H), 1.66-1.69 (d, 3H), 1.43-1.47 (m, 7H), 1.38-1.39 (d, 3H). LC-MS: (M+H)+=465.2; HPLC purity=99.73%.
Example 45
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-N-(4-fluorophenyl)-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (45)
Synthesis of Compound (45)
Compound (45) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (45). 1H NMR (300 MHz, CDCl3): δ 8.21-8.24 (d, 1H), 7.34-7.42 (m, 2H), 7.19 (m, 2H), 6.91-7.04 (m, 5H), 4.96 (s, 1H), 4.18 (s, 1H), 4.01-4.12 (m, 1H), 2.80-2.89 (m, 1H), 2.41-2.59 (m, 1H), 2.19-2.26 (m, 1H), 1.60-1.97 m, 10H), 1.37-1.40 (m, 3H). LC-MS: (M+H)+=494.2; HPLC purity=98.06%.
Example 46
3-[4-chloro-1-(methylsulfonyl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (46)
Synthesis of Compound (46)
Compound (46) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (46). 1H NMR (300 MHz, CDCl3): δ 7.74-7.77 (m, 1H), 7.20-7.22 (m, 3H), 5.01 (s, 1H), 4.22 (s, 1H), 4.08 (s, 1H), 3.02 (s, 3H), 2.73-2.802 (m, 1H), 2.33-2.42 (m, 1H), 2.28 (s, 1H), 1.77 (s, 2H), 1.60-1.66 (m, 9H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=451.1; HPLC purity=94.52%.
Example 47
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (47)
Synthesis of tert-butyl 3-(4-(5-carbamoyl-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-4-chloro-1H-indole-1-carboxylate (Intermediate-46)
To a stirred solution of compound 43 (0.070 g, 0.17 mmol) in MeCN (2 mL), pyridine (0.016 g, 0.21 mmol) was added, followed by di-tert-butyl dicarbonate (0.045 g, 0.21 mmol) and stirred for 1 hour at room temperature. To this solution solid ammonium bicarbonate (0.021 g, 0.27 mmol) was added and stirred at room temperature for 12 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O and extracted with EtOAc and concentrated to give Intermediate-46 (30 mg) as white solid.
Synthesis of Compound (47)
To a stirred solution of Intermediate-46 (0.030 g, 0.017 mmol) in DCM (1 mL), TFA (0.013 g, 0.11 mmol) was added at 0° C. and stirred at room temperature for 4 hours. After completion of the reaction, the reaction mixture was concentrated to remove DCM and TFA. The reaction mixture was further diluted with H 2 O and extracted with EtOAc and was then concentrated to give crude material which was purified by using Silica-gel column chromatography eluting with mixture of hexanes:EtOAc to give Compound (47) (145 mg) as white solid. 1H NMR (300 MHz, CDCl3): δ 11.20 (s, 1H), 7.29-7.31 (d, 2H), 6.96-7.04 (m, 3H), 6.81 (s, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 3.89-4.02 (m, 1H), 2.68-2.72 (m, 2H), 2.10 (s, 1H), 1.62-1.85 (m, 10H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=400.2; HPLC purity=99.92%.
Example 48
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (48)
Synthesis of ethyl 3-(4-bromo-1H-indol-3-yl)butanoate (Intermediate-47)
Intermediate-47 was synthesized by following the procedure used to make Intermediate-41 (Scheme 11).
Synthesis of ethyl 3-(4-methyl-1H-indol-3-yl)butanoate (Intermediate-48)
A 100 mL RB flask fitted with magnetic stirrer and reflux condenser was charged with 25 mL of toluene and 5 mL of water. To the stirred solvent Intermediate-47 (4.4 g, 14.185 mmol) was added followed by the addition of methyl boronic acid (1.696 g, 28.37 mmol), Potassium phosphate tribasic (10.535 g, 49.647 mmol) and tricyclohexyl phosphine (0.397 g, 1.4185 mmol). The resulting mass was stirred at room temperature under argon purging for 30 minutes. Then Palladium acetate (0.159, 0.7092 mmol) was added and the resulting mixture was stirred at 100° C. for 16 hours. After completion of the reaction mass was diluted with 10 mL of water and was extracted with ethyl acetate (100 mL×3) and the combine organic layer was washed with brine solution and was dried over anhydrous sodium sulfate and solvent from the organic layer was removed under reduced pressure to yield the crude compound. Crude mass was purified by column chromatography using 60-120 silica gel and 8% of ethyl acetate in Pet ether as eluent to give Intermediate-48 (2.55 g).
Synthesis of 3-(4-methyl-1H-indol-3-yl)butanoic acid (Intermediate-49)
Compound Intermediate-49 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (48)
Compound (48) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate (1:4) as eluent to obtain Compound (48). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=98.43%.
Example 49
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (49)
Synthesis of Compound (49) (Peak-1)
Racemate of Compound (48) was separated by using chiral HPLC to give enantiomer Compound (49) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=95.87%; Chiral purity=100% (RT=17.45 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 50
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (60)
Synthesis of Compound (50) (Peak-2)
Racemate of Compound (48) was separated by using chiral HPLC to give enantiomer, Compound (50) (peak-2). 1H NMR (300 MHz, DMSO-d6): δ 10.78 (s, 1H), 7.12-7.15 (d, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.80 (s, 1H), 4.64-4.65 (d, 1H), 4.33 (s, 1H), 3.69-3.76 (m, 1H), 2.63-2.68 (m, 2H), 2.60 (s, 3H), 2.15-2.19 (d, 1H), 1.68 (s, 2H), 1.42-1.63 (m, 8H), 1.23-1.25 (d, 3H). LC-MS: (M+H)+=353.2; HPLC purity=98.64%; Chiral purity=100% (RT=21.17 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 51
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (51)
Synthesis of Compound (51)
Compound (51) was synthesized by following the procedure used to make Compound 43 (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum DCM:MeOH as eluent to obtain Compound (51). 1H NMR (300 MHz, DMSO-d6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.2; HPLC purity=91.19%.
Example 62
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (52)
Synthesis of Compound (52) (Peak-1)
Racemate of Compound (51) was separated by using chiral HPLC to give enantiomer Compound (52) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.3; HPLC purity=89.77%; Chiral purity=100% (RT=8.29 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 53
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (53)
Synthesis of Compound (53) Peak-2
Racemate of Compound (51) was separated by using chiral HPLC to give enantiomer, Compound (53) (peak-2). 1H NMR (300 MHz, DMSO-6): δ 12.23 (s, 1H), 10.801 (s, 1H), 7.11-7.17 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.75 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (m, 1H), 3.37-3.41 (m, 2H), 2.68-2.73 (m, 1H), 2.09 (s, 1H), 1.62-1.88 (m, 13H), 0.85-00.91 (m, 2H), 0.70-0.77 (m, 2H). LC-MS: (M+H)+=407.3; HPLC purity=86.37%; Chiral purity=94.78% (RT=11.60 min), Column: Chiralpak IC 4.6 mm×250 mm, Mobile phase, hexane:IPA:DCM (75:15:10).
Example 64
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid sodium salt (sodium salt) (54)
Synthesis of Compound (54) (Sodium Salt)
To a stirred solution of Compound (51) (306 mg, 0.72 mmol) in THF:MeOH:H 2 O (2 mL: 3 mL: 1 mL), sodium hydroxide (26 mg, 0.65 mmol) was added at 0° C. Resulted reaction mixture was allowed to stir at room temperature for 16 hours. Then reaction mixture was concentrated, followed by trituration with mixture of hexane:ether to give Compound (54) (sodium salt) (25 mg) as a white solid. 1H NMR (300 MHz, DMSO-6): δ. 10.92 (s, 1H), 7.12-7.15 (m, 2H), 6.87-6.92 (t, 1H), 6.54-6.57 (d, 1H), 4.69 (s, 1H), 4.17 (s, 1H), 4.02-4.03 (m, 1H), 3.39-3.41 (m, 2H), 2.61-2.7 (m, 2H), 1.28-1.79 (m, 13H), 0.89-0.92 (m, 2H), 0.70-0.76 (m, 2H) LC-MS: (M+H)+=407.3; HPLC purity=96.31%.
Example 55
2-[3-(4-bromo-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (55)
Synthesis of Compound (55)
Compound (55) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum DCM:MeOH as eluent to obtain Compound (55). 1H NMR (300 MHz, DMSO-d6): δ 12.25 (s, 1H), 11.20 (s, 1H), 7.32-7.36 (m, 2H), 7.14-7.17 (d, 1H), 6.92-6.97 (t, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 4.01-4.05 (m, 1H), 2.70-2.77 (m, 2H), 2.11 (s, 2H), 1.60-1.89 (m, 9H), 1.26-1.28 (d, 3H). LC-MS: (M+H)+=445.1; HPLC purity=90.50%.
Example 56
2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (56)
Synthesis of Compound (56)
Compound (56) was synthesized by following the procedure used to make Compound (47) (Scheme 16). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (56). 1H NMR (300 MHz, DMSO-d6): δ 10.79 (s, 1H), 9.50 (s, 2H), 7.01-7.17 (m, 1H), 6.88-6.93 (m, 1H), 6.79 (s, 1H), 6.55-6.58 (d, 1H), 4.74 (s, 1H), 4.26 (s, 1H), 4.01-4.04 (d, 1H), 2.6-2.8 (m, 3H), 2.07-2.08 (m, 2H), 1.15-1.98 (m, 12H), 0.83-0.95 (m, 2H), 0.70-0.95 (m, 2H). LC-MS: (M+H)+=406.2; HPLC purity=88.73%.
Example 57
2-[3-(4-methyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (57)
Synthesis of Compound (57)
Compound (57) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (57). 1H NMR (300 MHz, DMSO-d6): δ 12.25 (s, 1H), 10.78 (s, 1H), 7.12-7.15 (m, 2H), 6.87-6.92 (t, 1H), 6.67-6.69 (d, 1H), 4.74 (s, 1H), 4.28 (s, 1H), 3.76-3.80 (m, 1H), 2.61-2.68 (m, 5H), 2.08-2.11 (m, 1H), 1.48-1.88 (m, 10H), 1.24-1.26 (d, 3H). LC-MS: (M+H)+=381.2; HPLC purity=99.05%.
Example 58
3-(4-chloro-1H-indol-3-yl)-1-[5-(hydroxymethyl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (58)
Synthesis of Compound (58)
Compound (58) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (58). 1H NMR (300 MHz, CDCl3): δ 11.19 (s, 1H), 7.28-7.31 (m, 2H), 6.96-7.04 (m, 2H), 4.72 (s, 1H), 4.42-4.45 (m, 1H), 4.24 (s, 1H), 3.91-3.95 (m, 1H), 2.99-3.01 (m, 2H), 2.67-2.75 (m, 3H), 2.07 (s, 1H), 1.42-1.63 (m, 9H), 1.25-1.28 (d, 3H). LC-MS: (M+H)+=387.1; HPLC purity=97.41%.
Example 59
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (59)
Synthesis of Compound (59)
Compound (59) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (59). 1H NMR (300 MHz, CDCl3): δ 8.10 (s, 1H), 7.21-7.25 (m, 1H), 7.00-7.03 (m, 3H), 4.90 (s, 1H), 4.02-4.12 (m, 2H), 2.77-2.87 (m, 1H), 2.37-2.49 (m, 1H), 2.06-2.12 (m, 3H), 1.60-1.94 (m, 8H), 1.37-1.40 (m, 3H). LC-MS: (M+H)+=382.3; HPLC purity=97.62%.
Example 60
3-(4-chloro-2-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (60)
Synthesis of Compound (60)
Compound (60) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (60). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.08-7.10 (d, 1H), 6.99-7.03 (m, 1H), 6.88-6.94 (t, 1H), 4.91-5.00 (m, 1H), 4.00-4.33 (m, 2H), 2.56-2.67 (m, 1H), 2.40 (s, 3H), 2.21-2.24 (m, 1H), 1.74-1.80 (m, 2H), 1.54 (m, 9H), 1.36-1.38 (d, 3H). LC-MS: (M+H)+=387.1; HPLC purity=98.42%.
Example 61
2-[3-(1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (61)
Synthesis of Compound (61)
Compound (61) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (61). 1H NMR (300 MHz, DMSO-d6): δ 12.21 (s, 1H), 10.77 (s, 1H), 7.51-7.54 (d, 1H), 7.29-7.32 (m, 1H), 7.12-7.13 (d, 1H), 7.01-7.06 (t, 1H), 6.92-6.97 (t, 1H), 4.72 (s, 1H), 4.20 (s, 1H), 3.39-3.45 (m, 1H), 2.65-2.72 (m, 1H), 2.09 (s, 1H), 1.85 (s, 2H), 1.73-1.77 (d, 3H), 1.43-1.66 (m, 6H), 1.29-1.31 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=93.96%.
Example 62
2-{3-[4-(4-fluorophenyl)-1H-indol-3-yl]butanoyl}-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (62)
Synthesis of Compound (62)
Compound (62) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (62). 1H NMR (300 MHz, CDCl3): δ 8.30 (s, 1H), 7.31-7.39 (m, 2H), 7.25-7.29 (d, 1H), 7.08-7.12 (t, 1H), 7.04-7.05 (m, 3H), 6.82-6.85 (d, 1H), 4.75 (s, 1H), 3.56-3.68 (t, 1H), 3.13-3.14 (d, 1H), 2.25-2.30 (m, 2H), 1.88-1.92 (m, 3H), 1.71-1.75 (m, 6H), 1.58 (s, 3H), 1.48-1.54 (d, 2H). LC-MS: (M+H)+=461.2; HPLC purity=95.42%.
Example 63
4-{[({2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}carbonyl)amino]methyl}benzoic acid (63)
Synthesis of Compound (63)
Compound (63) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (63). 1H NMR (300 MHz, DMSO-d6): δ 12.80 (s, 1H), 10.81 (s, 1H), 8.12-8.20 (m, 1H), 7.86-7.89 (d, 2H), 7.28-7.31 (m, 2H), 7.12-7.17 (t, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.77 (s, 1H), 4.30 (s, 2H), 4.04 (s, 1H), 2.61-2.80 (m, 1H), 2.50-2.54 (m, 2H), 2.08-2.13 (t, 1H), 1.86-1.91 (m, 4H), 1.63-1.78 (m, 6H), 1.50-1.55 (d, 1H), 1.28-1.31 (d, 3H), 0.89-0.91 (m, 2H), 0.69-0.74 (m, 2H). LC-MS: (M+H)+=540.3; HPLC purity=95.62%.
Example 64
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)pentan-1-one (64)
Synthesis of Compound (64)
Compound (64) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (64). 1H NMR (300 MHz, CDCl3): δ 8.03 (s, 1H), 7.58-7.61 (d, 1H), 7.26-7.29 (d, 1H), 7.07-7.12 (t, 1H), 6.99-7.04 (t, 1H), 6.94 (s, 1H), 4.93 (s, 1H), 4.01-4.04 (d, 1H), 3.25-3.35 (m, 1H), 2.70-2.79 (m, 1H), 2.56-2.59 (m, 1H), 2.03-2.17 (d, 1H), 1.75-1.85 (m, 2H), 1.56-1.65 (m, 5H), 1.31-1.45 (m, 3H), 1.18-1.22 (m, 2H), 0.77-0.82 (m, 3H) LC-MS: (M+H)+=353.2; HPLC purity=94.01%.
Example 65
2-[3-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (65)
Synthesis of Compound (65)
Compound (65) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (65). 1H NMR (300 MHz, CDCl3): δ 7.92-7.95 (d, 1H), 7.58-7.61 (d, 1H), 7.27-7.32 (t, 1H), 7.09-7.13 (t, 1H), 7.01-7.06 (t, 1H), 6.95 (d, 1H), 4.83-4.87 (d, 1H), 3.83-3.94 (d, 1H), 3.55-3.62 (m, 1H), 2.69-2.77 (m, 1H), 2.42-2.50 (m, 1H), 2.07-2.10 (m, 1H), 1.93-2.00 (m, 4H), 1.86 (s, 1H), 1.74-1.79 (d, 1H), 1.57-1.64 (m, 4H), 1.40-1.43 (m, 3H). LC-MS: (M+H)+=348.2; HPLC purity=91.69%.
Example 66
3-cyclopropyl-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (66)
Synthesis of Compound (66)
Compound (66) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (66). 1H NMR (300 MHz, CDCl3): δ 8.01-8.05 (m, 1H), 7.59-7.62 (d, 1H), 7.26-7.29 (d, 1H), 7.07-7.12 (t, 1H), 6.98-7.04 (m, 2H), 4.93 (s, 1H), 4.60-4.61 (d, 1H), 4.08-4.11 (d, 1H), 2.84-2.91 (m, 1H), 2.65-2.78 (m, 2H), 2.04-2.18 (s, 1H), 1.65 (s, 2H), 1.57 (s, 2H), 1.44 (m, 2H), 1.32-1.34 (m, 3H), 0.47-0.56 (m, 1H), 0.35-0.39 (m, 1H), 0.25-0.32 (m, 1H), 0.06-0.13 (m, 2H). LC-MS: (M+H)+=365.2; HPLC purity=93.07%.
Example 67
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)-3-phenylpropan-1-one (67)
Synthesis of 3-(1H-indol-3-yl)-3-phenylpropanoic acid (Intermediate-61)
Intermediate-51 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (67)
Compound (67) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (67). 1H NMR (300 MHz, DMSO-d6): δ 10.85 (s, 1H), 7.28-7.33 (m, 5H), 7.18-7.23 (t, 2H), 7.07-7.12 (t, 1H), 6.97-7.02 (t, 1H), 6.83-6.88 (t, 1H), 4.67-4.71 (m, 1H), 4.62-4.65 (m, 1H), 4.56 (s, 1H), 4.35 (s, 1H), 3.01-3.08 (m, 2H), 1.98-2.13 (d, 1H), 1.63 (s, 2H), 1.55 (s, 1H), 1.47-1.50 (d, 3H), 1.38-1.41 (m, 2H), 1.25-1.28 (m, 2H). LC-MS: (M+H)+=401.2; HPLC purity=94.67%.
Example 68
3-(5-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (68)
Synthesis of Compound (68)
Compound (68) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (68). 1H NMR (300 MHz, CDCl3): δ 8.10 (s, 1H), 7.55-7.56 (d, 1H), 7.21-7.25 (d, 1H), 7.04-7.07 (d, 1H), 6.99 (s, 1H), 4.97 (s, 1H), 4.03-4.13 (m, 1H), 3.54-3.62 (m, 1H), 2.64-2.72 (d, 1H), 2.44-2.54 (d, 1H), 2.15-2.30 (m, 2H), 1.76 (s, 4H), 1.70 (s, 3H), 1.62 (s, 2H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=373.1; HPLC purity=92.50%.
Example 69
3-(6-chloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (69)
Synthesis of Compound (69)
Compound (69) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (69). 1H NMR (300 MHz, CDCl3): δ 8.03 (s, 1H), 7.49-7.51 (d, 1H), 7.27 (s, 1H), 6.95-7.01 (m, 2H), 4.91-5.01 (s, 1H), 4.08 (s, 1H), 3.56-3.58 (m, 1H), 2.69-2.73 (d, 1H), 2.54 (s, 1H), 2.11-2.27 (m, 1H), 1.8 (s, 1H), 1.68 (s, 9H), 1.37-1.40 (d, 3H). LC-MS: (M+H)+=373.1; HPLC purity=91.91%.
Example 70
2-[3-(4-methyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (70)
Synthesis of Compound (70)
Compound (70) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (70). 1H NMR (300 MHz, CDCl3): δ 7.94 (s, 1H), 7.12-7.14 (d, 1H), 6.96-7.02 (m, 2H), 6.77-6.79 (d, 1H), 4.91 (s, 1H), 4.04 (s, 1H), 3.89 (s, 1H), 2.65 (s, 3H), 2.37-2.48 (m, 1H), 2.25-2.30 (m, 1H), 2.12 (s, 2H), 2.06 (s, 2H), 1.98-2.02 (d, 2H), 1.86-1.94 (s, 2H), 1.71-1.77 (m, 3H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=362.2; HPLC purity=95.85%.
Example 71
3-(4-chlorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (71)
Synthesis of Compound (71)
Compound (71) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (71). 1H NMR (300 MHz, CDCl3): δ 8.01-8.13 (t, 1H), 7.25-7.28 (d, 2H), 7.18 (m, 4H), 7.05-7.10 (t, 1H), 6.93-6.96 (d, 2H), 4.92 (s, 1H), 4.79 (s, 1H), 4.11 (s, 1H), 2.97-3.05 (m, 2H), 2.15 (s, 1H), 1.69 (s, 7H), 1.45 (d, 3H). LC-MS: (M+H)+=435.1; HPLC purity=95.96%.
Example 72
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ′]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)-3-phenylpropan-1-one (72)
Synthesis of Compound (72)
Compound (72) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (72). 1H NMR (300 MHz, CDCl3): δ 8.13-8.21 (d, 1H), 7.14-7.15 (d, 4H), 7.04-7.11 (m, 2H), 6.99 (s, 1H), 6.90-6.96 (m, 1H), 6.64-6.66 (d, 1H), 5.08-5.13 (t, 1H), 4.92 (s, 1H), 4.13 (s, 1H), 2.89-3.02 (m, 2H), 2.4 (d, 3H), 2.08-2.21 (m, 1H), 1.81 (s, 1H), 1.68 (s, 2H), 1.62 (s, 2H), 1.39 (s, 2H), 0.78-0.90 (m, 3H). LC-MS: (M+H)+=415.2; HPLC purity=99.51%.
Example 73
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (73)
Synthesis of Compound (73)
Compound (73) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (73). 1H NMR (300 MHz, DMSO-d6): δ 10.87 (s, 1H), 7.28-7.31 (m, 5H), 6.98-7.05 (m, 3H), 6.84-6.89 (t, 1H), 4.58-4.71 (m, 3H), 4.36 (s, 1H), 2.97-3.12 (m, 2H), 2.08-2.13 (d, 1H), 1.64 (s, 2H), 1.41-1.55 (m, 6H), 1.20.-1.35 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=95.83%.
Example 74
1-(5-hydroxy-2-azatricyclo[3.3.1.1 7 ]dec-2-yl)-4-methyl-3-(4-methyl-1H-indol-3-yl)pentan-1-one (74)
Synthesis of Compound (74)
Compound (74) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (74). 1H NMR (300 MHz, DMSO-d6): δ 10.77 (s, 1H), 7.11-7.13 (d, 2H), 6.85-6.90 (t, 1H), 6.64-6.66 (d, 1H), 4.66 (s, 1H), 4.58-4.62 (d, 1H), 4.38-4.40 (d, 1H), 3.70 (s, 1H), 2.67-2.76 (m, 2H), 2.64 (s, 3H), 2.05-2.16 (d, 1H), 1.84-1.86 (m, 1H), 1.52-1.64 (m, 5H), 0.1.36-1.48 (m, 5H), 0.82-0.90 (m, 6H). LC-MS: (M+H)+=381.2; HPLC purity=97.77%.
Example 76
3-(5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (75)
Synthesis of Compound (75)
Compound (75) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (75). 1H NMR (300 MHz, DMSO-d6): δ 10.88 (s, 1H), 7.28-7.32 (m, 2H), 7.21-7.24 (m, 1H), 6.85-6.91 (m, 1H), 4.78 (s, 1H), 4.58-4.64 (d, 1H), 4.23-4.25 (d, 1H), 3.16-3.39 (m, 2H), 2.53-2.69 (m, 2H), 2.15-2.17 (m, 1H), 1.65 (s, 2H), 1.54-1.57 (m, 3H), 1.36-1.49 (m, 4H), 1.29-1.30 (d, 3H). LC-MS: (M+H)+=356.1; HPLC purity=98.0%.
Example 76
3-(4-chloro-1H-indol-3-yl)-1-[5-(1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (76)
Synthesis of Compound (76)
Compound (76) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (76). 1H NMR (300 MHz, CD3OD): δ 7.10-7.21 (m, 3H), 6.93 (s, 2H), 4.30-4.35 (d, 1H), 4.08 (s, 1H), 2.89 (s, 1H), 2.54-2.61 (m, 2H), 1.90-1.94 (m, 4H), 1.74-1.77 (m, 5H), 1.24-1.37 (m, 6H). LC-MS: (M+H)+=426.1; HPLC purity=99.36%.
Example 77
3-(4-methyl-1H-indol-3-yl)-1-[5-(1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (77)
Synthesis of Compound (77)
To a stirred solution of Intermediate-52 (20 mg, 0.05 mmol) in toluene (10 mL) NaN 3 (37 mg, 0.5 mmol) was added along with trimethyltin chloride (49 mg, 0.25 mmol) under N 2 atmosphere, Resulted reaction mixture was heated at 110° C. for 12 hours. After completion of the reaction (monitored by TLC), the reaction mixture was quenched with water and was extracted with ethyl acetate (3×10 mL). The combined organic layer was concentrated to obtain a crude product. The resulted crude product was purified by prep. TLC eluted with DCM:MeOH to give Compound (77) (8 mg) as white solid. 1H NMR (300 MHz, CD3OD): δ 7.06-7.15 (m, 2H), 6.84-6.94 (m, 11H), 6.67-6.72 (m, 1H), 4.69-4.81 (m, 1H), 4.30-4.35 (d, 1H), 3.92-3.98 (m, 1H), 2.82-2.90 (m, 1H), 2.68 (d, 3H), 2.57-2.64 (m, 1H), 2.21 (s, 1H), 1.96-2.11 (m, 5H), 1.8 (s, 3H), 1.70-1.74 (m, 2H), 1.57-1.61 (d, 1H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=405.2; HPLC purity=98.31%.
Example 78
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(7-methyl-1H-indol-3-yl)butan-1-one (78)
Synthesis of Compound (78)
Compound (78) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (78). 1H NMR (300 MHz, CDCl3): δ 7.88 (s, 1H), 7.44-7.46 (d, 1H), 6.90-7.03 (m, 3H), 3.52-3.61 (m, 1H), 2.72-2.79 (m, 1H), 2.40-2.50 (m, 1H), 2.40 (m, 3H), 2.22-2.23 (m, 1H), 1.70 (s, 3H), 1.49-1.61 (m, 6H), 1.45 (s, 3H), 1.40-1.43 (m, 3H). LC-MS: (M+H)+=353.2; HPLC purity=97.30%.
Example 79
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (79)
Synthesis of Compound (79)
Compound (79) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (79). 1H NMR (300 MHz, CDCl3): δ 7.99 (s, 1H), 7.55-7.60 (m, 1H), 6.98-7.04 (m, 2H), 6.84-6.91 (m, 1H), 5.04 (s, 1H), 4.15 (s, 1H), 3.56-3.68 (m, 1H), 2.74-2.82 (m, 1H), 2.48-2.55 (m, 1H), 2.29-2.18 (s, 1H), 1.76 (s, 2H), 1.67 (s, 2H), 1.57-1.62 (m, 4H), 1.48-1.50 (m, 2H), 1.43-1.46 (m, 3H). LC-MS: (M+H)+=357.2; HPLC purity=91.94%.
Example 80
3-[4-cyclopropyl-1-(2-hydroxyethyl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (80)
Synthesis of Compound (80)
Compound (80) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (80). 1H NMR (300 MHz, CDCl3): δ 7.14-7.19 (m, 1H), 7.06-7.11 (m, 1H), 7.00 (s, 1H), 6.73-6.75 (d, 1H), 5.06 (s, 1H), 4.27 (s, 1H), 4.20-4.24 (m, 3H), 3.91-3.95 (m, 2H), 2.76-2.90 (m, 1H), 2.56-2.64 (m, 1H), 2.43-2.51 (m, 1H), 2.31 (s, 1H), 1.79 (s, 2H), 1.68 (s, 2H), 1.63-1.65 (d, 4H), 1.57 (s, 3H), 1.42-1.46 (m, 3H), 0.97-1.02 (m, 2H), 0.79-0.90 (m, 2H). LC-MS: (M+H)+=423.2; HPLC purity=97.26%.
Example 81
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (81)
Synthesis of Compound (81) (Peak-1)
Racemate of Compound (73) was separated by using chiral HPLC to give enantiomer Compound (81) (peak-1) 1H NMR (300 MHz, CDCl3): δ 10.87 (s, 1H), 7.20 (m, 5H), 7.00-7.05 (m, 3H), 6.83 (m, 1H), 4.66-4.68 (m, 1H), 4.58 (m, 2H), 4.40 (s, 1H), 3.10 (s, 2H), 2.08-2.13 (d, 1H), 1.61.23-1.55 (m, 8H), 1.11-1.15 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=94.26%; Chiral purity=100% (RT=8.57 min), Chiral column: Chiralpak IC 4.6 mm×250 mm, Mobile phase hexane:EtOH:DCM (75:15:10).
Example 82
3-(4-fluorophenyl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (82)
Synthesis of Compound (82) (Peak-2)
Racemate of Compound (73) was separated by using chiral HPLC to give enantiomer Compound (82) (peak-2). 1H NMR (300 MHz, CDCl3): δ 10.87 (s, 1H), 7.20 (m, 5H), 7.00-7.05 (m, 3H), 6.83 (m, 1H), 4.66-4.68 (m, 1H), 4.58 (m, 2H), 4.40 (s, 1H), 3.10 (s, 2H), 2.08-2.13 (d, 1H), 1.61.23-1.55 (m, 8H), 1.11-1.15 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=97.71%; Chiral purity=100% (RT=10.56 min), Chiral column: Chiralpak IC 4.6 mm×250 mm, Mobile phase hexane:EtOH:DCM (75:15:10).
Example 83
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (83)
Synthesis of Compound (83)
Compound (83) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (83). 1H NMR (300 MHz, DMSO-d6): 511.17 (s, 1H), 7.35-7.37 (m, 1H), 7.14-7.27 (m, 4H), 7.06-7.11 (m, 2H), 6.93-7.00 (m, 1H), 6.58-6.64 (m, 1H), 4.80-4.85 (t, 1H), 4.70 (s, 1H), 4.60-4.65 (d, 1H), 4.37 (s, 1H), 2.93-3.17 (m, 2H), 2.07-2.27 (m, 2H), 1.64 (s, 2H), 1.40-1.53 (m, 3H), 1.36 (m, 2H), 1.23-1.28 (m, 2H). LC-MS: (M+H)+=419.2; HPLC purity=96.72%.
Example 84
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (84)
Synthesis of Compound (84)
Intermediate-53 was synthesized by following the procedure used to make Intermediate-36 (Scheme 7). Compound (84) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain (84). 1H NMR (300 MHz, CDCl3): δ 7.90-7.93 (d, 1H), 7.76-7.79 (d, 1H), 7.36-7.41 (t, 1H), 7.26-7.31 (t, 1H), 4.96 (s, 1H), 4.33 (s, 1H), 3.84-3.86 (d, 1H), 3.04-3.11 (m, 1H), 2.58-2.73 (m, 1H), 2.23-2.27 (d, 1H), 1.72-1.76 (d, 4H), 1.55-1.65 (m, 6H), 1.45-1.47 (d, 3H). LC-MS: (M+H)+=357.1; HPLC purity=98.96%.
Example 86
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (86)
Synthesis of 3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butanoic acid (Intermediate-64)
Intermediate-54 was synthesized by following the procedure used to make Intermediate-42 (Scheme 11).
Synthesis of Compound (85)
Compound (85) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether Ethyl acetate as eluent to obtain Compound (85). 1H NMR (300 MHz, CDCl3): δ 9.29 (s, 1H), 8.19-8.21 (m, 1H), 7.93-7.96 (m, 1H), 7.07 (s, 1H), 6.97-7.01 (m, 1H), 4.76 (s, 1H), 3.89 (s, 1H), 3.52-3.66 (m, 1H), 2.65-2.73 (m, 1H), 2.42-2.49 (m, 1H), 1.97 (s, 11H), 1.84 (s, 1H), 1.65-1.68 (m, 4H), 1.61-1.65 (m, 3H), 1.56-1.57 (d, 2H), 1.41-1.49 (m, 1H), 1.35 (d, 3H). LC-MS: (M+H)+=324.2; HPLC purity=94.58%.
Example 86
1-(5-hydroxy-2-azatricyclo[3.3.1.1]dec-2-yl)-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (86)
Synthesis of Compound (86)
Compound (86) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (86). 1H NMR (300 MHz, CDCl3): δ 8.82-9.01 (m, 1H), 8.19-8.21 (d, 1H), 7.94-7.96 (m, 1H), 7.05 (s, 1H), 6.98-7.02 (m, 1H), 4.96 (s, 1H), 4.08 (s, 1H), 3.55-3.62 (m, 1H), 2.65-2.72 (m, 1H), 2.42-2.55 (m, 1H), 2.09-2.29 (m, 1H), 1.69 (s, 3H), 1.50 (s, 2H), 1.18-1.44 (m, 5H), 1.18 (s, 1H), 0.78-0.98 (m, 2H). LC-MS: (M+H)+=340.2; HPLC purity=99.20%.
Example 87
3-(4-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (87)
Synthesis of Compound (87)
Compound (87) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (87). 1H NMR (300 MHz, DMSO-d6): δ11.77 (s, 1H), 8.09-8.11 (d, 1H), 7.38-7.43 (m, 1H), 7.10-7.11 (d, 1H), 4.80 (s, 1H), 4.66 (s, 1H), 4.35 (s, 1H), 3.84 (s, 1H), 2.69 (m, 3H), 2.18 (s, 1H), 1.45-1.68 (m, 9H), 1.23-1.30 (m, 3H). LC-MS: (M+H)+=374.2; HPLC purity=96.68%.
Example 88
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butan-1-one (88)
Synthesis of Compound (88)
Compound (88) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether. Ethyl acetate (1:4) as eluent to obtain Compound (88). 1H NMR (300 MHz, CDCl3): δ11.91-11.95 (d, 1H), 7.97-7.99 (d, 1H), 7.26-7.29 (d, 1H), 7.05-7.06 (d, 1H), 4.89-4.94 (d, 1H), 4.26 (s, 1H), 3.91 (s, 1H), 3.04-3.06 (m, 1H), 2.90 (s, 3H), 2.50-2.66 (m, 2H)(, 2.27 (s, 1H), 1.36-1.78 (m, 9H), 1.29-1.32 (d, 3H). LC-MS: (M+H)+=354.2; HPLC purity=99.38%.
Example 89
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)propan-1-one (89)
Synthesis of Compound (89)
Compound (89) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (89). LC-MS: (M+H)+=402.2; HPLC purity=95.83%.
Example 90
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)pentan-1-one (90)
Synthesis of Compound (90)
Compound (90) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using Petroleum ether:Ethyl acetate (1:4) as eluent to obtain Compound (90). 1H NMR (300 MHz, CDCl3): δ11.48-11.50 (d, 1H), 8.28-8.33 (t, 1H), 8.14-8.16 (d, 1H), 7.22 (m, 2H), 4.75-4.80 (d, 1H), 4.13 (s, 1H), 3.32-3.37 (m, 1H), 2.63-2.69 (m, 3H), 2.12-2.20 (d, 1H), 1.95-2.04 (m, 1H), 1.36-1.70 (m, 9H), 0.89-0.93 (m, 3H), 0.77-0.81 (m, 3H). LC-MS: (M+H)+=368.2; HPLC purity=94.67%.
Example 91
2-[3-(1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (91)
Synthesis of Compound (91)
Compound (91) was synthesized by following the procedure used to make Intermediate-26 (Scheme 4). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (91). 1H NMR (300 MHz, CDCl3): δ 11.09 (s, 1H), 8.08-8.13 (m, 2H), 7.06-7.10 (m, 2H), 4.71 (s, 1H), 3.64-3.72 (m, 2H), 2.66-2.74 (t, 1H), 2.36-2.41 (m, 1H), 2.01-2.04 (d, 1H), 1.80-1.84 (d, 1H), 1.48-1.70 (m, 8H), 1.43-1.45 (d, 3H), 1.18-1.22 (m, 1H). LC-MS: (M+H)+=368.2; HPLC purity=98.93%.
Example 92
2-[4-methyl-3-(1H-pyrrolo[2,3-b]pyridin-3-yl)pentanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (92)
Synthesis of Compound (92)
Compound (92) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (92). 1H NMR (300 MHz, CDCl3): δ 10.75-10.78 (d, 1H), 8.18-8.25 (m, 2H), 7.19-7.20 (m, 2H), 4.72 (s, 1H), 4.03 (s, 1H), 3.33-3.35 (m, 1H), 2.61-2.70 (m, 2H), 2.13 (s, 1H), 1.97-2.02 (m, 4H), 1.81-1.90 (m, 2H), 1.09-1.68 (m, 5H), 0.90-0.92 (m, 3H), 0.77-0.79 (d, 3H). LC-MS: (M+H) + =377.2; HPLC purity=97.71%.
Example 93
3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (93)
Synthesis of Compound (93)
Compound (93) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (93). 1H NMR (300 MHz, DMSO-d6): δ 10.91 (s, 1H), 7.36 (m, 1H), 7.18-7.23 (m, 2H), 7.12-7.15 (d, 1H), 7.01-7.06 (t, 2H), 6.85-6.902 (t, 1H), 6.58-6.60 (d, 1H), 4.99-5.02 (m, 1H), 4.74 (m, 1H), 4.58-4.66 (d, 1H), 4.36 (m, 1H), 2.95-2.97 (m, 2H), 2.42 (s, 3H), 2.07-2.17 (m, 1H), 1.28-1.65 (m, 10H). LC-MS: (M+H) + =433.2; HPLC purity=94.79%.
Example 94
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (94)
Synthesis of Compound (94)
Compound (94) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (94). 1H NMR (300 MHz, DMSO-d6): δ 10.94 (s, 1H), 7.30-7.32 (m, 4H), 7.19-7.26 (m, 2H), 7.04-7.13 (m, 2H), 6.69-6.75 (t, 1H), 4.71 (s, 1H), 4.56-4.65 (m, 2H), 4.35 (s, 1H), 3.02-3.05 (m, 2H), 2.06-2.13 (d, 1H), 1.63 (s, 2H), 1.20-1.59 (m, 8H). LC-MS: (M+H) + =419.1; HPLC purity=93.86%.
Example 95
3-cyclopropyl-3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (95)
Synthesis of Compound (95)
Compound (95) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (95). 1H NMR (300 MHz, CDCl3): δ 8.13 (s, 1H), 6.93-7.08 (m, 3H), 6.66-6.73 (m, 1H), 4.93 (s, 1H), 4.24 (s, 1H), 2.94-3.04 (m, 1H), 2.66-2.75 (m, 1H), 2.60 (s, 1H), 2.08-2.20 (d, 1H), 1.21-1.67 (m, 10H), 0.76-0.97 (m, 1H), 0.49-0.53 (m, 1H), 0.26-0.32 (m, 2H), 0.05-0.07 (m, 1H). LC-MS: (M+H) + =383.1; HPLC purity=96.02%.
Example 96
3-(2,4-difluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1H-indol-3-yl)propan-1-one (96)
Synthesis of Compound (96)
Compound (96) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (96). 1H NMR (300 MHz, DMSO-d6): δ 10.90 (s, 1H), 7.36-7.41 (m, 1H), 7.32 (m, 2H), 7.29 (m, 1H), 7.11-7.15 (t, 1H), 6.97-7.05 (t, 1H), 6.88-6.95 (m, 2H), 4.93 (t, 1H), 4.69 (s, 1H), 4.62-4.64 (d, 1H), 4.40 (s, 1H), 2.72-3.11 (m, 2H), 2.14-2.27 (m, 1H), 1.24-1.66 (m, 10H). LC-MS: (M+H)=437.1; HPLC purity=92.20%.
Example 97
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (97)
Synthesis of Compound (97) (Peak-1)
Racemate of (79) was separated by chiral HPLC column chromatography to give Compound (97) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.90 (S, 1H), 7.48-7.53 (m, 1H), 6.92-6.97 (m, 2H), 6.78-6.84 (t, 1H), 4.97 (s, 1H), 4.09 (s, 1H), 3.52-3.96 (m, 1H), 2.67-2.75 (m, 1H), 2.41-2.48 (m, 1H), 2.11-2.22 (d, 1H), 1.60 (m, 6H), 1.36-1.39 (m, 6H). LC-MS: (M+H) + =357.1; HPLC purity=93.22%; Chiral purity: 100% (RT=15.45 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 98
3-(6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-) (98)
Synthesis of Compound (98) (Peak-2)
Racemate of Compound (79) was separated by chiral HPLC column chromatography to give Compound (98) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.89 (S, 1H), 7.48-7.53 (m, 1H), 6.93-6.97 (m, 2H), 6.78-6.84 (t, 1H), 4.97 (s, 1H), 4.08 (s, 1H), 3.52-3.59 (m, 1H); 2.67-2.75 (m, 1H), 2.41-2.48 (m, 1H), 2.11-2.22 (d, 1H), 1.54-1.69 (m, 9H), 1.36-1.38 (d, 3H). LC-MS: (M+H) + =357.2; HPLC purity=95.14%; Chiral purity: 99.35% (RT=19.0 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 99
3-(4-fluoro-1H-indol-3-yl)-3-(4-fluorophenyl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (99)
Synthesis of Compound (99)
Compound (99) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (99). 1H NMR (300 MHz, DMSO-d6): δ 11.19-11.23 (d, 1H), 7.37 (s, 1H), 7.27-7.29 (t, 2H), 7.12-7.14 (d, 1H), 6.93-7.05 (m, 3H), 6.58-6.65 (m, 1H), 4.80-4.84 (m, 1H), 4.70 (s, 1H), 4.59-4.65 (d, 1H), 4.37 (s, 1H), 2.96-3.11 (m, 2H), 2.08-2.16 (d, 1H), 1.29-1.65 (m, 1 OH). LC-MS: (M+H) + =437.1; HPLC purity=99.01%.
Example 100
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile Peak-1 (100)
Synthesis of Compound (100) (Peak-1)
Racemate of Compound (59) was separated by preparative chiral column to give Compound (100) (peak-1). 1H NMR (300 MHz, CDCl3): δ 8.06 (s, 1H), 7.32 (m, 1H), 7.00-7.02 (m, 3H), 4.90 (s, 1H), 3.96-4.11 (m, 2H), 2.77-2.87 (m, 1H), 2.40-2.48 (m, 1H), 1.60-2.12 (m, 11H), 1.37-1.40 (m, 3H). LC-MS: (M+H) + =382.1; HPLC purity=98.74%; Chiral purity: 100% (RT=16.17 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 101
2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile Peak-2 (101)
Synthesis of Compound (101) (Peak-2)
Racemate of Compound (59) was separated by preparative chiral column to give Compound (101) (peak-2). 1H NMR (300 MHz, CDCl3): δ 8.07 (s, 1H), 7.00-7.04 (m, 4H), 4.90 (s, 1H), 3.96-4.11 (m, 2H), 2.77-2.87 (m, 1H), 2.40-2.48 (m, 1H), 1.60-2.12 (m, 11H), 1.37-1.40 (m, 3H). LC-MS: (M+H) + =382.1; HPLC purity=98.08%; Chiral purity: 100% (RT=30.89 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 102
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (102)
Synthesis of Compound (102) (Peak-1)
Racemate of Compound (41) was separated by preparative chiral column to give Compound (102) (peak-1). 1H NMR (300 MHz, DMSO-d6): δ 10.80 (s, 1H), 7.12-7.16 (m, 2H), 6.88-6.963 (t, 1H), 6.55-6.58 (d, 1H), 4.81 (s, 1H), 4.65 (d, 1H), 4.32 (s, 1H), 4.01-4.06 (m, 1H), 2.67-2.72 (m, 2H), 2.17 (s, 1H), 1.43-1.68 (m, 11H), 1.27-1.30 (d, 3H), 0.89-0.95 (m, 2H), 0.73-0.86 (m, 2H). LC-MS: (M+H) + =379.2; HPLC purity=98.53%; Chiral purity: 100% (RT=15.36 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 103
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-2 (103)
Synthesis of Compound (103) (Peak-2)
Racemate of Compound (41) was separated by preparative chiral column to give Compound (103) (peak-2). 1H NMR (300 MHz, DMSO-d6): δ 10.80 (s, 1H), 7.12-7.16 (m, 2H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.81 (s, 1H), 4.65 (d, 1H), 4.32 (s, 1H), 3.97-4.05 (m, 1H), 2.67-2.72 (m, 2H), 2.17 (s, 1H), 1.43-1.68 (m, 11H), 1.27-1.30 (d, 3H), 0.83-0.95 (m, 2H), 0.70-0.74 (m, 2H). LC-MS: (M+H) + =379.2; HPLC purity=99.43%; Chiral purity: 100% (RT=22.17 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7.5:1.5:1.0).
Example 104
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)butan-1-one (104)
Synthesis of Compound (104)
Compound (104) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (104). 1H NMR (300 MHz, DMSO-d6): δ 10.79 (s, 1H), 7.12-7.16 (m, 2H), 6.87-6.92 (mt, 1H), 6.67-6.69 (d, 1H), 4.92 (s, 1H), 4.48 (s, 1H), 3.73-3.80 (m, 1H), 2.65-2.72 (m, 1H), 2.61 (s, 3H), 2.27-2.36 (m, 2H), 1.42-1.93 (m, 10H), 1.24-1.26 (d, 3H). LC-MS: (M+H) + =355.2; HPLC purity=98.31%.
Example 106
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(1,3-benzothiazol-2-yl)butan-1-one (106)
Synthesis of Compound (105)
Compound (105) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (105). 1H NMR (300 MHz, CDCl3): δ 7.87-7.89 (d, 1H), 7.74-7.77 (d, 1H), 7.33-7.38 (tm 1H), 7.23-7.28 (t, 1H), 4.77 (s, 1H), 4.05 (s, 1H), 3.65-3.89 (m, 1H), 2.96-3.03 (m, 1H), 2.55-2.57 (m, 1H), 1.66-2.01 (m, 12H), 1.33-1.35 (d, 3H). LC-MS: (M+H) + =341.1; HPLC purity=98.67%.
Example 106
3-(1,3-benzothiazol-2-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (106)
Synthesis of Compound (106)
Compound (106) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (106). 1H NMR (300 MHz, CDCl3): δ 7.85-7.88 (d, 1H), 7.75-7.78 (m, 1H), 7.33-7.39 (m, 1H), 7.23-7.29 (m, 1H), 5.04 (s, 1H), 4.40 (s, 1H), 3.79-3.88 (m, 1H), 3.01-3.09 (m, 1H), 2.53-2.61 (m, 1H), 2.36 (d, 1H), 1.50-1.88 (m, 10H), 1.42-1.47 (d, 3H). LC-MS: (M+H) + =359.1; HPLC purity=95.97%.
Example 107
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (107)
Synthesis of (107)
Compound (107) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (107). 11H NMR (300 MHz, DMSO-d6): δ 7.91-8.00 (m, 2H), 7.22-7.50 (m, 7H), 4.95-5.00 (m, 1H), 4.64-4.69 (m, 2H), 4.43 (s, 1H), 3.52-3.59 (m, 1H), 2.95-3.04 (m, 1H), 2.08-2.20 (m, 1H), 1.23-1.79 (m, 10H). LC-MS: (M+H) + =419.1; HPLC purity=99.70%.
Example 108
3-(1,3-benzothiazol-2-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (108)
Synthesis of Compound (108)
Compound (108) was synthesized by following the procedure used to make Compound (24) (Scheme 12). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (108). 1H NMR (300 MHz, DMSO-d6): δ7.90-8.00 (m, 2H), 7.22-7.50 (m, 7H), 4.95-5.01 (m, 1H), 4.82 (s, 1H), 4.60 (s, 1H), 3.53-3.61 (m, 1H), 2.96-3.09 (m, 1H), 2.27-2.35 (m, 1H), 1.23-1.79 (m, 10H). LC-MS: (M+H) + =421.1; HPLC purity=92.61%.
Example 109
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (109)
Synthesis of Compound (109)
Compound (109) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (109). 1H NMR (300 MHz, DMSO-d6): δ 10.61 (s, 1H), 7.18-7.22 (d, 1H), 7.09 (s, 1H), 6.96 (s, 1H), 6.68-6.71 (m, 1H), 4.79 (s, 1H), 4.59-4.64 (d, 1H), 4.25-4.28 (m, 1H), 3.74 (s, 3H), 3.37-3.40 (m, 1H), 2.63-2.72 (m, 2H), 2.07-2.37 (m, 1H), 1.27-1.65 (m, 13H). LC-MS: (M+H) + =369.2; HPLC purity=98.14%.
Example 110
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methyl-1H-indol-3-yl)butan-1-one (110)
Synthesis of Compound (110)
Compound (110) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (110). 1H NMR (300 MHz, DMSO-d6): δ 10.62 (s, 1H), 7.29 (s, 1H), 7.18-7.21 (d, 1H), 7.06 (s, 1H), 6.85-6.88 (d, 1H), 4.80 (s, 1H), 4.61-4.65 (d, 1H), 4.28 (s, 1H), 3.39 (m, 1H), 2.62-2.72 (m, 2H), 2.36 (s, 3H), 2.10-2.27 (m, 1H), 1.27-1.66 (m, 13H). LC-MS: (M+H) + =353.2; HPLC purity=95.0%.
Example 111
2-[3-(4-fluoro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (111)
Synthesis of Compound (111)
Compound (111) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (111). 1H NMR (300 MHz, DMSO-d6): δ 12.17 (s, 1H), 11.18 (s, 1H), 7.37 (s, 1H), 7.17-7.31 (m, 4H), 7.05-7.14 (m, 2H), 6.92-6.99 (m, 1H), 6.57-6.64 (m, 1H), 4.81-4.86 (t, 1H), 4.64 (s, 1H), 4.31 (s, 1H), 3.00-3.07 (m, 2H), 1.30-2.07 (m, 11H). LC-MS: (M+H) + =447.3; HPLC purity=98.60%.
Example 112
2-[3-(6-fluoro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (112)
Synthesis of Compound (112)
Compound (112) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (112). 1H NMR (300 MHz, DMSO-d6): δ 12.19 (s, 1H), 10.94 (s, 1H), 7.30-7.33 (m, 4H), 7.18-7.27 (m, 2H), 7.03-7.13 (m, 2H), 6.69-6.74 (m, 1H), 4.61-4.66 (m, 2H), 4.29 (s, 1H), 3.02-3.05 (d, 2H), 2.72 (m, 2H), 1.32-2.08 (m, 9H). LC-MS: (M+H) + =447.2; HPLC purity=96.93%.
Example 113
3-(5-fluoro-2-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (113)
Synthesis of Compound (113)
Compound (113) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (113). 1H NMR (300 MHz, DMSO-d6): δ 10.74 (s, 1H), 7.26-7.31 (m, 1H), 7.15-7.20 (m, 1H), 6.73-6.80 (m, 1H), 4.72 (s, 1H), 4.51-4.61 (m, 1H), 4.09 (s, 1H), 3.35-3.39 (m, 1H), 2.70-2.80 (m, 2H), 2.29 (s, 3H), 1.97-2.14 (d, 1H), 0.74-1.60 (m, 13H). LC-MS: (M+H) + =371.2; HPLC purity=97.40%.
Example 114
3-(1,3-benzothiazol-2-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-1 (114)
Synthesis of Compound (114) (Peak-1)
Racemate of Compound (84) was separated by preparative chiral HPLC column to give Compound (114) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.75-7.78 (d, 1H), 7.34-7.39 (t, 1H), 7.24-7.29 (t, 1H), 4.96 (s, 1H), 4.31 (s, 1H), 3.79-3.86 (m, 1H), 2.99-3.07 (m, 1H), 2.54-2.62 (m, 1H), 2.22-2.27 (m, 1H), 1.43-1.75 (m, 14H). LC-MS: (M+H) + =357.1; HPLC purity=99.8%; Chiral purity: 100% (RT=16.99 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7:2:1).
Example 115
3-(1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Peak-2 (115)
Synthesis of Compound (115) (Peak-2)
Racemate of Compound (84) was separated by preparative chiral HPLC column to give Compound (115) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.86-7.89 (d, 1H), 7.75-7.78 (d, 1H), 7.34-7.39 (t, 1H), 7.24-7.29 (t, 1H), 4.96 (s, 1H), 4.31 (s, 1H), 3.79-3.86 (m, 1H), 2.99-3.07 (m, 1H), 2.54-2.62 (m, 1H), 2.22-2.27 (m, 1H), 1.43-1.76 (m, 14H). LC-MS: (M+H) + =357.1; HPLC purity=99.85%; Chiral purity: 100% (RT=23.47 min); Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexanes:i-PrOH:DCM (7:2:1).
Example 116
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methyl-1H-indol-3-yl)propan-1-one (116)
Synthesis of Compound (116)
Compound (116) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (116). 1H NMR (300 MHz, CDCl3): δ 7.90 (s, 1H), 7.10-7.13 (d, 1H), 6.96-7.01 (t, 1H), 6.92 (d, 1H), 6.76-6.78 (d, 1H), 5.02 (s, 1H), 4.13 (s, 1H), 3.18-3.23 (m, 2H), 2.64 (s, 3H), 2.58-2.63 (m, 2H), 2.24 (s, 1H), 1.49-1.74 (m, 11H). LC-MS: (M+H)=339.3; HPLC purity=91.46%.
Example 117
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (117)
Synthesis of Compound (117)
Compound (117) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (117). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H) + =403.2; HPLC purity=99.36%.
Example 118
2-[3-(1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (118)
Synthesis of Compound (118)
Compound (118) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (118). 1H NMR (300 MHz, CDCl3): δ 7.84-7.89 (dd, 1H), 7.76-7.78 (d, 1H), 7.34-7.40 (m, 1H), 7.25-7.30 (m, 1H), 4.86 (brs, 1H), 4.23 (brs, 1H), 3.79-3.87 (m, 1H), 3.00-3.09 (m, 1H), 2.49-2.59 (m, 1H), 1.90-2.18 (m, 8H), 1.63-1.76 (m, 3H), 1.45 (d, 3H). LC-MS: (M+H) + =366.2; HPLC purity=93.68%.
Example 119
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-chloro-1,3-benzothiazol-2-yl)butan-1-one (119)
Synthesis of Compound (119)
Compound (119) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexane:EtOAc as eluent to obtain Compound (119). 1H NMR (300 MHz, CDCl3): δ 7.64-7.67 (d, 1H), 7.36-7.39 (d, 1H), 7.15-7.21 (dd, 1H), 4.74 (brs, 1H), 4.10 (brs, 1H), 3.85-3.92 (q, 1H), 3.04-3.11 (dd, 1H), 2.53-2.61 (dd, 1H), 1.98-2.02 (m, 2H), 1.65-1.79 (m, 10H), 1.45 (d, 3H). LC-MS: (M+H) + =375.1; HPLC purity=98.71%.
Example 120
3-(4-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (120)
Synthesis of Compound (120)
Compound (120) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (120). 1H NMR (300 MHz, DMSO-d6): δ 8.02-8.05 (d, 1H), 7.56-7.58 (d, 1H), 7.36-7.41 (t, 1H), 4.65-4.72 (m, 2H), 4.34 (s, 1H), 3.80 (m, 1H), 2.80-3.20 (m, 2H), 1.45-2.22 (m, 11H), 1.39-1.42 (d, 3H). LC-MS: (M+H) + =391.1; HPLC purity=98.58%.
Example 121
3-(1H-benzotriazol-1-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-phenylpropan-1-one (121)
Synthesis of 3-(1H-benzotriazol-1-yl)-3-phenylpropanoic acid (Intermediate-55)
A 30 mL ACE pressure tube fitted with magnetic stirrer was charged with Starting Material-13 (2 g, 13.4 mmol) and Starting Material-8 (4.8 g, 40.4 mmol). Reaction mixture was heated at 150° C. for 12 hours. After completion of reaction, the mixture was diluted with ethyl acetate and concentrated. Resulted crude product was purified by Combiflash column chromatography eluting with hexanes:EtOAc to give Intermediate-55 (2.1 g).
Synthesis of Compound (121)
To a stirred solution of Intermediate-55 (75 mg, 0.28 mmol) in THF (4 mL) Intermediate-7 (43 mg, 0.28 mmol) and HBTU (126 mg, 0.3 mmol) was added. This was followed by addition of DIPEA (108 mg, 0.84 mmol) at 0° C. Resulted reaction mixture was stirred at room temperature for 1 hour. After completion of reaction, the resultant mass was first quenched with water, then extracted with ethyl acetate and then concentrated. Resulted crude product was purified by preparative TLC eluting with hexanes:EtOAc to give compound (121)(40 mg) as white solid. 1H NMR (300 MHz, DMSO-d6): δ 7.99-8.02 (d, 1H), 7.88-7.91 (d, 1H), 7.45-7.52 (m, 3H), 7.24-7.39 (m, 3H), 6.52-6.54 (d, 1H), 4.66-4.67 (d, 1H), 4.62 (s, 1H), 4.46 (s, 1H), 4.01-4.10 (m, 1H), 3.23-3.25 (m, 1H), 2.16 (s, 1H), 1.23-1.67 (m, 11H). LC-MS: (M+H)+=403.2; HPLC purity=93.95%.
Example 122
2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylic acid (122)
Synthesis of methyl 4-oxo-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-56)
To a stirred solution of Intermediate-27 (0.5 g, 2.3 mmol) in DCM (10 mL), PCC (1.01 g, 4.7 mmol) was added. The reaction mixture was then stirred at room temperature for 16 hours. After completion of reaction, the resultant mass was quenched with water and extracted with DCM. Organic layer was washed with 10% NaHCO 3 solution and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexanes:EtOAc to give Intermediate-56 (230 mg).
Synthesis of methyl 4-cyano-2-azatricyclo[3.3.1.1 3,7 ]decane-2-carboxylate (Intermediate-57)
To a stirred solution of Intermediate-56 (0.23 g, 1.1 mmol) and Tos MIC (0.3 g, 1.5 mmol) in DME:EtOH (5 mL: 0.2 mL), t-BuOK (0.37 g, 3.30 mmol) was added at 0° C. The reaction mixture was stirred at room temperature for 2 hours. Then reaction mixture was filtered. Filtrate portion was concentrated to give Intermediate-57 (230 mg).
Synthesis of 2-tert-butyl 4-ethyl 2-azatricyclo[3.3.1.1 3,7 ]decane-2,4-dicarboxylate (Intermediate-58)
A 100 mL RB fitted with magnetic stirrer was charged with Intermediate-57 (0.23 g, 1.04 mmol), and 5N H 2 SO 4 (25 mL). The reaction mixture was heated at 100° C. for 36 hours. After completion of reaction (monitored by LC-MS), the mixture was cooled to 0° C. Conc. HCl was added to the cooled mixture, followed by addition of EtOH. The mixture was then heated at 90° C. for 16 hours. The resultant mass was quenched with water, basified with sodium carbonate and washed with DCM. The aqueous layer was diluted with THF (40 mL) to which TEA (5 mL) and Boc-anhydride (0.360 g, 1.4 mmol) was added. The resulting mixture was stirred at room temperature for 12 hours. Then reaction mixture was extracted with ethyl acetate and concentrated. Resulted crude material was purified by silica gel column chromatography eluting with hexanes:EtOAc to give Intermediate-58 (130 mg).
Synthesis of ethyl 2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylate. Trifluoroacetic acid salt (Intermediate-59)
To a stirred solution of Intermediate-58 (0.13 g, 0.4 mmol) in DCM (5 mL), TFA (0.1 g, 0.8 mmol) was added at 0° C. Resulted reaction mixture was stirred for 4 hours at room temperature. After completion of the reaction (reaction was monitored by LC-MS), the resultant mass was concentrated followed by trituration with mixture of hexanes:ether (1:1) to give Intermediate-59 (130 mg).
Synthesis of ethyl 2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-4-carboxylate (Intermediate-60)
Intermediate-60 was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexanes:EtOAc as eluent to obtain Intermediate-60.
Synthesis of Compound (122)
Compound (122) was synthesized by following the procedure used to make Compound (43) (Scheme 14). 1H NMR (300 MHz, CDCl3): δ 8.30-9.30 (m, 1H), 7.00-7.02 (m, 2H), 6.87-6.89 (m, 1H), 6.77-6.79 (m, 2H), 6.62-6.65 (m, 1H), 6.46-6.56 (m, 1H), 5.02-5.33 (m, 1H), 4.34-4.73 (m, 1H), 3.99-4.12 (m, 1H), 2.92-3.61 (m, 2H), 1.45-2.64 (m, 11H). LC-MS: (M+H)+=453.2; HPLC purity=98.96%.
Example 123
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (123)
Synthesis of Compound (123)
Compound (123) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using hexanes:EtOAc as eluent to obtain Compound (123). 1H NMR (300 MHz, CDCl3): δ 7.65-7.67 (d, 1H), 7.36-7.40 (m, 1H), 7.22 (m, 1H), 4.84 (s, 1H), 4.26 (s, 1H), 3.84-3.91 (m, 1H), 3.11-3.20 (m, 1H), 2.48-2.58 (m, 1H), 1.55-2.15 (m, 11H), 1.45-1.47 (m, 3H). LC-MS: (M+H)+=400.1; HPLC purity=96.66%.
Example 124
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile Compound (124) peak 1
Synthesis of Compound (124) (Peak-1)
Racemic compound (123) was separated by chiral preparative HPLC to give Compound (124) (peak-1). LC-MS: (M+H)+=400.1; HPLC purity=91.31%; Chiral column, Chiralpak IC, 4.6 mm×250 m; Mobile Phase: hexane:i-PrOH:DCM (7:2:1); RT=23.47 minutes.
Example 126
2-[3-(4-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile Compound (125) peak 2
Synthesis of Compound (126) (Peak-2)
Racemate of Compound (123) was separated by chiral preparative HPLC to give Compound (125) peak-2 (125). LC-MS: (M+H)+=400.1; HPLC purity=97.74%; Chiral column, Chiralpak IC, 4.6 mm×250 m; Mobile Phase: hexane:i-PrOH:DCM (7:2:1); RT=27.72 minutes.
Example 126
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (126)
Synthesis of Compound (126)
Compound (126) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (126). 1H NMR (300 MHz, CDCl3): δ 8.00 (brs, 1H), 7.09-7.12 (d, 1H), 6.96-7.01 (t, 1H), 6.93-6.94 (d, 1H), 6.64-6.66 (1H, d), 5.01 (brs, 1H), 4.14 (brs, 1H), 3.31-3.36 (t, 2H), 2.65-2.70 (m, 2H), 2.32-2.41 (m, 1H), 2.23 (brs, 1H), 1.45-1.73 (m, 10H), 0.88-0.94 (m, 2H), 0.74-0.81 (M, 2H). LC-MS: (M+H)+=365.2; HPLC purity=98.22%.
Example 127
3-(4-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(thiophen-2-yl)propan-1-one (127)
Synthesis of Compound (127)
Compound (127) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (127). 1H NMR (300 MHz, CDCl3): δ 8.34 (brs, 0.5H), 8.30 (brs, 0.5H), 6.99-7.06 (m, 2H), 6.96-6.97 (m, 2H), 6.81-6.83 (m, 2H), 6.61-6.68 (m, 1H), 5.14-5.20 (m, 1H), 4.94 (brs, 1H), 4.23 (brs, 1H), 3.02-3.20 (m, 2H), 2.14 (brs, 1H), 1.35-1.70 (m, 10H). LC-MS: (M+H)+=425.2; HPLC purity=99.56%.
Example 128
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-propyl-1H-indol-3-yl)propan-1-one (128)
Synthesis of Compound (128)
Compound (128) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (128). 1H NMR (300 MHz, CDCl3): δ 7.99 (brs, 1H), 7.10-7.13 (d, 1H), 6.99-7.04 (t, 1H), 6.91-6.92 (d, 1H), 6.80-6.82 (d, 1H), 5.02 (brs, 1H), 4.13 (brs, 1H), 3.14-3.19 (t. 2H), 2.87-2.92 (t, 2H), 2.59-2.64 (m, 2H), 2.24 (brs, 1H), 1.53-1.74 (m, 12H), 0.93-0.98 (t, 3H). LC-MS: (M+H)+=367.2; HPLC purity=96.54%.
Example 129
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (129) peak 1
Synthesis of Compound (129) (Peak-1)
Racemate of Compound (117) was separated by chiral preparative HPLC to give Compound (129) (peak-1). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=403.2; HPLC purity=99.32%; Chiral Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexane:i-PrOH:DCM (7:2:1); RT=11.65 minutes.
Example 130
3-(6-chloro-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (130) peak 2
Synthesis of Compound (130) (Peak-2)
Racemate of compound (117) was separated by chiral preparative HPLC to give Compound (130) (peak-2). 1H NMR (300 MHz, CDCl3): δ 7.85 (brs, 1H), 7.30-7.31 (d, 1H), 7.09 (brs, 1H), 6.92-6.93 (m, 1H), 4.98 (brs, 1H), 4.09 (brs, 1H), 3.87 (s, 3H), 3.52-3.59 (m, 1H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.10 (brs, 1H), 1.41-1.70 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=403.2; HPLC purity=99.76%; Chiral Column: Chiralpak IC, 4.6 mm×250 mm; Mobile phase: hexane:i-PrOH:DCM (7:2:1); RT=14.60 minutes.
Example 131
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-methyl-3-(4-methyl-1H-benzotriazol-1-yl)pentan-1-one (131)
Synthesis of Compound (131)
Compound (131) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (131). 1H NMR (300 MHz, CDCl3): δ 7.37-7.40 (d, 1H), 7.26-7.31 (t, 1H), 7.02-7.04 (d, 1H), 5.00-5.06 (m, 1H), 4.81 (brs, 1H), 4.25 (brs, 1H), 3.47-3.65 (m, 2H), 2.72 (s, 3H), 2.2-2.34 (m, 1H), 2.10 brs, 1H), 1.35-1.75 (m, 10H), 0.96-0.98 (d, 3H), 0.72-0.74 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=94.65%.
Example 132
3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (132)
Synthesis of Compound (132)
Compound (132) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (132). 1H NMR (300 MHz, CDCl3): δ 9.30 (brs, 11H), 8.03-8.05 (d, 1H), 7.03 (s, 1H), 6.47-6.49 (d, 11-1H), 5.02 (brs, 1H), 4.21 (brs, 1H), 4.01 (brs, 1H), 2.73-2.78 (m, 1H), 2.33-2.49 (m, 2H), 2.26 (brs, 1H), 1.42-1.75 (m, 10H), 1.35-1.37 (d, 3H). LC-MS: (M+H)+=380.2; HPLC purity=98.45%.
Example 133
3-(6-chloro-5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (133)
Synthesis of Compound (133)
Compound (133) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (133). 1H NMR (300 MHz, CDCl3): δ 7.91 (brs, 1H), 7.31-7.34 (d, 1H), 7.28-7.30 (d, 1H), 6.99-7.00 (d, 1H), 4.98 (brs, 1H), 4.10 (brs, 1H), 3.47-3.54 (q, 11H), 2.63-2.71 (m, 1H), 2.40-2.44 (m, 1H), 2.15 (brs, 11H), 1.40-1.71 (m, 10H), 1.34-1.36 (d, 3H). LC-MS: (M+H)+=391.2; HPLC purity=97.57%.
Example 134
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (134)
Synthesis of Compound (134)
Compound (134) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (134). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.2; HPLC purity=99.58%.
Example 135
3-(5-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (135)
Synthesis of Compound (135)
Compound (135) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (135). 1H NMR (300 MHz, CDCl3): δ 9.15 (brs, 0.5H), 9.01 (brs, 1H), 8.15-8.16 (d, 1H), 7.91 (s, 1H), 7.09-7.10 (d, 1H), 4.97 (brs, 1H), 4.10 (brs, 1H), 3.51-3.58 (q, 1H), 2.61-2.68 (dd, 1H), 2.42-2.50 (dd, 1H), 2.24 (brs, 0.5H), 2.14 (brs, 0.5H), 1.44 (1.71 (m, 10H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=374.2; HPLC purity=98.36%.
Example 136
2-[3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (136)
Synthesis of Compound (136)
Compound (136) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (136). 1H NMR (300 MHz, DMSO-d6): δ 11.28 (brs, 1H), 7.99-8.00 (d, 11H), 7.25 (s, 11H), 6.52-6.53 (d, 1H), 4.72 (brs, 1H), 4.29 (brs, 1H), 3.85-3.89 (m, 11H), 2.55.-2.72 (m, 3H), 2.09 (brs, 1H), 1.45-1.99 (m, 10H), 1.28-1.30 (d, 3H), 1.00-1.05 (m, 2H), 0.83-0.88 (m, 2H). LC-MS: (M+H)+=389.3; HPLC purity=98.69%.
Example 137
2-[3-(6-chloro-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ′]decane-5-carbonitrile (137)
Synthesis of Compound (137)
Compound (137) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (137). 1H NMR (300 MHz, CDCl3): δ 8.98 (brs, 0.5H), 8.88 (brs, 0.5H), 8.15-8.20 (m, 1H), 7.90 (s, 1H), 7.10 (s, 1H), 4.90 (brs, 1H), 4.00 (brs, 1H), 3.50-3.60 (m, 1H), 2.58-2.62 (dd, 1H), 2.40-2.45 (m, 1H), 2.13-2.16 (m, 1H), 1.60-1.93 (m, 10H), 1.38-1.40 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=97.99%.
Example 138
3-(6-chloro-5-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (138)
Synthesis of Compound (138)
Compound (138) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (138). 1H NMR (300 MHz, CDCl3): δ 7.98 (brs, 0.5H), 7.95 (brs, 0.5H), 7.29 (s, 1H), 7.23 (s, 1H), 6.88 (s, 1H), 4.96 (brs, 1H), 4.09 (brs, 1H), 3.46-3.52 (q, 1H), 2.64-2.72 (dd, 1H), 2.38-2.45 (dd, 1H), 2.21-2.24 (m, 1H), 2.08-2.14 (m, 2H), 1.40-1.70 (m, 9H), 1.34-1.36 (d, 3H), 0.83-0.95 (m, 2H), 0.58-0.63 (m, 2H). LC-MS: (M+H)+=413.3; HPLC purity=95.14%.
Example 139
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one Compound (139)
Synthesis of Compound (139)
Compound (139) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (139). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=96.42%.
Example 140
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (Peak-1) (140)
Synthesis of Compound (140)
Racemate of compound (134) was separated by chiral preparative HPLC to give Compound (140). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.1; HPLC purity=99.56%; Chiral RT=7.95 min [column: ChiralPak IC, Mobile phase: hexane:IPA:DCM (7:2:1)].
Example 141
2-[3-(6-chloro-1H-indol-3-yl)-3-phenylpropanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (Peak-2) (141)
Synthesis of Compound (141)
Racemate of compound (134) was separated by chiral preparative HPLC to give Compound (141). 1H NMR (300 MHz, DMSO-d6): δ 12.34 (brs, 1H), 11.03 (s, 1H), 7.10-7.40 (m, 8H), 6.84-6.91 (m, 1H), 4.66 (brs, 2H), 4.30 (brs, 1H), 3.01-3.10 (m, 2H), 2.05 (brs, 1H), 1.55-1.98 (m, 10H). LC-MS: (M+H)+=463.1; HPLC purity=99.15%; Chiral RT=11.99 min [column: ChiralPak IC, Mobile phase: hexane:IPA:DCM (7:2:1)].
Example 142
2-[3-(5-phenyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxylic acid (142)
Synthesis of Compound (142)
Compound (142) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (142). 1H NMR (300 MHz, CDCl3): δ 7.96 (br s, 1H), 7.80 (br s, 1H), 7.56-7.59 (d, 2H), 7.32-7.39 (m, 4H), 7.24-7.29 (dd, 1H), 6.97-6.99 (m, 1H), 4.89 (br s, 1H), 4.04 (br s, 1H), 3.61-3.63 (m, 1H), 2.75-2.81 (dd, 1H), 2.48-2.52 (dd, 1H), 1.54-2.09 (m, 11H), 1.41-1.44 (dd, 3H). LC-MS: (M+H)+=443.2; HPLC purity=98.51%.
Example 143
2-[3-(6-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carboxylic acid (143)
Synthesis of Compound (143)
Compound (143) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (143). 1H NMR (300 MHz, DMSO-d6): δ 12.20 (br s, 1H), 11.00 (br s, 1H), 7.54 (br s, 1H), 7.30-7.34 (dd, 1H), 7.23 (br s, 1H), 7.01-7.05 (m, 1H), 4.71 (br s, 1H), 4.18 (br s, 1H), 3.67-3.78 (m, 1H), 2.62-2.68 (m, 1H), 2.43-2.47 (m, 1H), 1.39-1.97 (m, 11H), 1.29-1.31 (d, 3H). LC-MS: (M+H)+=401.2; HPLC purity=97.21%.
Example 144
3-(6-chloro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (144)
Synthesis of Compound (144)
Compound (144) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (144). 1H NMR (300 MHz, CDCl3): δ 7.95 (br s, 1H), 7.09-7.12 (d, 1H), 7.03-7.06 (d, 1H), 6.93-6.98 (d, 1H), 5.03 (br s, 1H), 4.19 (br s, 1H), 3.88-3.90 (m, 1H), 2.68 (s, 3H), 2.62-2.65 (m, 1H), 2.37-2.45 (m, 1H), 2.27 (br s, 1H), 1.54-1.76 (m, 10H), 1.32-1.34 (d, 3H). LC-MS: (M+H)+=387.2; HPLC purity=97.47%.
Example 145
{2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (145)
Synthesis of Compound (145)
Compound (145) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (145). 1H NMR (300 MHz, CDCl3): δ 8.39 (br s, 1H), 7.16-7.20 (m, 1H), 6.92-6.97 (m, 3H), 4.88 (br s, 1H), 4.20 (br s, 1H), 3.98-4.13 (m, 1H), 2.76-2.94 (m, 1H), 2.52-2.59 (m, 1H), 2.08 (br s, 2H), 2.04 (br s, 1H), 1.52-1.68 (m, 10H), 1.37-1.39 (d, 3H). LC-MS: (M+H)+=415.2; HPLC purity=97.51%.
Example 146
3-{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-6-yl}propanoic acid (146)
Synthesis of Compound (146)
Compound (146) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (146). 1H NMR (300 MHz, DMSO-d6): δ 12.01 (br s, 1H), 10.81 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.71 (br s, 1H), 4.20 (br s, 1H), 4.02-4.04 (m, 1H), 2.26-2.28 (m, 1H), 2.06-2.16 (m, 5H), 1.32-1.60 (m, 12H), 1.25-1.29 (d, 3H). LC-MS: (M+H)+=435.2; HPLC purity=98.38%.
Example 147
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (147)
Synthesis of Compound (147)
Racemic compound (139) was separated by using chiral preparative column chromatography to give Compound (147). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=96.98%. Chiral RT=10.82 min [Column: ChiralPak IC, Mobile phase: hexane:THF (7:3)].
Example 148
3-(5-fluoro-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (148)
Synthesis of Compound (148)
Racemic compound (139) was separated by using chiral preparative column chromatography to give Compound (148). 1H NMR (300 MHz, CDCl3): δ 7.89 (br s, 1H), 7.00-7.05 (dd, 1H), 6.98-6.99 (d, 1H), 6.81-6.87 (t, 1H), 5.04 (br s, 1H), 4.20 (br s, 1H), 3.84-3.93 (m, 1H), 2.65-2.71 (dd, 1H), 2.54-2.55 (d, 3H), 2.37-2.48 (dd, 1H), 2.26 (br s, 1H), 1.54-1.66 (m, 8H), 1.75 (br s, 2H), 1.39-1.43 (d, 3H). LC-MS: (M+H)+=371.2; HPLC purity=99.16%; Chiral RT=9.69 min [Column: ChiralPak IC, Mobile phase: hexane:THF (7:3)].
Example 149
3-(4-cyclopropyl-1H-indol-3-yl)-1-[5 (1H-tetrazol-5-yl)-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl]butan-1-one (149)
Synthesis of Compound (149)
Compound (149) was synthesized by following the procedure used to make Compound (77) (Scheme 21). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (149). 1H NMR (300 MHz, CDCl3): δ 8.38 (br s, 0.5H), 8.25 (br s, 0.5H), 7.02-7.07 (t, 1H), 6.98-7.00 (d, 1H), 6.89-6.94 (m, 1H), 6.56-6.66 (dd, 1H), 4.88-4.92 (d, 1H), 4.20 (br s, 1H), 3.47-3.50 (m, 1H), 2.78-2.85 (m, 1H), 2.46-2.59 (m, 1H), 2.29-2.34 (m, 1H), 2.17-2.19 (m, 1H), 1.61-2.01 (m, 10H), 1.32-1.38 (m, 3H), 0.72-0.79 (m, 2H), 0.63-0.65 (m, 2H). LC-MS: (M+H)+=431.2; HPLC purity=92.97%.
Example 150
3-(4-cyclopropyl-5-fluoro-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (150)
Synthesis of Compound (150)
Compound (150) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (150). 1H NMR (300 MHz, CDCl3): δ 7.93 (br s, 1H), 7.04-7.06 (d, 1H), 7.01-7.02 (d, 1H), 6.74-6.84 (dd, 1H), 5.02 (br s, 1H), 4.21-4.24 (m, 1H), 4.20 (br s, 1H), 2.68-2.75 (dd, 1H), 2.34-2.43 (dd, 1H), 2.22-2.25 (m, 1H), 2.00-2.09 (m, 1H), 1.52-1.75 (m, 10H), 1.31-1.34 (d, 3H), 0.99-1.03 (m, 2H), 0.83-0.87 (m, 2H). LC-MS: (M+H)+=397.2; HPLC purity=97.0%.
Example 151
3-(6-chloro-4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (151)
Synthesis of Compound (151)
Compound (151) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (151). 1H NMR (300 MHz, DMSO-d6): δ 11.04 (br s, 11H), 7.29 (br s, 1H), 7.17-7.20 (d, 1H), 6.98-7.00 (d, 1H), 4.79 (br s, 1H), 4.64-4.65 (d, 1H, OH group), 4.31 (br s, 1H), 4.22-4.23 (m, 1H), 2.60-2.72 (m, 2H), 2.07-2.27 (m, 2H), 1.38-1.68 (m, 10H). 1.24-1.27 (d, 3H), 0.80-0.85 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=413.1; HPLC purity=95.99%.
Example 152
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (152)
Synthesis of Compound (152)
Compound (152) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (152). 1H NMR (300 MHz, DMSO-d6): δ 10.82 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.72 (br s, 1H), 4.22 (br s, 1H), 4.00-4.06 (m, 1H), 2.68-2.73 (m, 2H), 2.43-2.46 (m, 3H), 1.99-2.05 (m, 1H), 1.45-1.68 (m, 10H), 1.28-1.30 (d, 3H), 0.85-0.90 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=98.6%.
Example 153
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (153)
Synthesis of Compound (153)
Compound (153) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (153). 1H NMR (300 MHz, CDCl3): δ 8.16 (br s, 1H), 7.31-7.34 (d, 1H), 7.23-7.26 (m, 1H), 7.10-7.15 (t, 1H), 7.02-7.08 (m, 4H), 4.89 (br s, 1H), 3.80 (br s, 1H), 3.38-3.40 (m, 1H), 2.38-2.43 (m, 1H), 2.19-2.22 (m, 1H), 1.97-2.01 (m, 1H), 1.45-1.71 (m, 10H), 1.37-1.39 (d, 3H). LC-MS: (M+H)+=421.1; HPLC purity=96.43%.
Example 154
(2-{3-[4-(thiophen-2-yl)-1H-indol-3-yl]butanoyl}-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl)acetic acid (154)
Synthesis of Compound (154)
Compound (154) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (154). 1H NMR (300 MHz, CDCl3): δ 8.68 (br s, 0.5H), 8.57 (br s, 0.5H), 7.22-7.30 (m, 2H), 7.01-7.09 (m, 5H), 4.77 (br s, 1H), 3.46 (br s, 11-1H), 3.31-3.35 (m, 1H), 2.35-2.48 (m, 2H), 2.07 (br s, 1H), 1.40-1.78 (m, 13H). LC-MS: (M+H)+=463.1; HPLC purity=92.86%.
Example 155
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (Peak-1) (155)
Synthesis of Compound (155)
Racemic compound (152) was purified by using chiral preparative HPLC chromatography to give Compound (155). 1H NMR (300 MHz, CDCl3): δ 7.98 (br s, 1H), 7.09-7.12 (d, 1H), 6.99-7.01 (d, 1H), 6.97 (br s, 1H), 6.66-6.78 (d, 1H), 4.89 (br s, 1H), 4.14-4.16 (m, 1H), 4.06 (br s, 1H), 2.75-2.82 (dd, 1H), 2.37-2.45 (m, 2H), 2.08 (s, 2H), 2.04 (br s, 1H), 1.52-1.71 (m, 10H), 1.36-1.38 (d, 3H), 0.90-0.95 (m, 2H), 0.76-0.81 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=98.67%; Chiral RT=9.07 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 156
{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (Peak-2) (156)
Synthesis of Compound (156)
Racemic compound (152) was purified by using chiral preparative HPLC chromatography to give Compound (156). 1H NMR (300 MHz, DMSO-d6): δ 10.82 (br s, 1H), 7.17 (br s, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.56-6.58 (d, 1H), 4.72 (br s, 1H), 4.22 (br s, 1H), 4.00-4.06 (m, 1H), 2.68-2.73 (m, 2H), 2.43-2.46 (m, 3H), 1.99-2.05 (m, 1H), 1.45-1.68 (m, 10H), 1.28-1.30 (d, 3H), 0.85-0.90 (m, 2H), 0.70-0.75 (m, 2H). LC-MS: (M+H)+=421.2; HPLC purity=99.66%; Chiral RT=12.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 157
3-(4-cyclopropyl-6-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (157)
Synthesis of Compound (157) (Peak-1)
Racemic compound (150) was purified by using chiral preparative HPLC chromatography to give Compound (157). LC-MS: (M+H)+=397.2; Chiral RT=10.98 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 158
3-(4-cyclopropyl-5-fluoro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (158)
Synthesis of Compound (158) (Peak 2)
Racemic compound (150) was purified by using chiral preparative HPLC chromatography to give Compound (157). LC-MS: (M+H)+=397.2; HPLC purity=98.48%; Chiral RT=14.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 159
{2-[3-(4-fluoro-1H-indol-3-yl)-3-(thiophen-2-yl)propanoyl]-2-azatricyclo[3.3.1.1 7 ]dec-5-yl}acetic acid (159)
Synthesis of Compound (159)
Compound (159) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (159). 1H NMR (300 MHz, DMSO-d6): δ 11.93 (br s, 1H), 11.21 (br s, 1H), 7.35 (s, 1H), 7.21-7.23 (m, 1H), 7.15-7.18 (d, 1H), 6.97-7.04 (m, 1H), 6.85-6.88 (m, 1H), 6.81-6.83 (m, 1H), 6.63-6.70 (dd, 1H), 5.09-5.11 (t, 1H), 4.65 (br s, 1H), 4.27 (br s, 1H), 3.10-3.17 (m, 1H), 2.95-3.05 (m, 1H), 2.01 (s, 2H), 1.97 (s, 2H), 1.40-1.66 (m, 10H). LC-MS: (M+H)+=467.1; HPLC purity=99.63%.
Example 160
3-(4-cyclopropyl-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (160)
Synthesis of Compound (160)
Compound (160) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (160). 1H NMR (300 MHz, CDCl3): δ 7.84 (br s, 1H), 7.04-7.07 (d, 1H), 6.97 (br s, 1H), 6.88-6.91 (d, 1H), 5.00 (br s, 1H), 4.34-4.47 (m, 1H), 4.20 (br s, 1H), 2.67-2.73 (dd, 1H), 2.43 (s, 3H), 2.29-2.37 (dd, 1H), 2.15-2.22 (m, 1H), 2.00-2.05 (m, 1H), 1.45-1.78 (m, 10H), 1.33-1.36 (m, 3H), 1.04-1.10 (M, 2H), 0.64-0.69 (m, 2H). LC-MS: (M+H)+=393.3; HPLC purity=98.30%.
Example 161
3-(4-chloro-6-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (161)
Synthesis of Compound (161)
Compound (161) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (161). 1H NMR (300 MHz, CDCl3): δ 8.03 (br s, 1H), 7.08-7.10 (d, 1H), 7.01-7.01 (d, 1H), 6.74-6.77 (d, 1H), 5.02 (br s, 1H), 4.26 (br s, 1H), 4.10-4.12 (m, 1H), 2.37-2.46 (m, 1H), 2.26-2.29 (m, 1H), 2.15-2.24 (m, 1H), 1.45-1.75 (m, 11H), 1.36-1.39 (d, 3H), 0.89-0.96 (m, 2H), 0.59-0.62 (m, 2H). LC-MS: (M+H)+=413.1; HPLC purity=98.97%.
Example 162
{2-[3-(4-bromo-5-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}acetic acid (162)
Synthesis of Compound (162)
Compound (162) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (162). 1H NMR (300 MHz, CDCl3): δ 8.70 (br s, 0.5H), 8.62 (br s, 0.5H), 7.12-7.15 (d, 1H), 7.07-7.09 (d, 1H), 7.01 (s, 1H), 4.87 (br s, 1H), 4.15-4.21 (m, 1H), 4.01 (br s, 1H), 2.72-2.85 (m, 1H), 2.45-2.60 (m, 1H), 2.29 (s, 2H), 2.04 (s, 1H), 1.50-1.75 (m, 10H). LC-MS: (M+H)+=493.2; HPLC purity=91.99%.
Example 163
3-(5-chloro-4-cyclopropyl-1H-indol-3-yl)-1-(5,7-dihydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (163)
Synthesis of Compound (163)
Compound (163) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (163). 1H NMR (300 MHz, CDCl3): δ 8.01 (br s, 1H), 7.06 (s, 2H), 7.01-7.02 (d, 1H), 4.27-4.42 (m, 1H), 3.50 (br s, 1H), 3.43 (br s, 1H), 2.62-2.77 (dd, 1H), 2.37-2.46 (dd, 1H), 2.11-2.13 (m, 1H), 1.83-1.98 (m, 4H), 1.62-1.68 (m, 4H), 1.55-1.58 (m, 2H), 1.33-1.35 (d, 3H), 1.12-1.16 (m, 2H), 0.76-0.84 (m, 2H). LC-MS: (M+H)+=429.1; HPLC purity=99.90%.
Example 164
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (164)
Synthesis of Compound (164)
Compound (164) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (164). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=97.04%.
Example 165
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(5-methoxy-4-methyl-1H-indol-3-yl)butan-1-one (165)
Synthesis of Compound (165)
Compound (165) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (165). 1H NMR (300 MHz, CDCl3): δ 7.77 (br s, 1H), 7.05-7.08 (d, 1H), 6.95-6.96 (d, 1H), 6.82-6.85 (d, 1H), 5.04 (br s, 1H), 4.19 (br s, 1H), 3.87-3.89 (m, 1H), 3.77 (s, 3H0, 2.67-2.73 (dd, 1H), 2.54 (s, 3H), 2.36-2.44 (dd, 1H), 2.24-2.26 (m, 1H), 1.55-1.75 (m, 10H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=383.2; HPLC purity=95.78%.
Example 166
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (166)
Synthesis of Compound (166)
Compound (166) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (166). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=388.2; HPLC purity=99.97%.
Example 167
2-{2-[3-(4-cyclopropyl-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}propanoic acid (167)
Synthesis of Compound (167)
Compound (167) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (167). 1H NMR (300 MHz, DMSO-d6): δ 12.01 (br s, 1H), 10.81 (s, 1H), 7.16-7.17 (d, 1H), 7.12-7.15 (d, 1H), 6.88-6.93 (t, 1H), 6.55-6.58 (d, 1H), 4.72 (br s, 1H), 4.24 (br s, 1H), 4.02-4.04 (m, 1H), 2.67-2.723 (m, 2H), 2.38-2.43 (m, 1H), 2.05-2.07 (m, 1H), 1.99-2.02 (m, 1H), 1.46-1.74 M, 10H), 1.28-1.30 (d, 3H), 0.95-0.98 (d, 3H), 0.83-0.88 (m, 2H), 0.70-0.74 (m, 2H). LC-MS: (M+H)+=435.2; HPLC purity=96.54%.
Example 168
3-(4,5-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (168)
Synthesis of Compound (168)
Compound (168) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (168). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 11-1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.1; HPLC purity=99.28%
Example 169
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (169)
Synthesis of Compound (169)
Racemic compound (164) was purified by using chiral preparative HPLC chromatography to give Compound (169). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=93.27%; Chiral RT=20.93 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 170
3-(4,5-dimethyl-1H-indol-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (170)
Synthesis of Compound (170)
Racemic compound (164) was purified by using chiral preparative HPLC chromatography to give Compound (170). 1H NMR (300 MHz, CDCl3): δ 7.92 (br s, 1H), 7.01-7.03 (d, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 5.03 (br s, 1H), 4.18 (br s, 1H), 3.92-3.95 (m, 1H), 2.68-2.74 (dd, 1H), 2.54 (s, 3H), 2.35-2.43 (dd, 1H), 2.29 (s, 3H), 2.20-2.25 (m, 1H), 1.52-1.75 (m, 11H), 1.33-1.35 (d, 3H). LC-MS: (M+H)+=367.2; HPLC purity=99.81%; Chiral RT=25.61 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 171
3-(4-cyclopropyl-5-methoxy-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (171)
Synthesis of Compound (171)
Compound (171) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (171). 1H NMR (300 MHz, CDCl3): δ 7.83 (br s, 1H), 7.06-7.09 (d, 1H), 6.98-6.99 (d, 1H), 6.78-6.81 (d, 1H), 5.02 (br s, 1H), 4.26-4.29 (m, 1H), 4.19 (br s, 1H), 3.78 (s, 3H), 2.69-2.76 (dd, 1H), 2.31-2.39 (dd, 1H), 2.22-2.25 (m, 1H), 1.95-1.99 (m, 2H), 1.45-1.75 (m, 9H), 1.34-1.36 (d, 3H), 0.99-1.01 (m, 2H), 0.79-0.81 (m, 2H). LC-MS: (M+H)+=409.2; HPLC purity=92.57%.
Example 172
3-(4,5-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (172)
Synthesis of Compound (172)
Racemic compound (168) was purified by using chiral preparative HPLC chromatography to give Compound (172). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.0; HPLC purity=94.74%; Chiral RT=8.15 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7:2:1)].
Example 173
3-(4,6-dichloro-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (173)
Synthesis of Compound (173)
Racemic compound (168) was purified by using chiral preparative HPLC chromatography to give Compound (173). 1H NMR (300 MHz, CDCl3): δ 8.18 (br s, 1H), 7.10-7.13 (d, 2H), 7.06-7.07 (d, 1H), 5.00 (br s, 1H), 4.24 (br s, 1H), 4.04-4.07 (m, 1H), 2.78-2.84 (m, 1H), 2.37-2.47 (dd, 1H), 2.24-2.26 (m, 1H), 1.73-1.78 (m, 3H), 1.61-1.65 (m, 7H), 1.35-1.38 (d, 3H). LC-MS: (M+H)+=407.0; HPLC purity=99.34%; Chiral RT=11.31 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7:2:1)].
Example 174
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (174)
Synthesis of Compound (174)
Racemic compound (166) was purified by using chiral preparative HPLC chromatography to give Compound (174). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=387.1; HPLC purity=95.57%; Chiral RT=15.30 min [column: ChiralPak IC, mobile phase: hexane:THF (7:3)].
Example 175
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (peak 2) (175)
Synthesis of Compound (176)
Racemic compound 166) was purified by using chiral preparative HPLC chromatography to give Compound (175). 1H NMR (300 MHz, CDCl3): δ 8.00 (br s, 1H), 7.08-7.10 (d, 1H), 6.98-7.00 (d, 1H), 6.95 (s, 1H), 5.02 (br s, 1H), 4.25 (br s, 1H), 4.09-4.11 (m, 1H), 2.82-2.87 (m, 1H), 2.40-2.44 (m, 1H), 2.38 (s, 3H), 2.23-2.25 (m, 1H), 1.55-1.78 (m, 11H). LC-MS: (M+H)+=387.1; HPLC purity=98.33%; Chiral RT=17.15 min [column: ChiralPak IC, mobile phase: hexane:THF (7:3)].
Example 176
3-(4,5-dimethyl-1H-indol-3-yl)-1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (176)
Synthesis of Compound (176)
Compound (176) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (176). 1H NMR (300 MHz, CDCl3): δ 8.06 (br s, 1H), 8.02-8.04 (d, 1H), 7.31-7.34 (d, 1H), 7.11-7.13 (d, 1H), 4.99-5.05 (m, 1H), 4.70-4.71 (m, 1H), 4.61-4.62 (m, 1H), 2.57-2.62 (m, 1H), 2.33-2.41 (m, 1H), 2.25 (s, 3H), 2.10 (s, 3H), 1.33-1.87 (m, 14H). LC-MS: (M−19)+=413.3; HPLC purity=90.92%.
Example 177
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (177)
Synthesis of Compound (177)
Compound (177) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (177). 1H NMR (300 MHz, CDCl3): δ 7.91 (br s, 1H), 7.03-7.08 (t, 1H), 6.91-6.93 (d, 1H), 6.90 (s, 1H), 6.46-6.49 (d, 1H), 5.06 (br s, 1H), 4.74-4.80 (m, 1H), 4.22 (br s, 1H), 3.76-3.88 (m, 1H), 2.97-3.06 (m, 1H), 2.52-2.56 (m, 1H), 2.22-2.27 (m, 1H), 1.55-1.77 (m, 10H), 1.42-1.45 (m, 9H). LC-MS: (M+H)+=397.2; HPLC purity=90.56%.
Example 178
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-1) (178)
Synthesis of Compound (178)
Racemic compound (177) was purified by using chiral preparative HPLC chromatography to give Compound (178). LC-MS: (M+H)+=397.2; HPLC purity=99.12%. Chiral RT=9.72 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 179
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-2) (179)
Synthesis of Compound (179)
Racemic compound (177) was purified by using chiral preparative HPLC chromatography to give Compound (179). LC-MS: (M+H)+=397.2; HPLC purity=99.65%. Chiral RT=11.97 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 180
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(piperidin-1-yl)-1H-indol-3-yl]butan-1-one (180)
Synthesis of Compound (180)
Compound (180) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (180). 1H NMR (300 MHz, CDCl3): δ 7.90 (br s, 1H), 7.00-7.04 (m, 2H), 6.90-6.94 (m, 1H), 6.73-6.76 (m, 1H), 5.03 (br s, 1H), 4.13 (br s, 1H), 3.76-3.79 (m, 1H), 3.64-3.66 (m, 1H), 3.15-3.25 (m, 2H0, 2.86-2.92 (m, 1H), 2.76-2.77 (m, 1H), 2.37-2.41 (m, 1H), 2.19-2.21 (m, 1H), 1.34-1.98 (m, 19H). LC-MS: (M+H)+=422.2; HPLC purity=97.45%.
Example 181
1-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (181)
Synthesis of Compound (181)
Compound (181) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (181). 1H NMR (300 MHz, CDCl3): δ 7.85 (br s, 1H), 7.04-7.07 (m, 1H), 6.89-6.92 (m, 2H), 6.46-6.48 (m, 1H), 4.87 (br s, 1H), 4.75-4.79 (m, 1H), 4.04 (br s, 1H), 3.80-3.84 (m, 1H), 2.49-2.54 (m, 1H), 2.31-2.35 (m, 1H), 2.00-2.05 (m, 1H), 1.55-1.80 (m, 11H), 1.42-1.45 (m, 9H). LC-MS: (M+H)+=381.2; HPLC purity=99.41%
Example 182
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (182)
Synthesis of Compound (182)
Compound (182) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (182). 1H NMR (300 MHz, CDCl3): δ 7.82 (br s, 1H), 6.97-7.02 (t, 1H), 6.84-6.86 (d, 1H), 6.83 (s, 1H), 6.40-6.42 (d, 1H), 5.07 (br s, 1H), 4.65-4.73 (m, 1H), 4.21 (br s, 1H), 3.71-3.78 (m, 1H), 2.90-3.00 (m, 1H), 2.39-2.50 (m, 1H), 2.21-2.24 (m, 1H), 1.53-1.90 (m, 10H), 1.35-1.39 (m, 9H). LC-MS: (M+H)+=399.2; HPLC purity=93.52%.
Example 183
1-{3-[4-(2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1H-indol-4-yl}piperidine-4-carboxylic acid (183)
Synthesis of Compound (183)
Compound (183) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (183). LC-MS: (M+H)+=450.2; HPLC purity=97.82%.
Example 184
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-1) (184)
Synthesis of Compound (184)
Racemic compound (182) was purified by using chiral preparative HPLC chromatography to give Compound (184). LC-MS: (M+H)+=399.2; HPLC purity=95.51%. Chiral RT=13.60 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 185
1-(5-fluoro-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (Peak-2) (185)
Synthesis of Compound (185)
Racemic compound 182) was purified by using chiral preparative HPLC chromatography to give Compound (185). LC-MS: (M+H)+=399.2; HPLC purity=97.38%. Chiral RT=18.54 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (8:1:1)].
Example 186
2-{2-[3-(4-chloro-1H-indol-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-5-yl}propanoic acid (186)
Synthesis of Compound (186)
Compound (186) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (186). LC-MS: (M+H)+=429.13; HPLC purity=90.92%.
Example 187
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-3-yl)-1H-indol-3-yl]butan-1-one (187)
Synthesis of Compound (187)
Compound (187) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (187). LC-MS: (M+H)+=421.1; HPLC purity=96.22%.
Example 188
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (Peak-1) (188)
Synthesis of Compound (188)
Racemic compound (153) was purified by using chiral preparative HPLC chromatography to give Compound (188). LC-MS: (M+H)+=421.1; HPLC purity=92.0%; Chiral RT=6.57 min [column: ChiralPak IC, mobile phase: hexane:THF:EtOH (8:1:1)].
Example 189
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (Peak-2) (189)
Synthesis of Compound (189)
Racemic compound (153) was purified by using chiral preparative HPLC chromatography to give Compound (189). LC-MS: (M+H)+=421.1; HPLC purity=93.52%; Chiral RT=9.17 min [column: ChiralPak IC, mobile phase: hexane:THF:EtOH (8:1:1)].
Example 190
3-(5-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (190)
Synthesis of Compound (190)
Compound (190) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (190). LC-MS: (M+H)+=391.1; HPLC purity=96.40%.
Example 191
2-[3-(5-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carbonitrile (191)
Synthesis of Compound (191)
Compound (191) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (191). LC-MS: (M+H)+=400.1; HPLC purity=97.71%.
Example 192
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (192)
Synthesis of Compound (192)
Compound (192) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (192). LC-MS: (M+H)+=391.1; HPLC purity=94.40%.
Example 193
2-[3-(6-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-6-carbonitrile (193)
Synthesis of Compound (193)
Compound (193) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (193). LC-MS: (M+H)+=400.1; HPLC purity=94.39%.
Example 194
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (194)
Synthesis of Compound (194)
Racemic compound (192) was purified by using chiral preparative HPLC chromatography to give Compound (194). LC-MS: (M+H)+=391.1; HPLC purity=99.6%.
Example 195
3-(6-chloro-1,3-benzothiazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (195)
Synthesis of Compound (195)
Racemic compound (192) was purified by using chiral preparative HPLC chromatography to give Compound (195). LC-MS: (M+H)+=391.1; HPLC purity=99.56%.
Example 196
2-[3-(6-chloro-1,3-benzothiazol-2-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]decane-5-carboxamide (196)
Synthesis of Compound (196)
Compound (196) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (196). LC-MS: (M+H)+=418.1; HPLC purity=97.62%.
Example 197
3-(4,5-dichloro-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (197)
Synthesis of Compound (197)
Compound (197) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (197). LC-MS: (M+H)+=408.1; HPLC purity=94.42%.
Example 198
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (198)
Synthesis of Compound (198)
Compound (198) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (198). LC-MS: (M+H)+=414.2; HPLC purity=98.68%.
Example 199
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-1) (199)
Synthesis of Compound (199)
Racemic compound (198) was purified by using chiral preparative HPLC chromatography to give Compound (199). LC-MS: (M+H)+=414.2; HPLC purity=94.06%. Chiral RT=15.94 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 200
3-(5-chloro-4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (Peak-2) (200)
Synthesis of Compound (200)
Racemic compound (198) was purified by using chiral preparative HPLC chromatography to give Compound (200). LC-MS: (M+H)+=414.2; HPLC purity=98.40%. Chiral RT=20.09 min [column: ChiralPak IC, mobile phase: hexane:IPA:DCM (7.5:1.5:1)].
Example 201
3-(4,5-dicyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (201)
Synthesis of Compound (201)
Compound (201) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (201). LC-MS: (M+H)+=420.2; HPLC purity=90.88%.
Example 202
3-(6-chloro-1H-benzimidazol-2-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (202)
Synthesis of Compound (202)
Compound (202) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (202). LC-MS: (M+H)+=372.1; HPLC purity=84.69%.
Example 203
3-(6-cyclopropyl-1H-benzimidazol-2-yl)-1 (6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (203)
Synthesis of Compound (203)
Compound (203) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (203). LC-MS: (M+H)+=380.1; HPLC purity=98.88%.
Example 204
{2-[3-(4-cyclopropyl-1H-pyrrolo[2,3-b]pyridin-3-yl)butanoyl]-2-azatricyclo[3.3.1.1 3,7 ]dec-6-yl}acetic acid (204)
Synthesis of Compound (204)
Compound (204) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (204). LC-MS: (M+H)+=422.2; HPLC purity=99.63%.
Example 205
3-(1-cyclopropyl-4-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (205)
Synthesis of Compound (205)
Compound (205) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (205). LC-MS: (M+H)+=393.2; HPLC purity=99.04%.
Example 206
3-(1,4-dimethyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (206)
Synthesis of Compound (206)
Compound (206) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (206). LC-MS: (M+H)+=367.2; HPLC purity=98.36%.
Example 207
3-(4-chloro-1-methyl-1H-indol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (207)
Synthesis of Compound (207)
Compound (207) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (207). LC-MS: (M+H)+=387.1; HPLC purity=99.49%.
Example 208
3-[4-chloro-5-(furan-2-yl)-1H-indol-3-yl]-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (208)
Synthesis of Compound (208)
Compound (208) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (208). LC-MS: (M+H)+=439.1; HPLC purity=91.39%.
Example 209
1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-(4-methoxy-5-methyl-1H-indol-3-yl)butan-1-one (209)
Synthesis of Compound (209)
Compound (209) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (209). LC-MS: (M+H)+=383.2; HPLC purity=93.48%.
Example 210
1-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[5-methyl-4-(thiophen-2-yl)-1H-indol-3-yl]butan-1-one (210)
Synthesis of Compound (210)
Compound (210) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (210). LC-MS: (M+H)+=435.2; HPLC purity=91.98%.
Example 211
4-chloro-3-[4-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-5-methyl-1,3-dihydro-2H-indol-2-one (211)
Synthesis of Compound (211)
To a stirred solution of Compound (166) (15 mg, 0.03 mmol) in DMF (2 mL) was added pyridinium tribromide (16 mg, 0.050 mmol) at 0° C. Resulted reaction mixture was stirred at room temperature for 3 hours. After reaction quenched with H 2 O (10 mL), extracted with ether (2×20 mL). The combined organic layers were washed with brine and concentrated. Resulted crude material was purified by preparative TLC eluting with DCM:MeOH (95:05) to give Compound (211) (5.5 mg, off white solid).
Example 212
4-cyclopropyl-3-[4-(6-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-4-oxobutan-2-yl]-1,3-dihydro-2H-indol-2-one (212)
Synthesis of Compound (212)
Compound (212) was synthesized by following the procedure used to make Compound (211) (Scheme 26). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (212). 1H NMR (300 MHz, CDCl3): δ 7.50 (br s, 1H), 7.07-7.12 (t, 1H), 6.59-6.62 (d, 1H), 6.48-6.51 (d, 1H), 5.11 (br s, 1H), 4.54 (br s, 1H), 3.81 (br s, 1H), 3.79-3.81 (m, 1H), 2.37-2.41 (m, 2H), 2.21-2.23 (m, 1H). 1.43-1.88 (m, 11H), 1.06-1.08 (m, 2H), 0.83-0.88 (m, 2H), 0.72-0.74 (d, 3H). LC-MS: (M+H)+=395.2; HPLC purity=99.65%.
Example 213
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-fluoro-7-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)butan-1-one (213)
Synthesis of Compound (213)
Compound (213) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (213). 1H NMR (300 MHz, CDCl3): δ 8.06 (br s, 1H), 7.18-7.20 (d, 1H), 7.05-7.10 (t, 1H), 7.04 (s, 1H), 6.74-6.76 (d, 1H), 5.26 (br s, 1H), 4.40 (br s, 1H), 4.23-4.25 (m, 1H), 2.85-2.90 (m, 1H), 2.45-2.53 (m, 2H), 1.99 (br s, 2H), 1.62-1.81 (m, 8H), 1.44-1.46 (d, 3H), 0.95-0.99 (m, 2H), 0.81-0.85 (m, 2H). LC-MS: (M+H)+=397.3; HPLC purity=93.84%.
Example 214
1-(6-hydroxy-7-methyl-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)-3-[4-(propan-2-yloxy)-1H-indol-3-yl]butan-1-one (214)
Synthesis of Compound (214)
Compound (214) was synthesized by following the procedure used to make Compound (1) (Scheme 2). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (214). 1H NMR (300 MHz, CDCl3): δ 7.86 (br s, 1H), 6.96-7.01 (t, 1H), 6.84-6.86 (d, 1H), 6.83 (s, 1H), 6.39-6.42 (d, 1H), 5.00 (br s, 1H), 4.67-4.72 (m, 1H), 4.20 (br s, 1H), 3.72-3.79 (m, 1H), 2.89-3.01 (m, 1H), 2.39-2.51 (m, 1H), 1.25-1.65 (m, 19H). LC-MS: (M+H)+=411.3; HPLC purity=90.45%.
Example 215
2-(2-(3-(4-(5-fluorofuran-2-yl)-1H-indol-3-yl)butanoyl)-2-azaadamantan-5-yl)acetic acid (215)
Synthesis of Compound (215)
Compound (215) was synthesized by following the procedure used to make Compound (43) (Scheme 14). The crude product was obtained by evaporating the organic layer under reduced pressure and was purified by silica gel column using DCM:MeOH as eluent to obtain Compound (215). LC-MS: (M+H)+=465.4; HPLC purity=99.37%.
Example 216
1-(5-hydroxy-2-azaadamantan-2-yl)-3-(4-methyl-1-(quinolin-8-ylsulfonyl)-1H-indol-3-yl)butan-1-one (216)
Synthesis of Compound (216)
Compound (216) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=544.3; HPLC purity=98.61%.
Example 217
4-chloro-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-5-methyl-1H-indole-2-carbonitrile (217)
Synthesis of Compound (217)
Compound (217) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=412.3.
Example 218
4-chloro-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carbonitrile (218)
Synthesis of Compound (218)
Compound (218) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=398.2; HPLC purity=98.47%.
Example 219
3-(4-chloro-5-methyl-1H-indol-3-yl)-1-(5-hydroxy-7-methyl-2-azaadamantan-2-yl)butan-1-one (219)
Synthesis of Compound (219)
Compound (219) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=401.2; HPLC purity=89.36%.
Example 220
4-cyclopropyl-3-(4-(5-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carbonitrile (220)
Synthesis of Compound (220)
Compound (220) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=404.3; HPLC purity=98.29%.
Example 221
2-(3-(4,5-dimethyl-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (221)
Synthesis of Compound (221)
Compound (221) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=376.3; HPLC purity=85.11%.
Example 222
2-(3-(4-(furan-2-yl)-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carboxylic acid (222)
Synthesis of Compound (222)
Compound (222) was synthesized by following the procedure used to make Compound (43) (Scheme 14). LC-MS: (M+H)+=433.3; HPLC purity=98.85%.
Example 223
4-cyclopropyl-3-(4-(6-hydroxy-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indole-2-carboxylic acid (223)
Synthesis of Compound (223)
Compound 220 (0.070 g, 0.17 mmol) was taken in a sealed tube and MeOH (3 mL) was added to it followed by addition of 50% aqueous KOH solution (2 mL). The reaction mixture was then heated at 110° C. for 24 hours and concentrated to give crude material, which was diluted with H 2 O, acidified with 2N HCl (PH=2), extracted with EtOAc and concentrated to give crude product. The crude product was then purified by using silica gel column chromatography eluting with mixture of DCM:MeOH to give 30 mg of Compound (223) as brown solid. LC-MS: (M+H)+=423.1; HPLC purity=98.09%.
Example 224
1-(5-fluoro-2-azaadamantan-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (224)
Synthesis of Compound (224)
Compound (224) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=371.2; HPLC purity=92.10%.
Example 226
3-(4-(5-bromo-2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-5-yl trifluoromethanesulfonate (225)
Synthesis of Compound (225)
Compound (225) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=549.2; HPLC purity=92.61%.
Example 226
1-(2-azaadamantan-2-yl)-3-(5-methoxy-1H-indol-3-yl)butan-1-one (226)
Synthesis of Compound (226)
Compound (226) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=353.2; HPLC purity=90.02%.
Example 227
3-(5-methoxy-1H-indol-3-yl)-1-(5-methyl-2-azaadamantan-2-yl)butan-1-one (227)
Synthesis of Compound (227)
Compound (227) was synthesized by following the procedure used to make Compound (1) (Scheme 2). LC-MS: (M+H)+=367.3; HPLC purity=92.59%.
Example 228
3-(4-(2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-6-yl trifluoromethanesulfonate (228)
Synthesis of Compound (228)
Compound (228) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, DMSO-d6): δ 11.24 (br s, 1H), 7.59 (s, 1H), 7.44-7.47 (d, 1H), 7.36 (s, 1H), 7.11-7.14 (d, 1H), 4.62 (br s, 1H), 4.01 (br s, 1H), 3.43-3.48 (m, 1H), 2.62-2.65 (m, 1H), 2.43.2.47 (m, 1H), 2.10 (s, 1H), 2.00 (s, 1H), 1.44-1.86 (m, 10H), 1.30-1.33 (d, 3H). LC-MS: (M+H)+=471.1; HPLC purity=89.84%.
Example 229
3-(4-(2-azaadamantan-2-yl)-4-oxobutan-2-yl)-1H-indol-5-yl methanesulfonate (229)
Synthesis of Compound (229)
Compound (229) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 8.37 (br s, 1H), 7.50 (s, 1H), 7.23-7.26 (d, 1H), 6.98-7.05 (m, 2H), 4.74 (br s, 1H), 3.92 (br s, 1H), 3.51-3.58 (m, 1H), 3.08 (s, 1H), 2.68-2.75 (m, 1H), 2.41-2.48 (m, 1H), 1.96 (br s, 1H), 1.84 (br s, 1H), 1.45-1.72 (m, 10H), 1.39-1.42 (d, 3H). LC-MS: (M+H)+=417.1; HPLC purity=92.90%.
Example 230
2-(3-(5-methoxy-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (230)
Synthesis of Compound (230)
Compound (230) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.95 (br s, 1H), 7.22-7.28 (m, 1H), 7.09-7.12 (m, 1H), 6.99-7.00 (d, 1H), 6.83-6.89 (m, 1H), 4.91-4.95 (d, 1H), 3.97-4.03 (d, 1H), 3.86 (s, 3H), 3.61-3.67 (m, 1H), 2.72-2.81 (m, 1H), 2.45-2.55 (m, 1H), 2.13-2.16 (m, 1H), 1.58-2.05 (m, 10H) 1.48-1.51 (d, 3H). LC-MS: (M+H)+=378.3; HPLC purity=99.49%.
Example 231
1-(5-amino-2-azaadamantan-2-yl)-3-(4-cyclopropyl-1H-indol-3-yl)butan-1-one (231)
Synthesis of Intermediate-61
To a stirred solution of compound-41 (0.10 g, 0.26 mmol) in DCM (5 mL) in AcOH (2 mL), chloroaceto nitrile (117 mg, 1.56 mmol) was added at 0° C. The reaction mixture was then treated with sulfuric acid (0.75 mL). The reaction mixture was stirred at 0° C. for 1 hour and continued to stir at room temperature for 12 hours. After completion of the reaction, the reaction mixture was quenched with saturated aqueous NaHCO 3 solution and extracted with EtOAc to give Intermediate-61 (90 mg). It was used for next step without any purification.
Synthesis of Compound 231
A stirred solution of Intermediate-61 (0.090 g, 0.19 mmol)) and thiourea (0.028 g, 0.38 mmol) in EtOH (5 mL) at 0° C. was treated with acetic acid (0.5 mL). The reaction mixture was heated to reflux for 12 hours. After completion of the reaction, the reaction mixture was quenched with saturated sodium bicarbonate solution, extracted with DCM and concentrated to give Compound 231 (30 mg).
Example 232
3-(4-cyclopropyl-1H-indol-3-yl)-1-(5-(methylamino)-2-azaadamantan-2-yl)butan-1-one (232)
Synthesis of 232
To a stirred solution of Compound 231 (0.020 g, 0.053 mmol)) in DMF, K 2 CO 3 (14.6 mg, 0.16 mmol) was added at 0° C. To this solution MeI was added and stirred at room temperature for 2 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc, and concentrated to give crude product, which was purified by using prep TLC to give Compound 232 (5 mg).
Example 233
3-(4-cyclopropyl-1H-indazol-3-yl)-1-(5-hydroxy-2-azatricyclo[3.3.1.1 3,7 ]dec-2-yl)propan-1-one (233)
Synthesis of Intermediate-62
To a stirred solution of Starting Material-14 (2.0 g, 8.6 mmol) in THF:MeOH (40 mL, 1:1), activated Zn powder (3.71 g, 69.5 mmol) was added, followed by saturated NH 4 Cl solution and stirred at room temperature for 3 hours. After completion of the reaction, the reaction mixture it was concentrated and diluted with H 2 O, extracted with EtOAc and concentrated to give Intermediate-62 (1.7 g) as pale yellow solid.
Synthesis of Intermediate-63
To a stirred solution of Intermediate-62 (1.8 g, 9.7 mmol) in chloroform (20 mL), Ac 2 O (2.25 mL, 22.0 mmol) was added at 0° C. The resulted reaction mixture was stirred at room temperature for 24 hours. Then KOAc (0.28 g, 2.9 mmol), followed by isoamylnitrite (2.44 g, 20 mmol) were added, and heated at 60° C. for 18 hours. After completion of the reaction, the reaction mixture quenched with H 2 O and concentrated, to this conc HCl (5 mL) was added and heated at 60° C. for 2 hours. The reaction mixture was then basified with 50% aqueous NaOH solution and extracted with EtOAc and concentrated to give Intermediate-63 (420 mg) as brown solid.
Synthesis of Intermediate-64
To a stirred solution of Intermediate-63 (0.50 g. 2.5 mmol) in DMF (5 mL), KOH (0.28 g, 5.0 mmol) was added and stirred at room temperature for 20 minutes. To the reaction mixture iodine (0.26 g, 5.0 mmol) in DMF was added and the reaction was continued at room temperature for 12 hours. After completion of the reaction the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give Intermediate-64 (750 mg) as brown solid, which was used in next step without any purification.
Synthesis of Intermediate-66
To a stirred solution of Intermediate-64 (0.75 g, 2.3 mmol) in MeCN (5 mL), TEA (0.696 g, 6.9 mmol), DMAP (0.024 g, 0.2 mmol) and (Boc) 2 O (1.00 g, 4.6 mmol) were added at 0° C. The resulted reaction mixture was stirred at room temperature for 4 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give crude material. The crude material was purified by using silica gel column chromatography eluting with mixture of hexane:EtOAc to give Intermediate-65 (700 mg) as white solid.
Synthesis of Intermediate-66
To a stirred solution of Intermediate-65 (0.25 g, 0.7 mmol) in DMF (5 mL), TEA (0.31 mL, 2.3 mmol), ethyl crotanoate (0.11 g, 1.1 mmol) and TBAl (0.05 g, 0.14 mmol) were added, and purged with argon gas for 15 minutes. To the reaction mixture PdCl 2 (dppf) (0.06 g, 0.07 mmol) was added. The resulted reaction mixture was kept under micro wave conditions at 100° C. for 2 hours. After completion of the reaction, the reaction mixture was filtered through celite and concentrated, resulted crude material was purified by using silica gel column chromatography eluting with mixture of hexanes:EtrOAc to give Intermediate-66 (20 mg) as white solid.
Synthesis of Intermediate-67
To a stirred solution of Intermediate-66 (0.05 g, 0.12 mmol) in dioxane:H2O (4 mL, 3:1) cyclopropyl boronic acid (0.02 g, 0.25 mmol), Cs 2 CO 3 (0.136 g, 0.42 mmol) were added, and purged with argon gas for 10 minutes. To the reaction mixture PdCl 2 (dppf) 0.009 g, 0.012 mmol) was added. The resulted reaction mixture was kept under micro wave conditions at 120° C. for 1 hour. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated. The resulted reaction mixture was purified by using silica gel column chromatography eluting with mixture of hexane:EtOAc to give Intermediate-67 (30 mg) as brown gummy material.
Synthesis of Intermediate-68
To a stirred solution of Intermediate-67 (0.030 g, 0.11 mmol) in DMF:MeOH (2 mL, 1:1), NaBH 4 (0.006 g, 0.17 mmol) was added, followed by cobalt chloride (0.002 g, 0.022 mmol). The resulted reaction mixture was stirred at rt for 45 min. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with EtOAc and concentrated to give Intermediate-68 (25 mg) as brown gummy material.
Synthesis of Intermediate-69
Intermediate-69 was synthesized by following the procedure used to make Intermediate-26 (scheme-4).
Synthesis of Compound (233)
Compound (233) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.22-7.33 (m, 2H), 6.75-6.78 (m, 1H), 5.09 (br s, 1H), 4.40 (br s, 1H), 3.61-3.66 (t, 2H), 2.93-2.98 (t, 2H), 2.18-2.22 (t, 1H), 1.60-2.04 (m, 11H), 1.06-1.08 (m, 2H), 0.86-0.88 (m, 2H). LC-MS: (M+H)+=366.1.
Example 234
2-(3-(4-fluoro-6-methyl-1H-indol-3-yl)butanoyl)-2-azaadamantane-5-carbonitrile (234)
Synthesis of Compound (234)
Compound (234) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 7.97 (br s, 1H), 7.02-7.06 (m, 1H), 6.93-6.99 (m, 2H), 4.96 (br s, 1H), 4.17-4.21 (m, 1H), 3.60-3.68 (m, 1H), 2.84-2.88 (m, 1H), 2.47-2.56 (m, 1H), 2.36 (s, 3H), 2.10-2.13 (m, 1H), 1.61-2.05 (m, 10H), 1.45-1.48 (d, 3H). LC-MS: (M+H)+=380.2. HPLC purity=99.13%.
Example 235
2-(4-cyclopropyl-1H-indol-3-yl)-1-(5-hydroxy-2-azaadamantan-2-yl)propan-1-one (235)
Synthesis of Intermediate-70
To a stirred solution of Starting Material-15 (40 g, 206 mmol) in ether (400 mL), oxalyl chloride (23.2 mL, 268 mmol) was added at 0° C., and stirred at room temperature for 5 hours. The reaction mixture was then filtered and washed with ether to get solid material (42 g), which was treated with MeOH (28 mL) in ether (200 mL) at 0° C. to room temperature for 5 hours. After completion of the reaction the reaction mixture was diluted with hexanes, resulted precipitate was filtered and dried to get Intermediate-70 (35 g) as yellow solid.
Synthesis of Intermediate-71
To a stirred solution of Intermediate-70 (35 g, 129 mmol) in MeOH (350 mL), tosyl hydrazine (23.1 g, 129 mmol) was added and refluxed for 4 hours. After completion of the reaction, the reaction mixture was concentrated to give crude mixture, which is diluted with H 2 O, extracted with DCM and concentrated to give Intermediate-69 (35 g) as pale yellow solid.
Synthesis of Intermediate-72
To a stirred solution of Intermediate-71 (14 g, 31 mmol) in THF (140 mL), NaBH 4 (1.8 g, 46 mmol) was added at 0° C. and continued to stir at room temperature for 6 hours. After completion of the reaction, the reaction mixture was quenched with H 2 O, extracted with DCM and concentrated. The resulted crude product was purified by using silica gel column chromatography elutive with mixture of hexanes, EtOAc to give Intermediate-72 (3 g) as pale yellow liquid.
Synthesis of Intermediate-73
Intermediate-73 was synthesized by following the procedure used to make Intermediate-67 (Scheme 30).
Synthesis of Intermediate-74
Intermediate-74 was synthesized by following the procedure used to make Intermediate-65 (Scheme 30).
Synthesis of Intermediate-75
Intermediate-75 was synthesized by following the procedure used to make intermediate-30 (Scheme 6).
Synthesis of Intermediate-76
Intermediate-76 was synthesized by following the procedure used to make Intermediate-26 (Scheme 4).
Synthesis of Intermediate-77
Intermediate-77 was synthesized by following the procedure used to make Intermediate-7 (Scheme 1).
Synthesis of Compound (233)
Compound (233) was synthesized by following the procedure used to make Compound (1) (Scheme 2). 1H NMR (300 MHz, CDCl3): δ 8.13 (br s, 1H), 7.13-7.16 (d, 1H), 6.96-7.04 (m, 2H), 6.75-6.78 (d, 1H), 5.08 (br s, 1H), 4.62-4.67 (m, 1H), 4.32 (br s), 2.25-2.30 (m, 1H), 2.05-2.08 (m, 1H), 1.53-1.79 (m, 10H), 1.46-1.49 (d, 3H), 0.93-0.98 (m, 2H), 0.83-0.88 (m, 2H). LC-MS: (M+H)+=365.2. HPLC purity=95.44%.
Example 236
3-(4-cyclopropyl-1-methyl-1H-indazol-3-yl)-1-(5-hydroxy-2-azaadamantan-2-yl)propan-1-one (236)
Synthesis of Compound 236
Compound (236) was synthesized by following the procedure used to make Compound (233) (Scheme 30). LC-MS: (M+H)+=380.3. HPLC purity=99.86%.
Example 237
1-(2-azaadamantan-2-yl)-3-(4-cyclopropyl-1-methyl-1H-indazol-3-yl)propan-1-one (237)
Synthesis of Compound (237)
Compound (237) was synthesized by following the procedure used to make Compound (233) (Scheme 30). LC-MS: (M+H)+=364.3. HPLC purity=91.66%.
Example 238
1-(2-azaadamantan-2-yl)-2-(4-cyclopropyl-1H-indol-3-yl)propan-1-one (238)
Synthesis of Compound (238)
Compound (238) was synthesized by following the procedure used to make Compound (233) (Scheme 27). LC-MS: (M+H)+=349.2.
Biological Activity
In Vitro HSD11β1 Inhibition Assay:
CHO cells were maintained in Dulbecco's modified Eagle's medium/nutrient mixture F-12 containing 5% fetal bovine serum (v/v) and 2 mM glutamine. Cells were cultured at 37° C. with 5% CO 2 . For transient expression of human full length HSD11β1 expression vector (OriGene Technologies), cells were seeded at a density of 2×105 cells/well in a 6-well plate. Transfection was done using Turbofectin8 reagent (OriGene Technologies), according to the protocol provided with the reagent. After 24 hours post-transfection, cells were trypsinized and pooled together before they were re-seeding to 96-well plate at a density of 40000 cells/well. 24 hours after re-seeding, cells were incubated with 200 nM cortisone+500 uM NADPH (or along with small molecule inhibitors) overnight. The enzymatic activity or inhibition of enzyme activity was measured by estimating the conversion of cortisone to cortisol by LC/MS-MS method. The IC50 in nM was calculated from a 8 point log scale of concentration versus inhibition.
The results of the biological testing are shown in table 1:
Cmpd No
11βHSD1 (IC50)
1
*
2
****
3
*
4
*
5
**
6
*
7
*
8
*
9
*
10
*
11
*
12
*
13
*
14
****
15
*
16
*
17
****
18
****
19
**
20
*
21
*
22
*
23
*
24
*
25
*
26
**
27
*
28
**
29
****
30
***
31
*****
32
***
33
*
34
*
35
*****
36
**
37
*****
38
*
39
****
40
*****
41
*****
42
*
43
*
44
**
45
*
46
*
47
***
48
*****
49
*****
50
*
51
*
52
*
53
*
54
*
55
*
56
*****
57
*
58
*****
59
****
60
*
61
*
62
*
63
*
64
****
65
**
66
*
67
****
68
*
69
****
70
***
71
*
72
*
73
******
74
*
75
**
76
*
77
*
78
*
79
****
80
*
81
*
82
*****
83
*****
84
**
85
******
86
*
87
***
88
*
89
*
90
*
91
*
92
*
93
*
94
*****
95
****
96
****
97
*
98
*****
99
*****
100
*****
101
**
102
*****
103
*
104
*****
105
******
106
****
107
*
108
*
109
*
110
*
111
*
112
**
113
*
114
*
115
**
116
**
117
*
118
*
119
*****
120
*
121
*
122
*
123
*
124
*
125
*
126
*****
127
*****
128
*
129
*
130
*****
131
*
132
*****
133
****
134
***
135
*
136
*****
137
*
138
****
139
*****
140
*
141
****
142
*
143
*
144
*****
145
****
146
*
147
****
148
*****
149
*
150
*****
151
*****
152
****
153
*****
154
*
155
****
156
*
157
*****
158
*
159
****
160
****
161
*****
162
***
163
*
164
****
165
*
166
*****
167
**
168
*****
169
*****
170
*
171
**
172
*
173
*****
174
*
175
*****
176
*
177
*****
178
*****
179
*
180
*
181
*
182
***
183
*
184
*****
185
*
186
*
187
****
188
****
189
*
190
***
191
*
192
*****
193
***
194
*****
195
*
196
*
197
*****
198
*****
199
*****
200
*
201
*
202
*
203
*
204
*
205
*
206
*
207
****
208
****
209
**
210
****
211
***
212
*
213
****
214
*****
215
*
216
*
217
*
218
*
219
*****
220
*
221
*
222
*
223
*
224
*
225
*
226
*****
227
*****
228
****
229
*
230
*
***** = <100 nM
**** = 100 nM< and <150 nM
*** = 150 nM< and <200 nM
** = 200 nM< and <250 nM
* = 250 nM<
|
The present invention relates to certain amide derivatives that have the ability to inhibit 11-β-hydroxysteroid dehydrogenase type 1 (11β-HSD-1) and which are therefore useful in the treatment of certain disorders that can be prevented or treated by inhibition of this enzyme. In addition the invention relates to the compounds, methods for their preparation, pharmaceutical compositions containing the compounds and the uses of these compounds in the treatment of certain disorders. It is expected that the compounds of the invention will find application in the treatment of conditions such as non-insulin dependent type 2 diabetes mellitus (NIDDM), insulin resistance, obesity, impaired fasting glucose, impaired glucose tolerance, lipid disorders such as dyslipidemia, hypertension and as well as other diseases and conditions.
| 2
|
FIELD OF THE INVENTION
The present invention relates to a method of driving a plasma display panel and more particularly, to a method of driving an AC-type plasma display panel for displaying a dynamic image without intensity level disturbance and false color contours in a multi-scan driving method within a sustaining pulse period.
BACKGROUND OF THE INVENTION
Recently, a plasma display panel (referred to as “PDP” hereinafter) has advantageous characteristics capable of being utilized as a direct-view large HDTV display apparatus having large screen size but a small thickness and a wide viewing angle compared to other flat display devices.
A PDP is classified into a two-electrode type PDP in which an address discharge and a sustain discharge are performed by two electrodes and a three-electrode type PDP in which an address discharge and a sustain discharge are performed by three electrodes.
FIG. 1 is a schematic sectional view of a discharge cell of a typical PDP and FIG. 2 is a plan view of a three-electrode type of PDP.
The discharge cell 10 of the three-electrode type PDP 1 comprises two glass plates 12 and 13 arranged to be facing each other. On the first glass plate 13 the first electrode 14 (X electrode) and the second electrode 15 (Y electrode) are formed and arranged parallel to each other. The electrodes function as sustain electrodes. The first and second electrodes 14 and 15 are covered with a dielectric layer 18 . The upper surface of the dielectric layer 18 is covered with a MgO layer 21 , which protects the dielectric layer 18 .
On the second glass plate 12 a third electrode 16 is arranged orthogonal to the first and second electrodes 14 and 15 . The third electrode functions as a data electrode. A barrier rib 17 of a lattice or stripe shape is formed between the two glass plates 12 and 13 to define a discharge cell. A phosphor material 19 is coated on the surface of the third electrode and the inner surface of the barrier rib.
As shown in FIG. 2, a PDP display device using such three-electrode type PDP comprises a plurality of X electrodes and Y electrodes arranged parallel to each other and wherein Y electrodes are driven independently by separate Y scan driving circuits 4 - 1 to 4 -n coupled to a Y electrode sustain driving circuit and X electrodes are coupled in common and are driven by a common X electrode driving circuit 5 .
Data electrodes 16 - 1 to 16 -n arranged to be orthogonal to the X and Y electrodes are driven by a data driving circuit 6 . Also, each of separate Y electrode scan driving circuits 4 - 1 to 4 -n is coupled to the Y electrode sustain driving circuit 3 and generates a scan pulse and sustain pulse.
The Y electrode sustain driving circuit 3 generates a sustain discharge pulse and the generated sustain discharging pulse is applied to the Y electrodes 15 - 1 to 15 -n via the separate Y scan driving circuits 4 - 1 to 4 -n.
The common X electrode driving circuit 5 generates a sustaining pulse which is applied to the X electrodes.
The driving circuits 3 , 5 and 6 are controlled by a control circuit (not shown) which is in turn controlled sequentially by a synchronization signal and then a display data signal. In FIG. 2, numeral 1 denotes a PDP and numeral 10 denotes a cell constructing the PDP 1 .
There have been proposed several driving methods for a multi-gradation display of such plasma display device. As an example, U.S. Pat. No. 5,541,618 (assigned to Fujitsu Limited.) discloses a driving method in which a frame displaying a single picture is divided into a plurality of subfields and each of the subfields is separated in an addressing period and a sustain period and in each of the subfields, after addressing, a sustaining operation is carried out to all display electrodes at the same time.
FIG. 3 shows a frame structure illustrating a conventional driving method. When scan lines are 480, a frame of a single picture is divided into eight subfields, and a time taken to perform an addressing operation within a frame of a single picture is approximately 11 to 12 microseconds.
Substantially, since a display time (sustaining time) when a viewer can view an image is approximately 5 to 6 microseconds, a display period (sustaining period) that contributes to the brightness of an image is only approximately 30%, resulting in a deterioration of picture brightness. In this case, increasing a frequency of sustain pulse in order to compensate for such deterioration of image brightness can be considered, however, it also causes an increase of the power consumption and a deterioration of driving reliability.
The present applicant has suggested a new driving method capable of solving such problems encountered by the conventional driving method (see PCT/KR98/00204 filed in the name of the present applicant). According to a basic feature of the above-suggested driving method, a frame is divided into a plurality of subfields, and display lines corresponding to the total number of the divided subfields are selected. Then, scan pulses corresponding to the total number of the divided subfields are applied sequentially within a single sustain pulse applied to Y scan sustain electrodes and thereby cells of selected display lines to be displayed are designated. Thereafter, the designated cells of selected display lines are displayed by the following sustain pulse.
Next, after one sustain pulse period, display lines which are downwardly or upwardly shifted from the above selected display lines by one line are selected. Then, scan pulses corresponding to the total number of the divided subfields are applied sequentially within a single sustain pulse applied to Y scan sustain electrodes and thereby cells of selected display lines to be displayed are designated. Thereafter, the designated cells of selected display lines are displayed by following sustain pulse. Continuously, by repeating the display of the subfields for the display lines by shifting one line as a unit one sustain pulse period until each of the subfields for all display lines are completely displayed, the display for a frame is completed.
In this manner, a feature of the above driving method enables scanning of other display lines simultaneously by sustaining them. In order to realize it most suitably, the number of sustain pulses for one frame should be set to be equal to that of the display lines. Also,when selecting display lines, positioning of selected display lines should be determined by considering the number of sustain pulses for each of the subfields.
Now, a feature of the above driving method will be described in detail with reference to FIGS. 4 and 5. For convenience of the description, it assumed that a single frame is divided into three subfields (SF 1 , SF 2 , and SF 3 ) and display lines are 7 lines (D 1 to D 7 ). Accordingly, it is possible to establish sustain periods in subfields SF 1 , SF 2 , and SF 3 to 1 , 2 and 4 , respectively. Also, regarding the position of the display line selected firstly, it is possible to select the display lines D 1 , D 3 and D 7 in consideration of the sustain periods set for the subfields SF 1 , SF 2 and SF 3 . In FIG. 4, S 1 to S 7 represent sustain periods.
As shown in FIG. 4, firstly, display lines D 1 , D 3 and D 7 are selected, and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 1 , D 3 and D 7 are executed respectively. Next, selecting display lines D 2 , D 4 and D 1 , which are allocated downwardly by one display line from the above selected display lines D 1 , D 3 and D 7 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 2 , D 4 and D 1 are executed respectively. Next, selecting display lines D 3 , D 5 and D 2 , which are allocated downwardly by one display line from the above selected display lines D 2 , D 4 and D 1 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 3 , D 5 and D 2 are executed respectively. Next, selecting display lines D 4 , D 6 and D 3 , which are allocated downwardly by one display line from the above selected display lines D 3 , D 5 and D 2 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 4 , D 6 and D 3 are executed respectively. Next, selecting display lines D 5 , D 7 and D 4 , which are allocated downwardly by one display line from the above selected display lines D 4 , D 6 and D 3 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 5 , D 7 and D 4 are executed respectively. Next, selecting display lines D 6 , D 1 and D 5 , which are allocated downwardly by one display line from the above selected display lines D 5 , D 7 and D 4 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 6 , D 1 and D 5 are executed respectively. Finally, selecting display lines D 7 , D 2 and D 6 , which are allocated downwardly by one display line from the above selected display lines D 6 , D 1 and D 5 , and then the display of the subfields SF 1 , SF 2 and SF 3 for display lines D 7 , D 2 and D 6 are executed respectively.
At this time, the display of a previous frame for each of the display lines is completed together with selecting display lines for displaying the next frame, and then the display of the subfields of the next frame for display lines are executed. Thereby, the display of the subfields of the next frame and the display of the subfields of the previous frame are overlapped at the same time. In FIG. 4, when display lines D 2 , D 4 , D 5 and D 6 display subfields SF 2 , SF 3 , SF 3 and SF 3 of the previous frame, respectively, other display lines D 1 , D 3 and D 7 display subfields SF 1 , SF 2 and SF 3 of the next frame, respectively.
FIG. 5 is a pulse waveform diagram applied to each electrode in order to display the frame as shown in FIG. 4, and illustrates a driving in accordance with a select erase scheme.
First, display lines D 1 , D 3 and D 7 whose number is identical to that of the divided subfields are selected, and then the display of the subfields SF 1 , SF 2 and SF 3 for the selected display lines D 1 , D 3 and D 7 are executed respectively. In other words, by applying a negative write pulse to Y electrodes (Y 1 , Y 2 and Y 3 ) constituting the selected display lines D 1 , D 3 and D 7 and applying a positive pulse to common X electrodes, a write discharge for all cells of the selected display lines D 1 , D 3 and D 7 is performed.
Thereafter, within one sustain period, scan pulses generated from Y scan-driving circuit are sequentially applied to the selected Y electrodes (Y 1 , Y 2 and Y 3 ). At the same time, data pulses generated from the data driving circuit in accordance with input image data to be displayed are applied to the data electrodes.
If explaining the above state using a discharging principle, as a result of the above write discharge, (+) wall charge is accumulated on a dielectric layer covering Y electrodes and (−) wall charge is accumulated on a dielectric layer covering common X electrodes. Then, if applying a scan pulse and data pulse thereto, the accumulated wall charge is erased. Accordingly, the wall charge on the display lines applied data pulse is erased. Thus, even though a sustain pulse is applied to the common X electrodes and Y electrodes, sustain discharge between the common X electrodes and Y electrodes is not performed. However, since the wall charge is accumulated on the display line to which no data pulse is applied, sustain discharge is performed.
Next, in the next sustain period, the negative write pulses and the positive pulse are applied to the Y electrodes (Y 2 , Y 4 , and Y 1 ) and the common X electrode of display lines D 2 , D 4 and D 1 respectively, which is allocated downwardly by one display line from the above selected display lines D 1 , D 3 and D 7 . Then, scan pulses generated from the Y scan-driving circuit are sequentially applied to the selected Y electrodes (Y 2 , Y 4 and Y 1 ). At the same time, data pulses generated from the data driving circuit in accordance with the input image data to be displayed are applied to the data electrodes. At this time, by applying the write pulses to the Y electrodes (Y 2 , Y 4 and Y 1 ) of the display lines (D 1 , D 3 and D 7 ) which are selected in the next sustain pulse period, the display of the selected display line (D 1 ) in the previous sustain pulse period is finished. As a result, the display of a subfield (SF 1 ) for the selected display line (D 1 ) in the previous sustain pulse period is completed. In this way, setting of each of the subfields to each of the selected display lines is determined in advance in accordance with the position of the display lines selected firstly.
Continuously, by repeating the display of the subfields for the selected display lines by shifting one line as an unit of one sustain pulse period until each of the subfields for all display lines is completely displayed, the display for a frame is completed. Finally, the display lines, which have completed all subfields of one frame, will end their sustain discharges by applying a write pulse to display subfields of the next frame.
Accordingly, since within the period of one frame, it can perform simultaneously addressing (scan) of another display line during sustain period of one display line, such driving method can perform display with high efficiency.
As shown in FIGS. 4 and 5, however, such driving method has a problem that during at least a predetermined time, continuous two frames are displayed simultaneously. That is, as shown in FIG. 5, before finishing completely an image display of the first frame F 1 , an image display of the second frame F 3 is performed.
As a result, a mixing display period FH is produced, resulting in an incorrect image display of one frame. Also, there may be caused a problem of image distortion that when displaying a dynamic image, images in two frames are viewed as overlapped to a viewer.
In addition, a general driving method is limited to a fixed sequence in which a sequence of driving each of subfields and the number of subfields is predetermined, and these sequences become identical along the time axis. Accordingly, there is frequently caused a repeated occurrence of a specific gray level when displaying a dynamic image. If such occurrence arises in an area in which a bit carrier exists, a low frequency component is generated in the form of a partial flicker, resulting in a deterioration of image quality.
Now, the driving method will be described in more detail with reference to FIG. 6 .
First, it is assumed that one frame is divided into eight subfields SF 1 , SF 2 . . . SF 8 and sustain pulses are set as 1, 2, 4, 8, 16, 32, 64 and 128, respectively and that thereafter, by combining suitably these subfields, gray level of 2 8 =256 are displayed.
The 63rd gray level lights-on all the subfields SF 1 through SF 6 and the 64th gray level lights-on only subfield SF 7 . As shown in FIG. 6, when light on occurs repeatedly at the 63rd gray level and the 64th gray level for every frame, the human eyes view the 127th gray level and the 0 gray level as light on repeatedly every frame. Thus, there occurs the problem that a low frequency component is formed for two adjacent frames and thusly a flicker is generated.
Furthermore, if scrolling a display of gray level in the inclined direction of brightness when displaying a dynamic image, a bright line and a dark line occur in a specific gray level and thusly the dynamic image is displayed as a false contour.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a driving method capable of preventing images in two frames from being viewed overlapping to a viewer when displaying a dynamic image by clarifying a boundary between adjacent frames in a multi-scan driving method within a sustaining pulse period.
Another object of the present invention is to provide a driving method capable of reducing an occurrence of a flicker and a false contour in a multi-scan driving method.
According to the present invention, there is provided a method of displaying a halftone image on a PDP display unit by using a frame division technique that divides each frame of halftone image into subfields with each having specific sustain pulses to provide a specific intensity level, comprising:
selecting display lines whose number is identical to the total number of said divided subfields, the position of said selected display lines being determined based on the number of sustain pulses set previously to said each subfields, addressing for designating pixels of selected display lines to be displayed and displaying each subfield allocated for the said selected display lines;
shifting by a predetermined number of display lines from said selected display lines as a sustain pulse period unit, selecting display lines, addressing for designating pixels of selected display lines to be displayed and displaying each subfield allocated for the said selected display lines; and
repeating said shifting, said selecting, said addressing and said displaying steps until each of the subfields is completely displayed with regard to all display lines;
wherein display lines for all subfields of one frame have been completely displayed within an idle period, during which a subfield of the following frame is not displayed.
Moreover, the method is characterized in that said idle period is started by applying an erase pulse to the display lines where the display for all subfields has been already completed.
Also, the method is characterized in that the positions of the display lines which are firstly selected to display subfields of the following frame after completely displaying a previous frame are determined different from those of display lines which are firstly selected to display subfields of the previous frame.
BRIEF DESCRIPTION OF THE DRAWINGS
Now, embodiments of the present invention will be described in detail with reference to the accompanying drawings, wherein
FIG. 1 is a schematic sectional view of a discharge cell of a conventional plasma display panel;
FIG. 2 is a plan view of a conventional three electrode type plasma display panel;
FIG. 3 is a frame structure explaining a prior art driving method;
FIG. 4 is a timing diagram illustrating division of an image frame into subfields adapted for a conventional driving method;
FIG. 5 is a pulse waveform diagram applied by each electrode to display a frame in accordance with a conventional method;
FIG. 6 is a diagram illustrating a problem encountered by a conventional plasma display panel;
FIG. 7 is a timing diagram for displaying subfields between adjacent subfields in accordance with a first embodiment of the present invention;
FIG. 8 shows an example of a pulse waveform applied to each electrode in a first embodiment of the present invention;
FIG. 9 shows another example of a pulse waveform applied to each electrode in a first embodiment of the present invention;
FIGS. 10 a and 10 b are timing diagrams for displaying subfields between adjacent subfields in accordance with a second embodiment of the present invention; and
FIG. 11 is an example of a pulse waveform diagram applied to application examples of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 7 shows a timing diagram displaying subfields between two adjacent frames illustrating the first embodiment of the present invention. For convenience of a description, it is assumed that one frame divides into three subfields SF 1 , SF 2 and SF 3 , sustain periods in the subfields SF 1 , SF 2 and SF 3 set as 1 , 2 and 4 , respectively and the number of display lines is 7 . In practice, however, it is possible to divide one frame into six or eight more subfields and constitute display lines to have a conventional number of 480 lines. In FIG. 7, S 1 through S 7 represent the number of sustain pulses.
Since sustain periods (pulses) of each of subfields SF 1 , SF 2 and SF 3 are set as 1 , 2 and 4 respectively, it is possible to select display lines D 1 , D 3 and D 7 in consideration of the sustain periods (pulses) set for each of the subfields SF 1 , SF 2 and SF 3 . Of course, it is possible to select various combinations of display lines (D 2 , D 4 and D 1 ), (D 3 , D 5 and D 2 ), (D 4 , D 6 and D 3 ), (D 5 , D 7 and D 4 ), (D 6 , D 1 and D 5 ) and (D 7 , D 2 and D 6 ).
As shown in FIG. 7, the display lines D 1 , D 3 and D 7 are selected in consideration of the sustain pulses set for each of subfields SF 1 , SF 2 and SF 3 in the first sustain pulse period (S 1 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 1 , D 3 and D 7 is performed respectively. Next, the display lines D 2 , D 4 and D 1 which are allocated downwardly by one display line from the above-selected display lines are selected in the second sustain pulse period (S 2 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 2 , D 4 and D 1 is performed respectively. Next, the display lines D 3 , D 5 and D 2 which are allocated downwardly by one display line from the above-selected display lines are selected in the third sustain pulse period (S 3 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 3 , D 5 and D 2 is performed respectively. Next, the display lines D 4 , D 6 and D 3 which are allocated downwardly by one display line from the above-selected display lines are selected in the fourth sustain pulse period (S 4 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 4 , D 6 and D 3 is performed respectively. Next, the display lines D 5 , D 7 and D 4 which are allocated downwardly by one display line from the above-selected display lines are selected in the fifth sustain pulse period (S 5 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 5 , D 7 and D 4 is performed respectively. Next, the display lines D 6 , D 1 and D 5 which are allocated downwardly by one display line from the above-selected display lines are selected in the sixth sustain pulse period (S 6 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 6 , D 1 and D 5 is performed respectively. Next, the display lines D 7 , D 2 and D 6 which are allocated downwardly by one display line from the above-selected display lines are lastly selected in the seventh sustain pulse period (S 7 ). Then, the display of subfields SF 1 , SF 2 and SF 3 for the selected display lines D 7 , D 2 and D 6 is performed respectively. Thereby, the display of one frame is completed.
After lastly selecting display lines D 7 , D 2 and D 6 , the previously selected display lines complete sequentially display the subfields SF 1 , SF 2 and SF 3 , respectively. At this time, the display lines, which have sequentially completed the display, do not perform a selection for displaying the next frame. After displaying subfield SF 3 of the lastly selected display line D 6 , the display lines start the display of the next frame.
As a result, after the subfields SF 1 , SF 2 and SF 3 corresponding to one frame are completely displayed, there is provided an idle period H at every display line to the extent of at least the largest bit of subfield period.
FIG. 8 is a pulse waveform diagram applied to each electrode in order to display a frame as shown in FIG. 7 and shows a driving method in accordance with a selectively erasing process.
Firstly, the selecting step of display lines will be described hereafter. As shown in FIG. 8, there is provided with a predetermined negative voltage to the Y electrodes Y 1 , Y 2 and Y 3 constituting the display lines D 1 , D 3 and D 7 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 1 , D 3 and D 7 . As a result, a write discharge to the display lines D 1 , D 3 and D 7 is performed and thereby, the display lines D 1 , D 3 and D 7 are selected.
Thereafter, in the addressing step, scan pulses generated from the Y scan-driving circuit are sequentially applied to the selected Y electrodes Y 1 , Y 3 and Y 7 in first sustaining pulse period. At the same time, data pulses generated from the data driving circuit in accordance with image data to be displayed are applied to data electrodes. If the data pulses are applied, a wall charge on the dielectric layer generated by the write discharge is erased. Thus, even if the sustaining pulse is applied, the sustaining discharge is not performed. If the data pulse is not applied, the wall charge cannot be erased. Accordingly, the write discharge in the above selecting step is still maintained.
Next, in the sustaining step, there is provided with the sustaining pulse to the Y electrodes (Y 1 , Y 3 and Y 7 ) and the common X electrodes constituting the display lines D 1 , D 3 and D 7 . As the result, the sustaining discharge of the pixels that are designated in the addressing step is performed.
Continuously, by selecting the display lines D 2 , D 4 and D 1 which are allocated downwardly by one line from the display lines D 1 , D 3 and D 7 in the second sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 2 , Y 4 and Y 1 constituting the display lines D 2 , D 4 and D 1 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 2 , D 4 and D 1 . As a result, a write discharge to the display lines D 2 , D 4 and D 1 is performed and thereby, the display lines D 2 , D 4 and D 1 are selected. The display line D 1 is selected again among the display lines D 1 , D 3 and D 7 that were selected in the first sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 1 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 2 , D 4 and D 1 are performed sequentially.
Continuously, by selecting the display lines D 3 , D 5 and D 2 which are allocated downwardly by one line from the display lines D 2 , D 4 and D 1 in the third sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 3 , Y 5 and Y 2 constituting the display lines D 3 , D 5 and D 2 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 3 , D 5 and D 2 . As a result, a write discharge to the display lines D 3 , D 5 and D 2 is performed and thereby, the display lines D 3 , D 5 and D 2 are selected. The display line D 3 is selected again among the display lines D 1 , D 3 and D 7 that were selected in the first sustaining pulse period, and thereby the display of subfield SF 2 to the display line D 3 is finished. Also, the display line D 2 is selected again among the display lines D 2 , D 4 and D 1 that were selected in the second sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 2 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 3 , D 5 and D 2 are performed sequentially.
Continuously, by selecting the display lines D 4 , D 6 and D 3 which are allocated downwardly by one line from the display lines D 3 , D 5 and D 2 in the fourth sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 4 , Y 6 and Y 3 constituting the display lines D 4 , D 6 and D 3 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 4 , D 6 and D 3 . As a result, a write discharge to the display lines D 4 , D 6 and D 3 is performed and thereby, the display lines D 4 , D 6 and D 3 are selected. The display line D 3 is selected again among the display lines D 3 , D 5 and D 2 that were selected in the third sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 3 is finished. Also, the display line D 4 is selected again among the display lines D 2 , D 4 and D 1 that were selected in the second sustaining pulse period, and thereby the display of subfield SF 2 to the display line D 4 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 4 , D 6 and D 3 are performed sequentially.
Continuously, by selecting the display lines D 5 , D 7 and D 4 which are allocated downwardly by one line from the display lines D 4 , D 6 and D 3 in the fifth sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 5 , Y 7 and Y 4 constituting the display lines D 5 , D 7 and D 4 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 5 , D 7 and D 4 . As a result, a write discharge to the display lines D 5 , D 7 and D 4 is performed and thereby, the display lines D 5 , D 7 and D 4 are selected. The display line D 4 is selected again among the display lines D 4 , D 6 and D 3 that were selected in the fourth sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 4 is finished. Also, the display line D 5 is selected again among the display lines D 3 , D 5 and D 2 that were selected in the third sustaining pulse period, and thereby the display of subfield SF 2 to the display line D 5 is finished. Also, the display line D 7 is selected again among the display lines D 1 , D 3 and D 7 that were selected in the first sustaining pulse period, and thereby the display of subfield SF 3 to the display line D 7 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 5 , D 7 and D 4 are performed sequentially.
Continuously, by selecting the display lines D 6 , D 1 and D 5 which are allocated downwardly by one line from the display lines D 5 , D 7 and D 4 in the sixth sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 6 , Y 1 and Y 5 constituting the display lines D 6 , D 1 and D 5 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 6 , D 1 and D 5 . As a result, a write discharge to the display lines D 6 , D 1 and D 5 is performed and thereby, the display lines D 6 , D 1 and D 5 are selected. The display line D 1 is selected again among the display lines D 2 , D 4 and D 1 that were selected in the second sustaining pulse period, and thereby the display of subfield SF 3 to the display line D 1 is finished. Also, the display line D 5 is selected again among the display lines D 5 , D 7 and D 4 that were selected in the fifth sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 5 is finished. Also, the display line D 6 is selected again among the display lines D 4 , D 6 and D 3 that were selected in the fourth sustaining pulse period, and thereby the display of subfield SF 2 to the display line D 6 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 6 , D 1 and D 5 are performed sequentially.
Continuously, by selecting the display lines D 7 , D 2 and D 6 which are allocated downwardly by one line from the display lines D 6 , D 1 and D 5 in the seventh sustaining pulse period, the shifting step is performed. At this time, there is provided with a predetermined negative voltage to the Y electrodes Y 7 , Y 2 and Y 6 constituting the display lines D 7 , D 2 and D 6 . At the same time, there is provided with a positive voltage to the common X electrodes constituting the display lines D 7 , D 2 and D 6 . As a result, a write discharge to the display lines D 7 , D 2 and D 6 is performed and thereby, the display lines D 7 , D 2 and D 6 are selected. The display line D 2 is selected again among the display lines D 2 , D 4 and D 1 that were selected in the third sustaining pulse period, and thereby the display of subfield SF 3 to the display line D 1 is finished. Also, the display line D 6 is selected again among the display lines D 6 , D 1 and D 5 that were selected in the sixth sustaining pulse period, and thereby the display of subfield SF 1 to the display line D 6 is finished. Also, the display line D 7 is selected again among the display lines D 5 , D 7 and D 4 that were selected in the fifth sustaining pulse period, and thereby the display of subfield SF 2 to the display line D 7 is finished. Thereafter, the addressing and sustaining steps for the selected display lines D 7 , D 2 and D 6 are performed sequentially.
In the above described process, erase pulses (Pe) generated from the Y electrode scan driving circuit are applied to the Y electrodes after the total number of sustaining pulses of the corresponding frame are applied to every display line, and thereby wall charge accumulated during the sustain discharge is erased. As the result, the display of the corresponding frame for every display line is finished. The erase pulses (Pe) can be applied to the Y electrode within a sustaining pulse period of the Y electrode as shown in FIG. 8 and also immediately after a sustaining pulse is applied to the X electrode as shown in FIG. 9 . The display of the next frame starts after erase pulses (Pe) to all the display lines are applied.
Accordingly, an idle period H for all the display lines is from when applying erase pulse to when starting the display of the next frame. That is, the length of the idle period H depends on a display period of a largest bit of subfield SF 3 allocated in the display lines that are lastly selected. Therefore, it is desirable to shorten the idle period H. By dividing the largest bit of subfield into a plurality of subfields, the idle period H can be shortened.
FIGS. 10 a and 10 b show a driving method in accordance with a second embodiment of the present invention. As explained in FIG. 7, when displaying one frame of an image, three display lines identical to the number of subfields can be selected firstly. Also, the position of display lines selected can be determined as display lines D 1 , D 3 and D 7 with regard to each of subfields SF 1 , SF 2 and SF 3 in a consideration of the sustain periods 1 , 2 and 4 . At this time, the positioning of the display lines in consideration of sustain periods designated on each subfield is the same as the allocating of each subfield to the display lines. That is, if selecting one display line D 1 of seven display lines and allocating the subfield SF 1 for the display line D 1 , other display line D 7 or D 2 positioned above or below by one line from the display line D 1 should be selected.
In practice, even though the display line D 2 is positioned below by one line from the display line D 1 , the selecting of the display line D 2 can be considered in case that the scanning direction moves upwardly. Next, if selecting one display line D 7 of seven display lines and allocating the subfield SF 3 for the display line D 7 , the remaining display line D 3 can be automatically selected, and thereby subfield F 2 for the display line D 3 is allocated.
As described above, once the position of the display lines selected firstly is determined in accordance with the number of sustain pulses set to each of the subfields, the displaying order of each of the subfields SF 1 , SF 2 and SF 3 is constantly maintained until the display of one frame is completed.
In FIG. 7, there is shown that the position of display lines for displaying a next frame is selected identical to the previous frame. However, in the case that a specific gray level is repeatedly generated when displaying a dynamic image as shown in FIG. 6, a low frequency ingredient occurs in an area in which a bit carry exists. Thus, there is caused a problem that the low frequency ingredient is generated in the form of a partial flicker, resulting in deterioration of image quality.
According to the second embodiment of the present invention, in order to solve such problem, the position of display lines selected firstly to display the next frame is different from that of the display lines selected firstly to display the previous frame.
For example, as shown in FIG. 10 a , the position of display lines selected firstly in the previous frame are display lines D 1 , D 3 and D 7 allocated to the subfields SF 1 , SF 2 and Sf 3 , respectively. On the other hand, the position of display lines selected firstly in the next frame are display lines D 1 , D 2 and D 4 allocated to the subfields SF 3 , SF 1 and SF 2 , respectively. Likewise, as shown in FIG. 10 b , the position of display lines selected firstly in the next frame are display lines D 2 , D 3 and D 5 allocated to the subfields SF 3 , SF 1 and SF 2 , respectively.
In this way, a combination of display lines to be selected initially in a frame can be selected as any one of combinations of n×N!, wherein n is the number of display lines and N is total number of subfields of one frame. Accordingly, a combination of display lines to be selected initially in the next frame can be selected as any one of [n×N!]−1 combinations which excepts the combination selected in the previous frame. According to the second embodiment of the present invention, it is possible to display subfields in a different order at every frame.
Until now, even though the driving method according to the present invention was described based on a selective erase process, as shown in FIG. 11, it can be applicable to a selective writing process comprising writing discharge for the display lines selected, erase discharge for erasing wall charge accumulated on a dielectric layer, addressing discharge for designating pixels to be displayed, and sustain discharge for displaying pixels designated.
As mentioned above, according to the present invention, since after completing a display of one frame with respect to all display lines, a display for the next frame is initiated, and it is possible to prevent images in two frames being viewed to a viewer in an overlapped shape when displaying a dynamic image.
Moreover, even when a specific gray level is repeatedly displayed, since the display order of subfields of every frame varies, the occurrence of a low frequency ingredient can be prevented. Many different embodiments of the present invention can by provided without departing from the spirit and scope of the present invention which is not limited to the specific embodiments described in the specification. Also, the present invention can be applied to various kinds of flat display devices such LCD, FED, EL and the like.
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A method of displaying a halftone image on a PDP display unit by using a frame division technique, the method comprising selecting display lines whose number is identical to the total number of said divided subfields, addressing for designating pixels of selected display lines to be displayed and displaying each subfield allocated for the said selected display lines; shifting by a predetermined number of display lines from said selected display lines for at least a sustain pulse period unit, selecting display lines, addressing for designating pixels to be displayed and displaying each subfield allocated for the said display lines; and repeating said shifting, said selecting, said addressing and said displaying steps until each of the subfields is completely displayed for all display lines; wherein display lines for which all subfields of one frame have been completely displayed for an idle period. According to the present invention, there is provided a driving method capable of preventing images in two frames from being viewed overlapped to a viewer when displaying a dynamic image by clarifying a boundary between adjacent frames in a multi-scan driving method within a sustaining pulse period.
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This application is a continuation of co-pending U.S. patent application Ser. No. 11/770,615, filed Jun. 28, 2007, and entitled “THERMOSTAT WITH UTILITY MESSAGING”, which is incorporated herein by reference.
TECHNICAL FIELD
The disclosure pertains generally to controllers and more particularly to HVAC controllers such as thermostats that include a display panel.
BACKGROUND
Controllers are used on a wide variety of devices and systems for controlling various functions in homes and/or buildings and their related grounds. Some controllers have schedule programming that modifies device parameters such as set points as a function of date and/or time. Some such device or system controllers that utilize schedule programming for controlling various functions in homes and/or buildings and their related grounds include, for example, HVAC controllers, water heater controllers, water softener controllers, security system controllers, lawn sprinkler controllers, and lighting system controllers.
HVAC controllers, for example, are employed to monitor and, if necessary, control various environmental conditions within a home, office, or other enclosed space. Such devices are useful, for example, in regulating any number of environmental conditions with a particular space including for example, temperature, humidity, venting, air quality, etc. The controller may include a microprocessor that interacts with other components in the system. For example, in many modern thermostats for use in the home, a controller unit equipped with temperature and/or humidity sensing capabilities may be provided to interact with a heater, blower, flue vent, air compressor, humidifier and/or other components, to control the temperature and humidity levels at various locations within the home. A sensor located within the controller unit and/or one or more remote sensors may be employed to sense when the temperature or humidity reaches a certain threshold level, causing the controller unit to send a signal to activate or deactivate one or more component in the system.
The controller may be equipped with a user interface that allows the user to monitor and adjust the environmental conditions at one or more locations within the building. With more modern designs, the interface typically includes a liquid crystal display (LCD) panel inset within a housing that contains the microprocessor as well as other components of the controller. In some designs, the user interface may permit the user to program the controller to activate on a certain schedule determined by the user. For example, the interface may include a separate menu routine that permits the user to change the temperature at one or more times during a particular day. Once the settings for that day have been programmed, the user can then repeat the process to change the settings for the other remaining days. Such a schedule may help reduce energy consumption of the HVAC system by changing the set point to an energy saving set back temperature during certain times.
Most structures are serviced by one or more utilities, such as an electric utility, a gas utility, a water utility and others. The expense of using these utility services continues to rise, particularly during peak demand periods. In order to better serve its customers, and in some cases to help reduce demand during peak or other periods, it would be advantageous for a utility to be able to directly and more efficiently communicate with its customers.
SUMMARY
The present disclosure pertains generally to thermostats that are adapted to assist utilities in communicating with its customers. In particular, the present disclosure relates to a thermostat having a display, a controller and a receiver that is coupled to the controller. The receiver is adapted to receive messages from a utility, and the controller is adapted to display related display messages on the display.
The above summary is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and Detailed Description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE FIGURES
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
FIG. 1 shows an illustrative but non-limiting HVAC control system.
FIG. 2 shows an illustrative but non-limiting example of a thermostat of FIG. 1 ;
FIG. 3 shows an illustrative thermostat operating in accordance with its programming;
FIG. 4 shows the illustrative thermostat of FIG. 3 after the current energy demand and/or current energy cost has reached a critical level;
FIG. 5 shows the illustrative thermostat of FIG. 3 displaying a first stored or received message;
FIGS. 6-7 shows the illustrative thermostat of FIG. 5 displaying a second stored or received message;
FIG. 8 shows the illustrative thermostat of FIG. 3 displaying a “Please Conserve” message received from a utility;
FIG. 9 shows the illustrative thermostat of FIG. 3 displaying a “Storm Warning” message received from a utility or other source;
FIG. 10 show the illustrative thermostat of FIG. 3 displaying information related to electrical consumption including historical electrical consumption information;
FIG. 11 show the illustrative thermostat of FIG. 3 displaying information related to electrical costs including historical electrical cost information;
FIG. 12 show the illustrative thermostat of FIG. 3 displaying information related to water usage including historical water usage information;
FIG. 13 show the illustrative thermostat of FIG. 3 displaying information related to water usage costs including historical water usage cost information;
FIG. 14 show the illustrative thermostat of FIG. 3 displaying information related to gas usage including historical gas usage information;
FIG. 15 show the illustrative thermostat of FIG. 3 displaying information related to gas usage costs including historical gas usage cost information;
FIG. 16 is a flow diagram of an illustrative method in accordance with the present invention; and
FIG. 17 is a flow diagram of another illustrative method in accordance with the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION
The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials may be illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
FIG. 1 shows an illustrative but non-limiting HVAC control system 10 . The illustrative HVAC control system 10 includes a thermostat 12 that may be adapted to interact with and control HVAC equipment 14 . HVAC equipment 14 may include one or more of cooling equipment 16 , heating equipment 18 and/or ventilation equipment 20 . In some cases, cooling equipment 16 and heating equipment 18 may, for example, be combined in a forced air system, or perhaps a heat pump system, particularly in residential and/or light commercial applications. In other cases, one or more of cooling equipment 16 , heating equipment 18 and/or ventilation equipment 20 may be distinct systems controlled by thermostat 12 . In some instances, it is contemplated that thermostat 12 may represent two or more distinct thermostats, each controlling different equipment within HVAC equipment 14 , and or different zones within a structure.
In the illustrative embodiment, thermostat 12 may be adapted to interact and/or communicate with a utility 22 . Utility 22 may represent a utility company or another entity that produces or otherwise provides an energy source such as electricity, natural gas and the like, or provides another utility such as water and/or sewer service. Utility 22 may represent a utility company or other entity that provides a source of hot water that can be used for heating and/or any other desired use. Utility 22 may provide hot water from a geothermal source, or by heating water using biomass or even microwave energy.
In some instances, thermostat 12 may receive signals from utility 22 via a communication network 24 . Communication network 24 may include wireless communication between utility 22 and thermostat 12 , using radio frequencies and the like. In some cases, communication network 24 may represent a hard-wired communication network between utility 22 and thermostat 12 , such as copper wiring, coaxial cable, CAT 5 cable, fiber optics, and the like. In some instances, especially if utility 22 provides electrical power to the building in which thermostat 12 is located, communication network 24 may represent signals sent over the power lines themselves. In some cases, part of communication network 24 may be a wired and another part may be wireless. More generally, communication network 24 may be any suitable communication path between utility 22 or the like and thermostat 12 .
In some instances, thermostat 12 may receive information from utility 22 pertaining to utility usage, utility usage history, current and/or historical rate information, and the like. Alternatively, or in addition, thermostat 12 may receive information from meter 26 pertaining to utility usage, utility usage history, current and/or historical rate information, and the like. In some cases, thermostat 12 may receive information from utility 22 and/or meter 26 pertaining to a current electrical rate, say in cents per kilowatt-hour. In some instances, thermostat 12 may receive information regarding a remaining balance on a prepaid account, or perhaps monthly garbage and/or sewer charges.
Utility 22 and/or meter 26 may, for example provide information to thermostat 12 regarding a measure of utility usage. In some cases, the measure of utility usage may be related to current utility costs over a designated period of time (e.g. over a past year, a past month, a past week, a past day, a past hour, etc.), i.e., a current electrical cost over a designated period of time, a current gas cost over a designated period of time, a current water cost of a designated period or time and the like. In some instances, a measure of utility usage may include a quantity of utility usage, and thus utility 22 may provide thermostat 12 with information pertaining to how much energy (e.g. in KWH, which are kilowatt-hours), for example is currently being used over a designated period of time (e.g. over a past year, a past month, a past week, a past day, a past hour, schedule period, etc.).
In some instances, utility 22 and/or meter 26 may provide messages relating to utility usage. For example, utility 22 may provide, via communication network 24 , one or more messages intended for a homeowner, facilities manager or the like. In some cases, if utility demand is high, utility 22 may provide one or more messages that permit or instruct thermostat 12 to display suggestions on how to save energy, water or other resource. For example, if utility energy demand is high or expected to be high, thermostat 12 may display one or more messages suggesting that the homeowner or facilities manager conserve energy by changing a temperature set point, or perhaps suggesting that they wait and run energy intensive appliances later in the day, when utility demand may be lower. Utility 22 may, in some instances, provide one or more messages that permit or instruct thermostat 12 to display information pertaining to current or expected weather, current or expected energy demand, current or expected pricing tiers, etc.
In some cases, utility 22 and/or meter 26 may provide one or more messages that cause thermostat 12 to display information relating to utility billing. This may include utility billing history, current utility billing rates and/or current utility costs, and the like. Thermostat 12 may display information pertaining to a measure of utility usage during a first time period (e.g. a designated month such as the current month) and information pertaining to a measure of utility usage during a second time period (e.g. the designated month one year ago) that is different from the first time period. While not required, the first time period may occur temporally before the second time period. In some cases, controller 34 may compute a measure of utility usage that is consumed by the HVAC system of the building or other structure by monitoring the on-time of one or more HVAC system components 16 , 18 and/or 20 .
The first time period and the second time period may each, independently, be any desired length of time, and may be temporally separated by any desired time interval. In some cases, the first time period may immediately precede the second time period. The first time period may, if desired, be one or more months before the second time period. In some cases, the first time period may be about a year or more prior to the second time period.
In some cases, the first time period and the second time period may each correspond to a one week (168 hours) time period, and the first time period may correspond to an immediately preceding week relative to the second time period. In some instances, the first time period and the second time period may each correspond to a one month time period. The first time period may be a one month time period that immediately precedes the second time period. In some cases, the first time period (e.g. June 2006) may be a one month time period that is about one year prior to the second time period (e.g. June 2007).
In some cases, the indication of the measure of utility usage that is displayed for the first time period may include an indication of the cost of utility usage during the first time period, and the indication of the measure of utility usage that is displayed for the second time period includes an indication of the cost of utility usage during the second period of time. In some instances, the indication of the measure of utility usage that is displayed for the first time period includes an indication of the quantity of utility usage during the first period of time, and the indication of the measure of utility usage that is displayed for the second time period include an indication of the quantity of utility usage during the second period of time.
In some embodiments, thermostat 12 may be adapted to interact and/or communicate with a meter 26 over a communication line 28 . Meter 26 may, for example, be adapted to measure and/or regulate a flow of energy or other resource (e.g. water) from utility 22 , and may also provide thermostat 12 with usage information via a wireless, wired, optical, or any other suitable communication path. In some instances, although direct communication therebetween is not expressly shown in FIG. 1 , meter 26 may provide utility 22 with usage information.
Communication line 28 may represent wireless communication between meter 26 and thermostat 12 . In some cases, communication line 28 may represent a hard-wired line between meter 26 and thermostat 12 , such as copper wiring, coaxial cable, CAT 5 cable, fiber optic cable, and the like. In some instances, although not expressly illustrated in FIG. 1 , it is contemplated that meter 26 may also communicate with utility 22 , and may receive utility rate information and the like from utility 22 , but this is not required in all embodiments.
The preceding discussion describes communication that may occur between utility 22 and thermostat 12 and/or between meter 26 and thermostat 12 . In order to accommodate this communication, thermostat 12 may include a receiver and/or transceiver 30 that permits thermostat 12 to communicate with utility 22 via communication network 24 and/or to communicate with meter 26 via communication line 28 . As noted, one or both of communication network 24 and/or communication line 28 may be wired or wireless. In some cases, communication network 24 may, for example, include a wireless paging system, and receiver and/or transceiver 30 may be a load control receiver that uses, for example, a 900 MHz paging technology such as the FLEX® paging technology available from Motorola. One such load control receiver is available from Cannon Technologies, located in Wayzata, Minn., although it is contemplated that any suitable communication equipment may be used, as desired.
Thermostat 12 may include a user interface 32 that may be adapted to accept information from a user as well as to provide information to the user. In some cases, user interface 32 may include a liquid crystal display (LCD) as well as a keypad or similar entry device. In some instances, user interface 32 may include a touch screen LCD that provides both functions.
Thermostat 12 may include a controller 34 that is adapted to oversee the aforementioned communications between thermostat 12 and utility 22 and/or meter 26 . Controller 34 may regulate information that is solicited and/or displayed on user interface 32 . Controller 34 may be adapted to implement a control algorithm that is adapted to at least partially control one or more components of HVAC equipment 14 . Thermostat 12 may include a memory block 36 that can be used to store operating parameters, utility usage history and the like.
Thermostat 12 may include a sensor 38 , which may be located within thermostat 12 as well as one or more external sensors 40 , as desired. Each of sensors 38 and 40 may be any type of sensor, or may represent multiple sensors, such as temperature sensors, humidity sensors and the like. External sensors 40 may be hard wired to thermostat 12 , or may communicate wirelessly, as desired.
FIG. 2 shows an illustrative but non-limiting example of a thermostat 42 that may be considered as representing thermostat 12 ( FIG. 1 ), but showing additional detail regarding user interface 32 . Thermostat 42 includes a thermostat housing 44 and an LCD display 46 that is visible from outside thermostat housing 44 . Thermostat housing 44 may be formed of any suitable material and having any suitable dimensions. In some cases, thermostat housing 44 is stamped or molded from a polymeric material. In some cases, LCD display 46 is a touch screen LCD, but this is not required in all embodiments.
LCD display 46 may be considered as including a first region 48 and a second region 50 . In the illustrative embodiment, first region 48 includes an array of pixels 52 that are arranged into a plurality of rows and a plurality of columns to form an array of pixels that is suitable for displaying alphanumeric characters such as text in a dot matrix format. In some cases, one or more of pixels 52 may be square or round fixed segment pixels. For example, first region 48 may include an array of pixels 52 that are arranged into 7 rows and a total of 125 columns. To more clearly illustrate the individual pixels, pixels 52 are schematically illustrated in FIG. 2 as unlit.
First region 48 may be constructed using either fixed segment type LCD display or a graphic type LCD display. When first region 48 is constructed as a fixed segment LCD display, a number of relatively small fixed segments dots are provided, and in some cases, may be arranged into character blocks, with each character block having, for example, 5×7 dots. In some cases, each character block can be addressed separately and can form numbers, letters and a limited number of symbols. In other cases, each fixed segment dot can be addressed separately. When first region 48 is constructed as a graphics type LCD display, a relatively larger number of pixels are arranged in rows and columns, and each pixel can typically be individually addressed.
In an illustrative but non-limiting example, first region 48 may include or be formed as fixed segment LCD display, and may include a total of 25 5×7 characters, for a total of 875 individual pixels 52 . Each pixel 52 may be square and may be 0.5 millimeters by 0.5 millimeters in size. There may be a small gap between adjacent pixels 52 . In some cases, there may be a 0.05 millimeter gap between adjacent pixels 52 . These pixels 52 may be formed as part of the fixed segment mask used in fabricating the fixed segment LCD display.
In some cases, first region 48 may be used to display messages and other similar text. Controller 34 may be coupled to user interface 32 and may be adapted to display a message including two or more text characters in first region 48 using the array of fixed segment pixels 52 . If desired, controller 34 may be adapted to scroll messages across at least part of first region 48 . This may be useful in displaying messages that are too long to simultaneously fit in their entirety within first region 48 . Scrolling may also be useful in attracting attention to messages being displayed within first region 48 . In some cases, a message may be flashed, i.e., repeatedly turned on and off, within first region 48 to draw attention to the particular message.
In some cases, display 46 may include a left arrow icon 54 and/or a right arrow icon 56 , which may be used to scroll through a long message, or perhaps to scroll through multiple messages. Left arrow icon 54 and right arrow icon 56 may be constructed as fixed segment icons, and may not be considered part of first region 48 , even though they are located within an upper portion of display 46 . In some embodiments, pressing right arrow icon 56 may cause controller 34 ( FIG. 1 ) to display another message, if another message is available, or to cause a message to scroll. Pressing left arrow icon 54 may cause controller 34 to display a previous message or to cause a message to scroll.
Second region 50 of user display 46 may include a plurality of fixed segment graphical icons. At least some of the fixed segment graphical icons within second region 50 may be or may include a word, a perimeter boundary and/or a word within a perimeter boundary. In some instances, LCD display 46 is a touch screen LCD, and one or more of the fixed segment graphical icons may coincide with one or more touch sensitive buttons.
For example, second region 50 may include a message icon 58 . If thermostat 42 has received or otherwise generated a text message to be displayed within first region 48 , controller 34 ( FIG. 1 ) may flash message icon 58 and/or may illuminate the “VIEW” text within message icon 58 . The “VIEW” text may be formed as part of a fixed segment graphical icon, if desired. Message icon 58 may coincide with a touch sensitive button or portion of LCD display 46 . In some cases, message icon 58 may include a fixed segment perimeter boundary 59 .
Pressing message icon 58 may cause controller 34 to proceed with displaying and/or scrolling one or more messages within first region 48 of display 46 using the array of fixed segment pixels 52 . In some cases, once the message has been displayed, the “DELETE” text within message icon 58 may be illuminated, although this is not required. Pressing message icon 58 at this stage may cause controller 34 to delete the message that has been displayed or is currently being displayed. Second region 50 may include an “EXIT” icon 60 . Pressing EXIT icon 60 instead of message icon 58 may cause controller 34 to return to a previous screen without deleting the displayed message or messages. Example messages are shown and discussed with respect to subsequent Figures.
Fixed segment LCD displays are often configured to display Arabic numbers (0-9) using seven segments. In contrast, fourteen segments are often needed to display other characters such as the Roman alphabet, measurement units and other symbols. In some instances, second region 50 of display 46 may include a set 62 of fixed segments that are configured to display numbers. In particular cases, set 62 may be configured to display utility usage data including utility usage quantity data and/or utility usage cost data. In some cases, set 62 may include a total of five fixed segment numbers 64 , with each fixed segment number 64 having a total of seven distinct bar segments 66 .
Similarly, second region 50 of display 46 may include a set 68 of fixed segments that are configured to display numbers. In some cases, set 68 may be configured to display historical utility usage data including historical utility usage quantity and/or historical utility usage cost data. In some cases, set 68 may include a total of five fixed segment numbers 70 , with each fixed segment number 70 having a total of seven distinct bar segments 72 .
In some instances, second region 50 of display 46 may include a TIER icon 74 that may include one or more of a CRITICAL fixed segment 76 , a HIGH fixed segment 78 , a MEDIUM fixed segment 80 and/or a LOW fixed segment 82 . In some cases, utility 22 ( FIG. 1 ) may provide a signal to thermostat 42 informing thermostat 42 that current energy costs and/or current energy demand has reached a particular tier or level. For example, if energy demand and/or energy cost is low, the LOW fixed segment 82 may be illuminated. The other fixed segments may be illuminated in accordance with the energy demand and/or energy cost data provided by utility 22 . In some situations, TIER icon 74 may not be illuminated.
If the current energy demand and/or current energy costs reach a critical level, controller 34 ( FIG. 1 ) may illuminate CRITICAL fixed segment 76 . In some cases, when the current energy demand and/or current energy costs reaches a certain level (e.g. high or critical), a SAVING icon 84 may be illuminated or even flash indicating that controller 34 has altered a temperature set point in accordance with the energy demand information provided by utility 22 ( FIG. 1 ). In some cases, SAVING icon 84 may be illuminated irrespective of the current tier level.
In some instances, utility 22 may, in response to energy demand and/or energy cost data, may determine how temperature set points are to be altered. A customer may, for example, sign a contract permitting utility 22 to alter temperature set points and/or to determine temperature differentials as necessary and/or appropriate. If utility 22 determines that a particular tier level has been reached, utility 22 may send a signal to thermostat 42 temporarily altering a temperature set point, either by providing a temporary temperature set point or by providing a temperature differential that can be applied to the temperature set point specified by the current schedule under which thermostat 42 is otherwise operating. The contract may permit utility 22 to send a signal to thermostat 42 instructing thermostat 42 to shut down HVAC equipment 14 ( FIG. 1 ) for a length of time that may be predetermined and/or may be calculated based, for example, on current energy demand and/or current energy rates.
In some instances, for example, utility 22 may provide a signal to thermostat 42 instructing thermostat 42 to change to a temporary temperature set point. The temporary set point may vary, depending on the current energy tier. For example, utility 22 may suggest or require, based at least in part on the contract signed by the owner, a heating temperature set point of 70° F. for a low energy cost, 65° F. for a medium energy cost, 60° F. for a high energy cost, and 50° F. for a critical energy cost. Utility 22 may suggest or require, based at least in part on the contract, a cooling temperature set point of 72° F. for a low energy cost, 77° F. for a medium energy cost, 82° F. for a high energy cost, 86° F. for a critical energy cost. These temperatures are merely illustrative and are not intended to limit or define in any way or manner. In some cases, utility 22 may provide thermostat 42 with the heating and cooling temperature set point values corresponding to each tier level.
Controller 34 ( FIG. 1 ) may issue a control signal to HVAC equipment 14 for operating cooling equipment 16 and/or heating equipment 18 when the temperature is different than the temperature set point associated with the acceptable energy cost level. In the above example, when the current energy price is high, the control signal may issue control information for operating heating equipment 18 when the temperature fell to 60° F. or below. For cooling equipment 16 , the control signal would issue control information for operating cooling equipment 16 when the temperature rose to or above 82° F. Additionally, the receiver and/or transceiver 30 may receive information from the utility(s) for an energy (and/or water) bill for usage of energy (and/or water) during a time period. In some cases, the user may authorize payment of the energy (and/or water) bill and have the authorization transmitted to utility 22 via the thermostat 12 .
In some instances, utility 22 may send a signal instructing thermostat 42 to temporarily change its temperature set point by a particular temperature differential that depends on tier level. For example, utility 22 may provide a signal including a temperature differential or offset of 0° F. for a low energy cost, a temperature differential or offset of 2° F. for a medium energy cost, a temperature differential or offset of 6° F. for a high energy cost and a temperature differential or offset of 10° F. for a high energy costs.
If, for example, the current temperature set point for heating is set at 68° F. and the energy demand reaches the critical level, thermostat 42 may temporarily operate with a temperature set point of 58° F. (68° F.−10 F). If, for example, the current temperature set point for cooling is set at 76° F. and the energy demand reaches the high level, thermostat 42 may temporarily operate with a temperature set point of 86° F. (76° F.+10° F.).
Depending on the specifics of the contract between the owner and utility 22 , in some cases the owner may be able to override the temporary temperature set points provided by the utility. In some cases, the owner may not be permitted to make any changes, and in fact thermostat 42 may be instructed to not accept set point changes while utility 22 is providing a temporary temperature set point and/or a temperature differential to thermostat 42 .
In some cases, it is contemplated that a homeowner, a facilities manager and/or an installer may program thermostat 42 with information pertaining to how temperature set points are to be altered in response to various energy demand and/or energy cost levels provided by utility 22 . In some cases, setback information that has been programmed into thermostat 42 may be based at least in part upon which time period (WAKE, LEAVE, RETURN, SLEEP) thermostat 42 is currently operating under.
FIG. 3 shows the illustrative thermostat 42 operating in accordance with its programming. On second region 50 of display 46 , controller 34 ( FIG. 1 ) is displaying a current inside temperature value 86 and a current temperature set point 88 . If message icon 58 is blinking or otherwise illuminated, pressing message icon 58 may cause one or more messages to be displayed, as will be illustrated subsequently.
As TIER icon 74 is indicating that the current energy demand and/or current energy cost is at a medium level, the illustrative thermostat 42 may continue to operate in accordance with its schedule, as indicated by the “Following Schedule” fixed segment icon 90 . It can be seen that as the temperature set point 88 is higher than the current temperature value 86 , the heat is currently operational.
In FIG. 4 , TIER icon 74 is indicating that the current energy demand and/or current energy cost has reached a critical level 76 . While current inside temperature value 86 remains constant at 66° F., it can be seen that the temperature set point 88 has dropped from the 72° F. value shown in FIG. 3 to a savings temperature value of 58° F., and the heat has thus shut off. In some cases, controller 34 monitors the communication with utility 22 . In some cases, if the communication is broken or otherwise not functioning properly for some reason, thermostat 42 may return to its normal schedule until such time as communication is reestablished.
Returning to FIG. 3 , assume for illustrative purposes that message icon 58 is blinking or is otherwise illuminated. In the illustrative embodiment, pressing message icon 58 will cause controller 34 ( FIG. 1 ) to display stored or received messages, as shown in FIG. 5 . First region 48 of display 46 can be seen as displaying a message “Good Morning!”. Because there is more than one message to display (two, in this example), the message includes “½” in front of the message, and right arrow icon 56 is illuminated. Pressing right arrow icon 56 may cause controller 34 to display the second message, as shown in FIGS. 6 and 7 . It can be seen that once the message has been viewed, message icon 58 changes from illuminating the VIEW fixed segment icon to illuminating the DELETE fixed segment icon.
In this particular example, the second message is “2 Honeywell UtilityPRO Helps You to Save Energy”, which is too large to display within the 25 character blocks forming first region 48 . Thus, controller 34 ( FIG. 1 ) may scroll the message. This can be seen by comparing FIGS. 6 and 7 . In FIG. 6 , first region 48 includes “2 Honeywell UtilityPRO He”, which is the first 25 characters of the message while in FIG. 7 , first region 48 includes “0 Helps You to Save Energy”, which represents the last 25 characters of the message. These are screen captures illustrating how text fits within first region 48 . While the message is broken over two Figures, it will be understood that the message actually scrolls smoothly across first region 48 of display 46 . In some cases, it is contemplated that text may be scrolled vertically, rather than horizontally.
Because a second or subsequent message is being displayed, it can be seen that left arrow icon 54 is illuminated, so that a user may move back to the previous message. In some cases, if only one message is available or otherwise appropriate for display, neither left arrow icon 54 nor right arrow icon 56 may be illuminated.
A wide variety of messages may be displayed. For example, as shown in FIG. 8 , first region 48 of display 46 may, in response to a signal from utility 22 ( FIG. 1 ), display a message reading “Please Conserve!” This message may be displayed when, for example, the utility demand is high or expected to be high. Similar messages may suggest that the person refrain from running energy intensive appliances such as washing machines until the energy demand drops. Another illustrative message is seen in FIG. 9 , in which first region 48 of display 46 displays a message reading “Storm Warning”, perhaps in response to utility 22 forwarding a signal from the local weather authorities, or perhaps the local weather authorities are equipped to broadcast a warning signal directly to receiver and/or transceiver 30 ( FIG. 1 ). It is contemplated that at least some of the messages may be targeted toward certain customers. For example, a tornado warning message may only be sent to those thermostats that are within the geographic region that is currently under a tornado warning. In another example, an ozone or UV warning message may only be sent to those thermostats that are within the geographic region that is currently experiencing high ozone or UV. Likewise, if the demand for energy is particularly high or expected to be high for only some of a utility's customers or part of the utility's grid, a message may be directed to only those thermostats that correspond to those customers (e.g. a unique message to a particular group of customers).
It is also contemplated that promotional messages may be sent to certain thermostats. For example, messages that inform users of certain promotional or other events or services, such as sales at local stores, may be provided. Tips on saving energy and/or the maintenance of equipment may also be provided. In some cases, a water utility may have certain restrictions on water usage, such as limiting the watering of lawns to ever other day. In some cases, the water utility may send a message to the thermostat to notify the user of the water restrictions. In some cases, the water utility may send a message indicating that watering of lawns is prohibited for the customer on a particularly day (e.g. today) or during some other time period.
In some cases, thermostat 42 may be adapted to provide a user with information regarding current and/or historical energy consumption data and corresponding energy costs. For example, FIGS. 10-15 illustrative this feature. Returning briefly to FIG. 3 , in which thermostat 42 is operating in accordance with its schedule, it can be seen that lower region 50 of display 46 includes a USAGE icon 92 . In the illustrative embodiment, pressing USAGE icon 92 brings the user to the screen shown in FIG. 10 .
In FIG. 10 , controller 34 ( FIG. 1 ) is displaying information pertaining to electrical consumption. In particular, controller 34 is instructing first region 48 of display 46 to display “ELECTRICITY IN KWH”, so that the user can put into context the numerical data displayed within second region 50 of display 46 using set 62 of fixed segments and set 68 of fixed segments. Set 62 is displaying a value for the amount of electricity used thus far this month while set 68 is being used to display a value for the corresponding time period last year. Fixed segment icon 94 informs the user of the current time period while fixed segment icon 96 informs the user of the corresponding historical time period. As discussed above, other time periods may also be chosen or otherwise selected or displayed, as desired.
Pressing right arrow icon 56 brings the user to FIG. 11 , in which controller 34 ( FIG. 1 ) is displaying information regarding electrical costs, while instead pressing EXIT button 60 would return the user to FIG. 3 . In FIG. 11 , first region 48 of display 46 now reads “ELECTRICITY BILL”. Fixed segment icon 98 , representing a dollar sign, provides additional context for the information being displayed. In some cases, fixed segment icon 98 may be omitted, if desired.
Set 62 is being used by controller 34 to display the electrical bill to date for the month while set 68 is being used by controller 34 to provide the corresponding historical data. Pressing left arrow icon 54 would return the user to the screen shown in FIG. 10 while pressing right arrow icon 56 will bring the user to the screen shown in FIG. 12 . Pressing EXIT button 60 would return the user to FIG. 3 .
In FIG. 12 , controller 34 ( FIG. 1 ) is displaying information pertaining to water consumption. In particular, controller 34 is instructing first region 48 of display 46 to display “WATER USAGE IN KGAL”, so that the user can put into context the numerical data displayed within second region 50 of display 46 using set 62 of fixed segments and set 68 of fixed segments. Set 62 is displaying a value for the amount of water used thus far this month while set 68 is being used to display a value for the corresponding time period last year. Fixed segment icon 94 informs the user of the current time period while fixed segment icon 96 informs the user of the corresponding historical time period. As discussed above, other time periods may also be chosen or otherwise selected or displayed.
Pressing right arrow icon 56 brings the user to FIG. 13 , in which controller 34 ( FIG. 1 ) is displaying information regarding water costs, while instead pressing EXIT button 60 would return the user to FIG. 3 . In FIG. 13 , first region 48 of display 46 now reads “WATER BILL”. Fixed segment icon 98 , representing a dollar sign, provides additional context for the information being displayed. In some cases, fixed segment icon 98 may be omitted, if desired.
Set 62 is being used by controller 34 to display the water bill to date for the month while set 68 is being used by controller 34 to provide the corresponding historical data. Pressing left arrow icon 54 would return the user to the screen shown in FIG. 12 while pressing right arrow icon 56 will bring the user to the screen shown in FIG. 14 . Pressing EXIT button 60 would return the user to FIG. 3 .
In FIG. 14 , controller 34 ( FIG. 1 ) is displaying information pertaining to gas consumption. In particular, controller 34 is instructing first region 48 of display 46 to display “GAS USAGE IN CCF”, so that the user can put into context the numerical data displayed within second region 50 of display 46 using set 62 of fixed segments and set 68 of fixed segments. Set 62 is displaying a value for the amount of gas used thus far this month while set 68 is being used to display a value for the corresponding time period last year. Fixed segment icon 94 informs the user of the current time period while fixed segment icon 96 informs the user of the corresponding historical time period. As discussed above, other time periods may also be chosen or otherwise selected or displayed.
Pressing right arrow icon 56 brings the user to FIG. 15 , in which controller 34 ( FIG. 1 ) is displaying information regarding gas costs, while instead pressing EXIT button 60 would return the user to FIG. 3 . In FIG. 15 , first region 48 of display 46 now reads “GAS BILL”. Fixed segment icon 98 , representing a dollar sign, provides additional context for the information being displayed. In some cases, fixed segment icon 98 may be omitted, if desired.
Set 62 is being used by controller 34 to display the water bill to date for the month while set 68 is being used by controller 34 to provide the corresponding historical data. Pressing left arrow icon 54 would return the user to the screen shown in FIG. 14 while pressing right arrow icon 56 will return the user to the screen shown in FIG. 10 , unless thermostat 42 is equipped to display additional consumption or cost data. Pressing EXIT button 60 would return the user to FIG. 3 .
FIGS. 16 and 17 are flow diagrams illustrating methods that may be carried out using thermostat 42 ( FIG. 2 ). In FIG. 16 , control begins at block 100 , where thermostat 42 receives a message from utility 22 ( FIG. 1 ). The message received from utility 22 may be related to energy demand, current and/or past energy costs, energy conservation, weather alerts, promotional and/or advertisements and the like. At block 102 , controller 34 ( FIG. 1 ) displays on display 46 an indication of a measure of utility usage during a first time period. At block 104 , controller 34 displays on display 46 an indication of a measure of utility usage during a second time period. In some cases, the first time period may predate the second time period, but this is not required.
In FIG. 17 , control begins at block 100 , where thermostat 42 ( FIG. 2 ) receives a message from utility 22 ( FIG. 1 ). At block 106 , controller 34 ( FIG. 1 ) displays on display 46 an indication of a measure of utility usage during a period of time. Control passes to block 108 , where controller 34 displays on display 46 one or more display messages that are related to the message received from utility 22 . These messages may pertain to energy demand, current energy costs, energy conservation, weather alerts, advertisements and the like.
In some cases, the indication of the measure of utility usage during the period of time may be displayed on display 46 at the same time or nearly the same time as the one or more messages are displayed on display 46 . In some cases, they are not displayed simultaneously.
The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention can be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.
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The present disclosure pertains generally to thermostats that are adapted to assist utilities in communicating with its customers. In particular, the present disclosure relates to a thermostat having a display, a controller and a receiver that is coupled to the controller. The receiver is adapted to receive messages from a utility, and the controller is adapted to display one or more related display messages on the display.
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This application is a continuation of application Ser. No. 07/972,619, filed Nov. 6, 1992 now U.S. Pat. No. 5,494,024.
BACKGROUND OF THE INVENTION
The present invention relates generally to paint ball guns and more particularly to an improved paint ball gun and an improved rotary breech, regulator, control valve, power piston and power valve assemblies for utilization therein.
Numerous types of paint ball guns have been developed for utilization in various manners, such as in simulated war games. These paint ball guns generally include a CO 2 cartridge or cylinder which is utilized as the power source to propel paint balls, generally at a specified velocity, such as three hundred (300) feet per second. In general, the prior art paint ball guns include a typical firearm type mechanism including a bolt, spring and cocking handle. This standard configuration is not conducive to efficient operation of the paint ball guns.
These prior art paint ball guns generally do not operate at low ambient temperatures below about forty (40) degrees Fahrenheit. These paint ball guns have metal or metallic moving parts which require lubrication and preventive maintenance. The bolt type mechanism also leads to breakage of the paint balls themselves. The prior art paint ball guns generally do not include pressure regulators. One prior art paint ball gun includes a regulator which is of a conventional configuration including a heavy main spring adjusted by a screw bearing against the spring. If the screw is removed while the paint ball gun is under pressure, the regulator can be ejected under pressure causing potential injury.
It therefore would be desirable to provide an improved paint ball gun which eliminates lubricants and metal on metal surfaces, has pressure regulation and which will operate consistently and at low ambient temperatures. Further it also would be desirable to provide an improved rotary breech, regulator, control valve, power piston and power valve assemblies for utilization in paint ball guns and in other devices.
SUMMARY OF THE INVENTION
The present invention provides an improved paint ball gun which operates consistently, at low temperatures and is easily regulated. The moving parts of the paint ball gun do not have metal to metal surfaces and hence eliminate lubrication. The paint ball gun includes a pressure regulator and also operates at low gas operating pressures with minimal damage to the paint balls themselves. The paint ball gun has a rotary breech to eliminate the prior art bolts and spring assemblies. The improved paint ball gun rotary breech, regulator, control valve, power piston and power valve assemblies can be utilized in paint ball guns separately or together or in other type devices.
These and other features and advantages of the invention will be more readily apparent upon reading the following description of a preferred exemplified embodiment of the invention and upon reference to the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side plan view, partially broken away, of one embodiment of the paint ball gun of the present invention;
FIGS. 2 and 3 are an enlarged partial side views illustrating the operation of the paint ball gun of the present invention;
FIG. 4 is an enlarged side view of one embodiment of the paint ball gun regulator assembly of the present invention;
FIGS. 5A-5C and 6A-6C are side views illustrating the loading and firing of the paint balls.
FIG. 7 is another embodiment of a power valve assembly of the present invention; and
FIG. 8A-8D are side plan views of the individual regulator, power valve, rotary breech and control valve assemblies of the present invention.
While the invention will be described and disclosed in connection with certain preferred embodiments and procedures, it is not intended to limit the invention to those specific embodiments. Rather it is intended to cover all such alternative embodiments and modifications as fall within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4, an improved paint ball gun of the present invention is designated generally by the reference numeral 10. The paint ball gun includes a handle 12, a sliding trigger 14 and a barrel 16 (partially illustrated). The paint ball gun 10 includes a rotary breech assembly 18, into which is loaded one of a plurality of paint balls 20, one at a time, for firing through the barrel 16.
The paint ball gun 10 includes an adapter or seat 22 into which a standard CO 2 cartridge (not illustrated) is inserted to provide the operating power for the paint ball gun 10. As best illustrated in FIGS. 2-4, gas from the CO 2 cartridge enters a passageway 24 where it is fed to a regulator assembly 26. The gas enters the regulator 26 through a passageway 28 and an orifice 30 in a valve body 32. The lateral position of the valve body 32 controls the operating pressure of the paint ball gun 10. The position of the valve body 32 is controlled by a pressure adjusting screw 34, which is threadly mounted in a body portion 36 of the paint ball gun 10 in threads 37. The valve body 32 is mounted in a passageway 38 of the body portion 36. The valve body 32 has a diameter greater than the clearance between the threads 37. This difference in diameter prevents the valve body 32 from being ejected under pressure from the paint ball gun 10.
The passageway 38 also includes a piston 40 mounted therein. The gas passes through the orifice 30 into an axial outlet passageway 42 in the valve body 32. A spring 43 biases the piston 40 away from a lip 44 formed around an open end 46 of the passageway 42. With the piston 40 moved away from the lip 44, a seal formed by a disc 48, such as formed from urethane and mounted on or formed with the piston 40, pressing against the lip 44 is broken.
The gas passes out of the passageway 42 around the piston 40 and into a lateral inlet orifice 50 which couples the gas to a lateral passageway 52 formed in the piston 40. The gas then flows out of the passageway 52 through a passageway 54 and around a power piston assembly 56 to a control valve assembly 58.
The regulator 26 thus initially allows the gas to pass freely therethrough. As the gas pressure builds in the paint ball gun 10, as described in detail hereinafter, the gas exerts pressure on a face 59 of the piston 40 to close the regulator 26. The amount of gas pressure necessary to close the regulator 26 by pressing the piston 40 against the spring 43 and against the lip 44 is regulated by the adjusting screw 34. As the adjusting screw 34 is moved to the left, the operating pressure is increased and the spring 43 must be further compressed. As the adjusting screw 34 is moved to the right, the operating pressure is decreased, since the spring 43 is less compressed, before the piston 40 seals against the lip 44. Since the gas passes through the orifice 30 and the passageway 42, it cannot exhaust out of the paint ball gun 10 if the adjusting screw 34 is removed. This provides a significant safety advantage over the prior art regulators.
The gas flows into the control valve 58 through a passageway 60. The control valve 58 is illustrated in the fill/load position in FIG. 2 and the gas flows through a lateral reduced area passageway 62 in a control valve body 64. The control valve body 64 is biased into the fill (non-fire) position by a bias or return spring 66. The control valve body 64 is sealingly mounted in a passageway 68 by a plurality of O-rings 70 formed from synthetic resin polymers, such as sold under the trademark Teflon. The O-rings 70 form barriers to prevent gas flow along the valve body 64 in the passageway 68.
The gas flows from the passageway 62 into a passageway 72 and releases a ball type check valve 74 from a seat 76 (illustrated as seated in FIG. 2). The seat 76 is formed in a passageway 78 which is formed in a body 80 of the power piston 56. The gas pushes the power piston body 80 against an inlet end 82 of a power tube 83 which is coupled to the barrel 16. The power piston body 80 includes a seal 84 mounted thereto or formed therewith, also preferably formed of a synthetic resin polymer material, which seals the barrel 16 from the gas. The gas passes out of a passageway or passageways 86 into a gas or power chamber 88 formed around the power tube 83.
At the same time as the gas fills the power chamber 88, a portion of the gas flows through a port 90 formed in the passageway 72, where it flows into a passageway 92. The gas flows through the passageway 92 to the rotary breech 18 as illustrated in FIGS. 5-7.
The rotary breech 18 is first moved into the load position as illustrated in FIGS. 5A-5C. The rotary breech 18 includes a rotating body 94 having a paint ball receiving breech portion 96. In the load position, one of the paint balls 20 is loaded from a paint ball cartridge or tube 98 into the breech portion 96. The gas in the fill position flows through the passageway 92 behind a first piston 100. The piston 100 operates against a pivot pin 102 which moves laterally to rotate the rotary breech 18 into the load position. At the same time a second piston 104 is moved to exhaust gas through a passageway 106, through a lateral orifice 108 (FIG. 2), a passageway 110, a lateral passageway 112 and out through an exhaust orifice 114 formed in the control valve body 64.
The trigger 14 is depressed to fire the paint ball gun 10, as illustrated in FIGS. 3, 6 and 7. The depression of the trigger 14 moves the control valve body 64 against the return spring 66. The gas in the passageway 60 now flows through the passageway 112 into the passageway 110, through the orifice 108 and into the passageway 106. The gas in the passageway 106 pushes against the piston 104, which moves the pivot pin 102 and rotates the rotary breech 18 into the firing position, as illustrated in FIGS. 6A-6C. The paint ball 20 now is aligned with the power tube 83 and the barrel 16 for firing therethrough. The non-spring gas operated rotary action of the rotary breech 18 virtually eliminates breakage of the paint balls 20.
The gas behind the piston 100 exhausts through the passageway 92, the port 90 (FIG. 3), the passageway 72, the passageway 62 and through an exhaust port 116 formed in the control valve body 64. At the same time, the gas behind the power piston 56 exhausts also through the passageway 72, 62 and the port 116. The check valve 74 then seats against the seat 76 and the power piston body 80 moves away from the power tube 83, releasing the seal 84 and rapidly emptying the gas from the chamber 88 into and out the power tube 83, firing the paint ball 20 through the barrel 16.
The resultant pressure differential when the trigger 14 is depressed, causes the power piston 56 to snap back allowing the gas to exhaust quickly into the power tube 83 and propelling the paint ball 20 at a maximum efficiency. All of the gas pressure is utilized to propel the paint ball 20, since no springs are compressed with the firing gas pressure. The paint ball gun 10 will operate at pressures of below 150 psi although the operating pressure typically is about 500 psi. Other prior art types of paint ball guns typically require on the order of 2000 psi for the gas operating pressure and hence are much less efficient.
An in-line embodiment of a power valve assembly 120 of the present invention is illustrated in FIG. 7. The regulator 26 and the power piston 56 are formed in an in-line unit 122. The valving otherwise would be essentially the same as in the previous embodiment, but only the single unit 122 would need to be replaced or removed for repair, if needed. In this embodiment of the regulator 26, control of the gas pressure is achieved by adjusting the set screw shown in dashed lines (not numbered) is the same manner as with adjusting screw 34 of the embodiment of FIG. 4.
Enlarged separate views of the regulator 26, the power piston 56, the control valve 58 and the rotary breech assemblies 18 are illustrated in FIGS. 8A-8D. The improved rotary breech 18, regulator 26, power piston 56 and control valve 58 are described herein utilized together in the paint ball gun 10, however the assemblies can be provided separately in other paint ball guns or in related devices. The regulator 26, for example, can be utilized in other compressed air environments, such as utilized in diving equipment. The power piston 56 can be utilized for any type of rapid evacuation of a volume of gas.
Modifications and variations of the present invention are possible in light of the above teachings. The power piston 56 preferably is formed from a composite polymer material, which forms an excellent seal with the power tube 83. The rotary breech 18 also preferably is formed from a composite material and therefore should not exhibit any significant wear. The sliding trigger 14 preferably is coated with a Teflon type polymer, such as sold under the trade name "XLEN". Also, as illustrated in FIGS. 5A and 6A, a further safety feature of the paint ball gun 10 of the present invention is provided by a dove tail construction 130, which prevents the control valve 58 and the trigger 14 from inadvertently ejecting from the paint ball gun 10 under gas pressure. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced other than is specifically described.
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An improved paint ball gun and improved rotary breech, regulator, control valve, power piston and power valve assemblies for utilization in paint ball guns or related devices. The paint ball gun eliminates moving metal to metal surfaces to provide a consistent operation and easy regulation. The paint ball gun has a rotary breech to minimize damage to paint balls utilized in the paint ball guns.
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[0001] This application is a Continuation in Part of patent application Ser. No. 11/082,511, filed on Mar. 17, 2005, entitled Security Footwear.
FIELD OF THE INVENTION
[0002] This application pertains in general to the field of an article of footwear and in particular an article of footwear adapted for purposes of security to the wearer and those around the wearer.
BACKGROUND OF THE INVENTION
[0003] The events of Sep. 11, 2001 have made security an extremely high priority in the United States and else were around the world. Accordingly, there has been an increase in the level of security at many airports, federal and ordinary commercial buildings and other locales which are open to the public. Law enforcement agencies have increased their awareness of possible terrorists attacks, and even the public themselves are now more aware of possible danger
[0004] Most airports now require passengers to remove their shoes before the passenger passes through a metal detector as some types of footwear contain metal. And even if the metal detector does not alarm, many types of footwear will require additional x-ray screening such as boots, platform shoes, thick soled shoes, including but not limited to athletic footwear, construction shoes, and the like where dangerous devices can be hidden therein. Accordingly, it is desire able to have footwear that is easily removable, comfortable, and that will speed the process of screening at airports and other locations that are accessible to the public that may comprise possible terrorist's targets.
[0005] Further, it is known that terrorist groups will kidnap or abduct influential or rich travelers or pedestrians for purposes of ransom to further support their terrorist's activities, or to attempt to coerce a country to discontinue certain activities, or simply to kill the abductees. Accordingly, it is desirable to have footwear that identifies and provides the location of such persons whether traveling or not. Such footwear is also advantageous to monitor the whereabouts of children who are unfortunately readily available to child molesters.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a substantially transparent and or a substantially opaque article of footwear. This article of footwear comprises a resilient sole including a gripping surface and a shoe upper integrally dependent from the resilient sole. The upper can include means for aeration of a foot of a user, an insole disposed within the shoe upper, and closure means. The closure means can include means for stabilizing an ankle and in-step area of the foot of the user within the article of footwear. Said shoe includes a heel portion formed of a flexible material and a forward portion of integrally dependent from said heel portion. Said forward portion of the upper can comprise a mesh fabric for aeration of the foot of the user. One edge of said stabilizing means can further comprise means for elastic engagement of said ankle and in-step area of said foot. Preferably imbedded within the sole of the shoe are electronics that can comprise a power source, light source, an alarm, a radio frequency identification microprocessor, a location microprocessor, radio frequency oral communication means, an antennae, and switch means to activate, pause, and deactivate the electronics. Alternatively, all or part of said electronics can be packaged in one or more containers that can be attached to the shoe.
[0007] It is an object of the invention to provide an article of footwear that will allow travelers to pass through security detectors at a quicker pace.
[0008] It is another object to provide a comfortable and easily removable article of footwear that may also be used when traveling or in every day use.
[0009] It is a further object to provide an article of footwear than can be used as a normal shoe in every day use and provide personal security and safety to the user by providing for transmitting of the user's location, for singling the user and for allowing oral communication between the user and another party.
[0010] The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention, and Claims appended herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective side view of the article of footwear of the present invention.
[0012] FIG. 2 is a perspective top view of the article of FIG. 1 .
[0013] FIG. 3 is a perspective, exploded view of the article of footwear of FIG. 1 .
[0014] FIG. 4 is an illustrative view showing insertion of the foot of a user into the article of footwear of FIG. 1 .
[0015] FIG. 5 is a diagram showing the components of the shoe.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The instant invention relates to an article of footwear 10 , as shown in FIGS. 1 , 2 and 5 . The article of footwear 10 includes a resilient sole 20 , a flexible shoe upper 30 , an insole 40 , and a closure means 50 ; each of which can be substantially transparent or substantially opaque. Said resilient sole 20 can include a gripping surface 22 to provide traction of the article of footwear 10 when worn by a user, as is shown in FIG. 4 . Other configurations of the gripping surface as are known in the art can alternatively be used. The length and width of the sole 20 may vary to accommodate the sizes of a human foot. Said shoe upper 30 is integrally dependent from said sole 20 . Such dependence may be accomplished by bonding or integral molding of the elements. As shown in FIG. 1 , said shoe upper 30 includes a heel portion 60 that can be formed of more rigid material than sole 20 . Said shoe upper 30 also includes a forward portion 62 which is integrally dependent from said heel portion 60 .
[0017] Said shoe upper 30 and sole 20 are preferably made of a thermoplastic such as a polyvinyl. Said shoe upper 30 and sole 20 may also be made of other moldable polymers such as polyethylene and polypropylene, or even leather appropriately bonded to the sole 20 . It is noted that the article of footwear 10 can be formed of one or more substantially transparent materials or one or more substantially opaque materials such as an elastomeric polymer, but can be made of alternative materials if they are substantially transparent and resilient, or substantially opaque and resilient. However, it may be preferable to manufacture some parts of the article of footwear with non-transparent materials and some parts with substantially transparent materials. For example, the security teachings of the present invention can even be applied to ordinary non-molded leather or plastic shoes. When the footwear 10 is substantially transparent, the same enables security officers in various locations, including airports to visually inspect the entire shoe and foot of a user to see that no part of the article of footwear 10 includes metal or moving parts, besides those minimal components which are part of the article footwear, for enhanced security purposes discussed below. A security officer is able to accomplish this rapidly so that there will be little need for a traveler to have to remove one's shoes to have them especially scanned.
[0018] Said forward portion 62 of shoe upper 30 of said footwear 10 can, but not necessarily, define a mesh material or other breathable material 64 , as shown in FIGS. 1 and 2 . Said material 64 , in this manner, can comprise means 32 for aeration and expansion of the foot of the user. For example, the breathable or mesh material 64 can be made of a substantially transparent or opaque elastomeric polymer. The forward portion 62 of shoe upper 30 can be, but as noted, not limited to a mesh material and can be a solid material with small ventilation holes integrally placed on the shoe upper 30 . The mesh material or an alternative ventilated material 64 advantageously allows the foot to breathe within the article of footwear 10 . The appropriate selection of material 64 can also ensure adequate scanning of the foot of the user in the event a terrorist were to construct the shoe of a radio opaque material. Alternatively, the breathable material 64 can comprise a solid breathable material or even a solid non-breathable material, as opposed to a material with any type of holes.
[0019] To assist the user placing the article of footwear on one's foot and preventing of slipping up or down the ankle of the user, one edge of said aeration means 32 may comprise means for elastic engagement 70 of the ankle and instep area of the foot. Said engagement means may be integrally dependent from the shoe upper 30 , as shown in FIGS. 1 and 2 or may comprise one or more cross-over straps 50 for rapid attachment to a user's foot as discussed below. Alternatively, said article of footwear may not include said elastic engagement means and might be similar to a loafer or even a shoe with shoe laces. Said elastic engagement means 70 can comprise a substantially transparent material, which may include an elastomeric polymer.
[0020] As shown in FIGS. 2 and 3 , the article of footwear 10 includes a generally resilient insole 40 which can be transparent or opaque. In one embodiment of the present invention, the insole 40 may incorporate an arch system 42 to make the article of footwear 10 more comfortable for the user, which may be seen in FIG. 3 . The arch system 42 being substantially less resilient than the insole in general, but not made of metal. The article of footwear includes said closure means 50 . Said closure means may be a transparent or opaque cross-over strap 50 along with a means 52 for stabilizing the ankle of the foot in the article of footwear 10 . Said closure means may comprise one or more cross-over straps. Preferably, said cross-over strap 50 is made of hook and loop means such as Velcro® disposed on said cross-over strap 50 and its attachment area to the shoe upper 54 , which can be adjusted to fit the size of the user's foot. Said stabilizing means may also include snap closures disposed on the cross-over strap 50 , or may comprise any of a variety of closure methods, not limited to Velcro® or snap closures. The cross-over strap 50 may also be located across the instep of the foot or higher up on the ankle of the user. The location of the cross-over strap can be adjusted in accordance the users needs. For example, one user may prefer a low boot style of shoe as opposed to a slipper, hence the higher location of the cross-over strap 50 . Some users may prefer a high boot style, which would require two or three cross-over straps. Other users may prefer or need more support across the in-step of the foot, which would require that the cross-over strap be placed across the in-step of the foot. Further, the user may prefer to have a simple slip-on disposable type shoe that may have no stabilizing means.
[0021] As seen in FIG. 5 , further security of the article 10 may include light sources 24 in or on one or both shoes, such as LED's or any other appropriate lighting elements, embedded in the sole 20 . The light sources 24 can be mounted in the resilient sole 20 such that the light emitted from the light sources 24 is visible exteriorly. Alternatively, the light sources can be located on the shoe upper such as the front, back, sides, or top. Such light sources 24 can be any color and used for a variety of purposes depending on the make-up or configuration of the electronics imbedded in the sole 20 . For example the light sources can be used to assist security officers to detect travelers who have passed through security, but have set off the scanning device, which in turn, would activate the LED's thereby alerting the security officers that further security inspection is required. For example, the possible objectionable material within the shoe may be such that it is not detected by the security pass through but is detected by a more sophisticated or sensitive sensor at the location of the security officer station which would send a signal to the shoe electronics which in turn would activate the light sources. Other uses could be to activate the light sources to alert the user that he or she needs to return to a particular location, phone a particular party, or to do a prearranged act. As regards these uses, a radio frequency signal sent from a remote location would be received by an antenna within the shoe or on the person and thereby activate the shoe electronics which again would activate the light sources. The user, upon observing the activated light sources would then engage in a predetermined course of action consistent with his security. In lieu of or in combination with the visible light sources, infra red devices or digitally encoded pulse devices can be used to alert the security officer or the user.
[0022] Still referring to FIG. 5 , the article of footwear 10 may also include an audible alarm 26 embedded in the resilient sole 20 of one or both shoes. Such an audible alarm 26 would be heard by security officers who may have let travelers through security, but have then set off the scanning device. Such audible alarm could also be used to alert the user that he or she needs to return to a particular location, phone a particular party, or to do a prearranged act. The electronics for the audible alarm can be as described above.
[0023] For further security purposes, the article of footwear 10 may include a radio frequency identification device 27 in one or both shoes, or RFID, a generic term for technologies that use radio waves to automatically identify people or objects. There are several methods of identification, but the most common is to store a serial number that identifies a person or object, and perhaps other information, on a microchip 28 that is attached to an antenna 29 and a power source (the chip and antenna together are called an RFID transponder or an RFID tag). The antenna 29 enables the chip 28 to transmit the identification material to a reader via satellite or land based transmitters and ultimately to a reader such as used with wireless cell phones, or land telephone lines, or Wi-Fi, Blue Tooth, or other digital wireless network, or any commonly known combination of the same. A reader having for example, the capability to convert the radio waves reflected back from the RFID tag into digitally transponded information that can then be passed on to remote computers that can analyze it. The chip 28 and antenna 29 may be embedded in the sole 20 or other part of the shoe to allow transmission of the identification information. The imbedded electronics can further include GPS technology to transmit the location of the user to a remote microprocessor receiving the GPS radio signals. Indeed, the imbedded electronics can further include cell phone apparatus and technology such that the user can receive and transmit oral and or electronic communications. On, off, and pause switching apparatus for each of the imbedded electronic devices can be manually operated by the user by push button switches that are located on a side of the sole 20 and covered by an appropriate protective layer of flexible material. Or, the switches can be completely imbedded within the sole 20 and remotely activated by a hand held transmitter as such are known in the art. As noted above, the invention is not limited to having the electronics imbedded within the shoe sole. For, example, an alternative arrangement can have part of the electronics in the sole and a part of the electronics attached to the outer parts of the shoe. The invention further contemplates that a package of electronics be encased in a container and connected to an appropriate electric connector that is located on the outside or inside of the shoe. In this manner, the package of electronics can be primarily adapted to a particular use such as but not limited to GPS location, oral or electronic communications, or personnel identification.
[0024] The visible light sources, audible alarm and RFID chip, as well as any other incorporated electronic components of the article may be battery operated and recharged by piezoelectricity resulting from the application of mechanical pressure on a dielectric crystal. The components may also be recharged by photovoltaic means, electro-mechanical generators using motion or vibrations, or charged through an AC adapter. Alternatively, the batteries may simply be replaced at the end of their useful life.
[0025] When in use, the user places the article of footwear on one's foot at any time prior to passing through security at an airport or other location with secured entrances. Because of the gripping surface 22 on the sole 20 the article of footwear can be worn outdoors as well as indoors. The user may prefer to place the article of footwear 10 on one's feet just prior to entering an airport or building. Of course, the opaque security footwear can be used at times other than passing through a security gate such as in every day use. In this manner, the security footwear can be used to thwart abductions, or to alert a child to go home, or for any of the above described security purposes.
[0026] The article of footwear may be manufactured and/or sold with a companion, substantially transparent tote bag for the user to place their civilian shoes in while wearing the inventive security article of footwear. The companion substantially transparent tote bag may be manufactured with a Ziploc®, or a hook and-loop type of closure, e.g. Velcro®. The companion substantially transparent tote bag may also include a strap closure so that a person cannot add or subtract anything from the totebag upon reaching security, e.g. a non releasable plastic tie. Further, the shoe 10 can be provided with tamper poof electronic devices such that the initial codes and settings within the electronics can never be changed by electronic means and would therefore always be readable by an independent external system. And, any attempted changes to the initial settings and codes and information would be made known by the external system.
[0027] While the invention has been shown and describe in certain preferred embodiments, it is to be appreciated that the invention the invention is not to be limited thereby and may be otherwise embodied otherwise than is herein specifically shown and described and that within said embodiments, certain changes may be made in the form without departing from the scope, the underlying ideas and principles of this invention as set forth in the claims appended herewith.
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An article of security footwear includes electronic devices that protect the wearer and those about him by sounding an alarm, emitting an electronic signal, or activating a light source in the event the shoe contains an unauthorized or dangerous article. The shoe is of use when passing through a security pass point. The security shoe can also be provided with electronic communicating and or electronic locator devices with their attendant accessories i.e. power, activating devices, transmitter, antenna, etc. which can be activated by the user or a remote third party.
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BACKGROUND OF THE INVENTION
In the art of object detection, various "active" apparatus has been proposed which, for example, detect an object by projecting a beam of light (or IR) or sound and producing an output signal when this beam is interrupted to detect the presence of an object. Such a system requires two stations, the source (or a retroreflector) and a detector with a constantly generated source of light or sound. Some passive systems have also been proposed as, for example, a television scanner and memory where the outputs of the scene being viewed by the cameras are stored in the memory and this stored memory is compared periodically with a new scan. When an object moves into the area being scanned, the signals will not match those in the stored memory and an output will be produced indicating the presence of the object. These systems are fairly complex and quite costly.
In the art of range finding, particularly in auto focus cameras, a passive auto focus "module" is known. Various examples of such modules may be seen in the Stauffer U.S. Pat. No. 4,002,899 issued Jan. 11, 1977 which modules are quite accurate and low in cost. The auto focus module receives radiation from a scene being viewed and directs this radiation along two different paths to two similarly arranged detector arrays. One of the paths is usually made angularly variable and may cross the other path at various distances from the camera. When an object in the scene is located at the intersection of the two paths, then the radiation received by two detector arrays will be substantially equal and an in-focus condition is known to exist. On the other hand, when the object to be focussed upon is not at the intersection of the paths, the outputs of the detector arrays will be unmatched and an out-of-focus condition exists. By use of electronics disclosed in the above-mentioned U.S. Pat. No. 4,002,899, a correlation signal is obtained from the detector arrays and this correlation signal changes from a high level to a low level, or vice versa, as the ouputs of the detector arrays change from a matched to an unmatched condition. As used herein, the term "module" is intended to refer to the type of unit described above, that is, to a unit in which a pair of detector arrays receives radiation over a pair of radiation transmission paths from a scene being viewed and in which an output signal is produced that changes from a high state to a low state or vice versa when an object in the scene being viewed moves from a first range where the output of the detectors is substantially matched to a second range where the outputs of the detectors are unmatched.
SUMMARY OF THE INVENTION
The present invention utilizes a module to provide a passive object detection system. The module is mounted so as to receive radiation from a scene in which the presence of objects is to be detected. The module may be "focussed" at infinity in which case objects located at a remote distance will not be detected but objects which are located relatively close to the module will upset the balance of the detectors and produce an output signal. Alternately, the module may be focussed at a particular range less than infinity in which case objects located in the scene at or near that range will not be detected but objects located in the scene closer to or further from the module will cause an output signal to occur.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of one embodiment of the present invention with the module focussed at infinity;
FIG. 2 is a graph of the output voltage as a function of time during which an object moves into the scene;
FIG. 3 is a schematic diagram of the embodiment of FIG. 1 with the module focussed at a distance other than infinity; and
FIG. 4 is an alternate embodiment of the present invention wherein the module has a larger baseline.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a module 10 is shown which may be like one of the modules found in the above-referred to U.S. Pat. No. 4,002,899. The module consists of a housing 12 with a pair of lenses 14 and 16 mounted therein. An integrated circuit substrate 18 is also mounted within the housing 12 and carries a pair of radiation sensitive detector patterns 20 and 22 respectively. Lenses 14 and 16 direct radiation from a scene being viewed to the right of module 10 over paths such as dashed lines 24 and 26 respectively. In FIG. 1, the lines 24 and 26 are shown to be parallel and eminating from a remote wall 30. Radiation from wall 30 therefore passes along paths 24 and 26 to lenses 14 and 16 where it is directed to detector arrays 20 and 22 respectively. If wall 30 is a plane unmarked wall, the radiation received by detector arrays 20 and 22 will be substantially equal but if an object moves between module 10 and wall 30, the amount of radiation received by the two detector patterns 20 and 22 will change since the object is not at infinity. The circuitry which is included on the substrate 18 operates on the signals from the detector arrays 20 and 22 to produce a correlation signal V as discussed in the above-mentioned U.S. Pat. No. 4,002,899. The circuitry may either operate to cause the signal V to be at a low or high value when the outputs of the detectors are matched but in the preferred embodiment, the signal V will be high at a focussed condition where the outputs of the detectors are matched and will be low at a nonfocussed condition where the outputs are mismatched. A line 34 is shown in FIG. 1 connected to the integrated circuit chip 18 and carries the output correlation signal V from the circuit chip to one input terminal of a comparator 36 having its other input connected by a line 38 to a voltage source such as a potentiometer wiper 40 movable along a resistor 42 which is connected between a positive source of voltage 44 and ground at 46. The signal, V 0 , appearing on potentiometer wiper 40 is compared in the comparator 36 with the voltage V from the module 10 and an output signal on a line 50 indicative of the presence of an object is presented to a utilization device 52 which may be an indicator, alarm, counter or other device useful in an object detector.
Referring to FIG. 2, the output voltage V is shown plotted as a function of time by a curve 56 which, at the left hand of FIG. 2, is at a relatively high value indicating that the outputs of the detector arrays 20 and 22 are substantially matched and which, at the right hand of FIG. 2, drops to a low value indicating that the outputs of the detector arrays 20 and 22 are not matched and thereby showing the presence of an object in the area between module 10 and wall 30 of FIG. 1. The voltage V 0 is shown as a dashed line 58 in FIG. 2 extending about half way between the high and low values of the output voltage V on curve 56. In FIG. 1 comparator 36 may operate to produce a zero signal on line 50 whenever the voltage V is greater than the voltage V 0 but to produce an output signal whenever voltage V falls below V 0 .
As can be seen in FIG. 1, the module 10 can passively sit and watch the scene between itself and wall 30 and operate to produce a signal only when an object moves between them. Of course, as would frequently occur in outdoor situations, the presence of wall 30 is not necessary since the module may be focussed at infinity regardless of the presence of the wall but for interior use, a wall is usually present.
In the event that the scene being viewed has a definite pattern as, for example, if wall 30 in FIG. 1 were to have designs thereupon, or the scene contains other high frequency components, the output of module 10 in FIG. 1 would show an unfocussed condition in which event other objects moving into the area might not be detected. To overcome this problem, the auto focus module 10 may be focussed at a particular point in space so as to produce a balanced signal for objects near that range. For example, in FIG. 3, the module 10 is again shown having lenses 14 and 16 directing radiation over paths 24 and 26 to a pair of detectors 20 and 22 but in FIG. 3, lens 14, for example, has been moved so that the paths 24 and 26 now cross at a remote point 60. Objects which are located near point 60 as, for example, between dashed lines 62 and 64 will be in focus so that detectors 20 and 22 will be receiving substantially the same amounts of radiation and the output signal V on line 34 will be in its high state. If an object were to move between module 10 and the distance defined by dashed line 62, then the outputs of detectors 20 and 22 would change so that the signal V on line 34 would drop to its low state. Apparatus of FIG. 3 could be used for example to count automobiles passing along a road which exists between module 10 and distance 62 and ignore people or other objects on the far side of the road in between distances 62 and 64. Of course, it should be understood that whereas described above, the system becomes unbalanced when objects move between the module and a remote distance the opposite effect could be used. For example, in FIG. 3, the system may again be set up so that it was in focus at point 60. If no object existed at that point, the system would be unbalanced since the radiation received by detectors 20 and 22 would not be matched. Thereafter, should an object move between distances 62 and 64, detectors 20 and 22 would now receive substantially equal amounts of radiation from the object and the system would be in focus indicating the presence of an object between the two distances 62 and 64. To utilize such a signal, the comparator 36 would only have to be reversed so that it produced an output signal when the signal V indicated an in focus condition.
It is seen in FIG. 3 that the baseline for triangulation and range determination is the distance between lenses 14 and 16. If it is desired to provide for greater accuracy, the apparatus of FIG. 4 may be used. In FIG. 4, a reflecting prism 70 and a pair of mirrors 72 and 74 are shown for directing radiation to the detector arrays 20 and 22. As before, radiation will pass along paths 24 and 26 but will now be reflected off of mirrors 72 and 74 and prism 70 respectively before entering module 10 and passing through lenses 14 and 16 to the detector arrays 20 and 22 respectively. It is seen that the baseline for triangulation is now increased to the distance between the centers of mirrors 72 and 74. One of the mirrors 72 or 74 may be made rotatable as is discussed in the above-referred to U.S. Pat. No. 4,002,899 so as to make paths 24 and 26 cross at any predetermined range desired.
It is therefore seen that I have provided an object detection system which is passive in nature and is of low cost. Many obvious modifications and changes to the embodiments disclosed in connection with the preferred embodiments will occur to those skilled in the art and I do not wish to be limited to the specific disclosure used herein. I intend only to be limited by the following claims.
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A passive and low cost object detector utilizing a focus module used in auto focus cameras to determine the presence of objects within the field of view of the module.
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FIELD OF THE INVENTION
[0001] This invention generally relates to the field of electrostatic discharge (ESD) protection circuitry and, more specifically, improvements against Charged Device Model (CDM) stress cases in the protection circuitry of the integrated circuit (IC).
BACKGROUND OF THE INVENTION
[0002] Integrated circuits (ICs) and other semiconductor devices are extremely sensitive to the high voltages that may be generated by contact with an ESD event. As such, electrostatic discharge (ESD) protection circuitry is essential for integrated circuits. An ESD event commonly results from the discharge of a high voltage potential (typically, several kilovolts) and leads to pulses of high current (several amperes) of a short duration (typically, 100 nanoseconds). An ESD event can occur within an IC, illustratively, by human contact with the leads of the IC or by electrically charged machinery being discharged in other leads of an IC. During installation of integrated circuits into products, these electrostatic discharges may destroy or impair the function of the ICs and thus require expensive repairs on the products, which could have been avoided by providing a mechanism for dissipation of the electrostatic discharge to which the IC may have been subjected. When the IC itself is charged, discharge can happen even through a single pin of the IC substrate. This type of stress is modeled as the Charged Device Model (CDM).
[0003] There are various types of physical and chemical process to manufacture an IC. Many different processes exist, having many different process options. In many cases, one or more of these process options allow the creation of an isolated well. A well is considered ‘Isolated’ when it is possible to create a voltage difference between the well and the substrate.
[0004] To protect an IC against ESD, many different type of clamps exist. In general, these clamps exhibit low leakage (i.e. extremely high resistivity) during normal operation, and low resistivity during ESD. These clamps are connected to power pads and/or IO pads. Any pad which is connected to an outside pin should have some kind of ESD clamp attached to it. Also, even some pins inside the chip need some ESD protection. Some typical examples of pins are drivers and receivers connected between different power domains.
[0005] U.S. Pat. No. 6,885,529 discloses a CDM protection design using deep N-Well structure solving a CDM threat. The CDM threat in this patent is introduced because the functional device is placed directly in the substrate (not in an isolated well). Under CDM conditions, the substrate is filled with many electrostatic charges. This issue is solved by isolating the functional device from the substrate by introducing an isolating well. The functional device is placed within said isolating well, such that the charges in the substrate do not damage the functional device. A clamp between substrate and pad is placed to discharge the substrate. The U.S. Pat. No. 6,885,529 states that the charges in the isolated well in which the functional device is placed are ‘too few to damage the gate oxide’. This is however not true. Although the number of charges is limited, they can damage the gate oxide.
[0006] FIG. 1A illustrates a prior art cross-section diagram of an Integrated Circuit 100 for CDM ESD protection. The circuit 100 comprises a lightly doped region, such as a P-substrate 102 having a first conductivity type and first lightly doped regions, such as deep N-well 108 and the N-well 110 of the second conductivity type. The circuit further comprises a second lightly doped isolated region 106 , preferably a P-well of the first conductivity type formed within the first lightly doped regions deep N-well 108 and N-well 110 . Thus, as shown in FIG. 1A , the region 110 preferably forms a ring structure around the isolated region 106 and together with the N-well region 108 isolates the P-well region 106 from the substrate 102 .
[0007] Referring back to FIG. 1A , the circuit further comprises a semiconductor device 104 such as a transistor, an exemplary MOSFET as shown in FIG. 1A . The transistor 104 is preferably formed in the second lightly doped isolated region 106 , i.e. the isolated Pwell of the first conductivity type. The transistor 104 comprises a first heavily doped region 104 a , a second heavily doped region 104 b and a gate 104 c . The gate is connected to a sensitive node 118 such as an input/output (I/O) pad leading to a periphery external to the circuit 100 . The transistor 104 comprises a first heavily doped region of the second conductivity type in the case of the FIG. 1A N+ 104 a and a second heavily doped region N+ 104 b , also of the second conductivity type formed in the isolated well 106 of a the first conductivity type.
[0008] As shown as an example scenario in FIG. 1A , the N-well 110 and the Deep N-well are coupled to a first power supply, i.e. first voltage potential, 122 , for example VDD. The P-substrate 102 is connected to a second power supply, i.e. second voltage potential 124 , for example ground through a heavily doped region, P+ 120 . The isolated P-well region 106 is connected to the second potential, 124 through a core circuitry 114 . Thus, a heavily doped region P+ 116 is added. The region 116 will make a low ohmic path between the isolated region 106 and the core circuitry 114 . The transistor 104 is preferably connected to the potentials 122 and 124 through the core circuitry 114 . The core circuitry 114 may preferably be transistors, resistors, inductors, capacitors, metals, etc. The core circuitry 114 is placed accordingly to fulfill requirement for the normal operation and its function depends on the application.
[0009] Additionally as illustrated in FIG. 1A , clamps represented as diodes 126 are placed between the sensitive node, I/O pad 118 and the power supply 122 or 124 . The diodes are added to protect the gate 104 c for ESD stress. Although, not shown in this figure, but other ESD protection elements such as local clamps can preferably be placed between the node 118 and the power supply 122 or 124 . The failure under CDM stress conditions is possible for this diagram as described herein below.
[0010] Referring to FIGS. 1B , 1 C and 1 D, there is shown a working example for the IC circuit 100 of FIG. 1A . Specifically, FIG. 1B illustrates an explanation of CDM for the IC circuit 100 of FIG. 1A before CDM. Before the CDM event happens, the IC is charged up. This means that charges 132 (i.e. positive charges for positive CDM, negative charges for negative CDM) are stored all over the IC 100 , and thus also in the isolated p-well region 106 . During CDM, the charges inside the P-substrate 102 and deep Nwell 108 typically have a low resistive path to the supply lines 122 and 124 . So, during CDM, the charges 132 from the P-substrate 102 and deep N-well 108 can typically flow easily to supply lines 122 or 124 as illustrated in FIG. 1C . However, this case scenario does not occur for the charges 132 inside the isolated P-well region 106 as shown in FIG. 1D . These charges 132 will either flow through a core circuitry 114 or through the gate oxide 104 c , depending on the resistivity of the core circuitry 114 , thickness of the gate oxide and CDM stress level. If the charges 132 flow through the core circuitry 114 , damage of the IC 100 is possible due to inefficient ESD protection from the core circuitry 114 . If the charges 132 flow through the gate oxide, damage of the IC 100 is also almost certain. As illustrated in FIG. 1D , the gate oxide of the gate 104 c will be damaged. Therefore, these isolated wells, exemplary, P-well isolated region 106 can pose a threat to the IC 100 during CDM stress.
[0011] Thus, there is a need in the art to provide an improved electrostatic discharge (ESD) protection circuitry, specifically, improvement against Charged Device Model (CDM) stress cases in the protection circuitry of the integrated circuit (IC).
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A depicts an illustration of a prior art cross-section diagram of an Integrated Circuit for CDM ESD protection
[0013] FIG. 1B depicts an illustrative prior art cross-section diagram of FIG. 1A when the chip is charged
[0014] FIG. 1C depicts an illustrative prior art cross-section diagram of FIG. 1A during CDM.
[0015] FIG. 1D depicts an illustrative prior art cross-section diagram of FIG. 1A during CDM.
[0016] FIG. 2A depicts an illustrative cross-section diagram of an Integrated Circuit with CDM ESD protection in accordance with one embodiment of the present invention.
[0017] FIG. 2B depicts an illustrative cross-section diagram of FIG. 2A during CDM in accordance with the embodiment of the present invention.
[0018] FIG. 2C depicts an illustrative exemplary cross-section diagram of FIG. 2A in accordance with alternate embodiment of the present invention.
[0019] FIG. 2D depicts an illustrative cross-section diagram of FIG. 2A in accordance with another alternate embodiment of the present invention.
[0020] FIG. 2E depicts an illustrative cross-section diagram of a further alternate embodiment with reference to FIG. 2A of the present invention.
SUMMARY OF THE INVENTION
[0021] In one embodiment of the present invention, there is provided a circuit having charged-device model (CDM) electrostatic discharge (ESD) protection comprising a substrate, a semiconductor device isolated from the substrate and an ESD clamp device coupled to the device to discharge the charges located in the device.
[0022] In a preferred embodiment of the present invention, there is provided a circuit having charged-device model (CDM) electrostatic discharge (ESD) protection comprising a substrate of first conductivity type, a first lightly doped region of second conductivity type formed within the substrate and a second lightly doped region formed within the first lightly doped region. The second lightly doped region of the first conductivity type. The circuit further comprises a semiconductor device formed in the second lightly doped region and an ESD clamp device coupled between the second lightly doped region and a reference node.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The invention relates to a technique to increase the CDM performance of an IC by connecting additional ESD clamps to isolated wells (or junctions). FIG. 2A illustrates a cross-section diagram of an Integrated Circuit IC 200 for CDM ESD protection in accordance with one embodiment of the present invention. The IC 200 illustrates a cross-section diagram of the transistor 104 formed in the isolated P-well region 106 with the deep N-well 108 and N-well 110 forming a ring structure around the isolated region to isolate/separate the P-well region 106 from the P-substrate 104 . Furthermore, an additional ESD clamp 202 is coupled to the isolated P-well, 106 as shown in FIG. 2A . Specifically, the ESD clamp 202 is placed between the isolated P-well 106 and a reference node. The selection of the reference node depends on the normal operation requirements such as noise, cross-coupling, and other ESD elements. Preferably for ESD and in this example of FIG. 2A , the terminal to the isolated well 106 is coupled to the second potential 124 (i.e. the reference node) with the ESD clamp 202 . Depending on the normal operation requirements the ESD clamp 202 may preferably comprise one of: SCR (with or without trigger device), MOS, diode, resistor, or other elements. As discussed above, one implementation is that the second potential 124 is one of the ground lines. However, there exist a lot of cases where the isolated well 106 is coupled to another ground besides the ground potential 124 . This is preferably due to normal operation requirements such as noise. Now the voltage of the isolated well 106 is nearly equal to the second potential 124 and so one or more diodes in series can be utilized as ESD clamp 202 . However there are also other possible cases where the voltage difference between the isolated well 106 and the second potential 124 is larger during normal operation or there are some other more severe requirements. In those cases, other elements such as SCR, transistor, resistor, capacitor or inductor are preferably utilized as the ESD clamp 202 to remove the charges of the isolated P-well 106 .
[0024] Referring to FIG. 2B , there is illustrated a cross-section diagram of IC 200 of FIG. 2A during CDM in accordance with the embodiment of the present invention. As shown in FIG. 2B , the ESD clamp 202 is added to remove the charges from the isolated P-well 106 . Thus, during CDM, as shown in FIG. 2B , the charges 132 in the isolated P-well 106 are allowed to flow through the dedicated ESD path i.e. via the ESD clamp 202 to prevent the damage to either the core circuitry 114 or the gate oxide thus, avoiding the damage to the IC 100 . As shown earlier in FIG. 1 C, the charges in the substrate 102 and in the N-Well 110 (and Deep N-Well Well 108 ) will flow easily to the node potentials 124 and 122 respectively. In an initial stage of the ESD discharge, the charges will remain in the isolated Well 106 . Due to the difference in discharging between the substrate 102 and N-well 110 at one side and the isolated P-well 106 at the other side, a voltage difference will be created between the I/O pad 118 and the substrate 102 . In the prior art the voltage built up will be large enough to damage the gate, but in this invention the ESD clamp 202 will turn on at a voltage below the gate oxide breakdown or the failure of the core circuitry 114 . The triggering of the clamp 202 will further limit the voltage built-up over the gate oxide, thus protecting it, and will discharge the charges of the isolated well 106 to the reference node, (i.e. node potential 124 in FIG. 2A and FIG. 2B ) and then ultimately to the I/O pad 118 .
[0025] Note that the invention is not limited to the placement of the ESD clamp 202 . FIG. 2C shows an exemplary cross-section diagram of IC 200 of FIG. 2A where the ESD clamp 202 is placed between the isolated P-well 106 and the first potential 122 instead of the second potential 124 . Thus, in this example of FIG. 2C , the terminal to the isolated well 106 is coupled to the first potential 122 (i.e. the reference node) with the ESD clamp 202 . For negative CDM this can be advantage such that if the ESD protection of the sensitive node comprises only the ESD diodes 126 a and 126 b and no local clamps, the charges in FIG. 2B will flow to the second potential 124 . A power clamp (not shown) is always located between the first potential 122 and the second potential 124 . Thus the charges in FIG. 2B will need to travel through the power clamp to the first potential 122 , then, they will go through the diode 126 a to the I/O pad 118 . However, in this embodiment of the present invention, the charges will flow directly to the first potential 122 , without any need to go through the power clamp anymore. The voltage built over the gate 104 c will be now lower, i.e. having a less resistive path.
[0026] Referring to FIG. 2D there is shown an illustrative exemplary cross-section diagram of IC 200 of FIG. 2A utilizing the invention for the isolated well inside the core of the IC. In this example, the isolated well, i.e. P-well 106 is placed in the core of the IC 100 , instead of in the periphery as illustrated in FIG. 2A . In the prior art, during CDM stress the internal node can discharge with a different speed than the isolated well 106 , which creates as in the I/O pad 118 , a voltage built-up over the gate 104 c . So, in order to prevent gate damage, in the present embodiment, the charges in the isolated well 106 are preferably discharged also with an ESD clamp 202 coupled to another internal node. One example in FIG. 2D shows that the another internal node is one of the potentials, i.e. second potential 124 as described in FIG. 2A . Thus, in this application, the charges of the substrate 102 and the isolated well 106 will be discharged at the same rate. Although, as shown in FIG. 2D of the present embodiment, the gate 104 c of the transistor 104 is connected to a core circuitry 114 , it can also preferably be connected to the internal node.
[0027] Now referring to FIG. 2E , there is shown an illustrative exemplary cross-section diagram of IC 200 of FIG. 2A utilizing protecting another device, for example, a capacitance used to show the advantage of the technique described in the present invention. Thus, the problem that the isolated well 106 can not be discharged and will damage a device is not limited to transistors only. FIG. 2E illustrates a scenario where the device within the isolated Well, i.e. device 106 is a capacitance 204 , instead of a transistor 104 . The ESD clamp 202 is shown to be coupled between the potential node 124 and the isolated P-Well 106 . In this case, the connection to the isolated well 106 (and 204 a ) is not a separate tap 116 but a part of the device. The charges will flow during the stress through the tap region 204 a (or even through 204 b , in this case these two taps are coupled together) to the ESD clamp 202 . Further the charges will flow to the potential Vss 124 which in this figure is the output. When the charges has reached this potential, they can flow to the stressed pin (not shown) internal to the chip as described in the previous embodiments. It is important to note that those skilled in the art can utilize many other devices to utilize the above-described invention technique.
[0028] Although the invention is illustrated for an NMOS component, those skilled in the art would appreciate that a PMOS structure device can preferably be utilized. Furthermore, the present invention is not restricted for the use for an Isolated Pwell. Any well which is isolated from the Vss or Vdd busses or only connected to those busses through some core circuitry, requires the protection as described in this invention.
[0029] A typical case where this kind of protection might be appropriate beside technologies with deep n-well (or buried layer), is the case of silicon-on-insulator (SOI) integrated circuit, where the body region of the transistor is easily isolated from Vss and Vdd bus, since there is no substrate connection between the body region of the transistor (i.e. the well) and a ground connection. Other processes are for example bipolar technologies (BCD, HV technologies), where a lot of isolated wells are used.
[0030] Although various embodiments that incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings without departing from the spirit and the scope of the invention.
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The present invention provides a charged-device model (CDM) electrostatic discharge (ESD) protection circuit for an integrated circuit (IC). The ESD protection circuit comprises a substrate of first conductivity type; a MOS component of second conductivity type formed on a first well on the substrate, and coupled to a pad; an isolating well/region having the second conductivity type being formed between the first well and the substrate to separate the first well and the substrate. Additionally, the circuit comprises an ESD clamp coupled to the isolated well/region. Under normal power operation, the ESD clamp is open. During a CDM ESD event, the CDM charges accumulated in the substrate and the MOS component are removed by the ESD clamp to prevent damage to the IC.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a CONTINUATION application claiming the benefit of priority of the co-pending U.S. Utility Non-Provisional patent application Ser. No. 12/038,176 with a filing date of 27 Feb. 2008, the entire disclosure of which is expressly incorporated by reference in its entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to extruded moldings and, more particularly, to a set of interlocking extrusions for use in attaching panels of a shower enclosure.
[0004] 2. Background
[0005] Certain shower enclosures, such as are used in recreational vehicles and the like, are constructed of prefabricated glass panels and at least one door panel that includes a door and doorframe. During the installation of such a shower enclosure, it is required to join together multiple panels of glass and their respective frames that protect the edges of the glass. One example of such a shower enclosure is designed for a corner installation with three panels, two adjoining the walls and perpendicular thereto, and a third, often comprising the door and doorframe, diagonally between the other two at 135° angle with respect to each other. This is often referred to as a “Neo-Angle” shower design.
[0006] There are numerous connection systems for attaching adjoining panels of framed glass of shower enclosures. Most existing shower enclosures use some form of an interlocking design feature to engage multiple glass panels/doorframes within the installation process, however there remains additional room for improvement.
[0007] During the installation process it is required to quickly and safely bring together and stabilize multiple glass panels/doorframes prior to permanent engagement. During this initial assembly and adjustment process, there is usually one installer who must maneuver numerous panels/doorframes at the same time prior to fastening them together in a “permanent” engagement. Existing shower enclosures lack a feature that is effective in securing the panels prior to the permanent fastening stage. Disengagement of adjoining panels during installation is problematic as a result of delays in the installation process as well as the risk for damaged property and personal injury to the installer.
SUMMARY OF THE INVENTION
[0008] The present invention provides a set of extruded interlocking moldings that provide a unique and superior method of joining together panels of framed glass and/or framed glass doors. A first molding has a channel along an edge of one face and a groove in the opposite face. A second molding has a tongue extending along an edge of one face and a flange along an edge of the opposite face. The channel of the first molding is configured to receive and hold the tongue of the second molding to secure the moldings together as the panels are aligned. The flange of the first molding snaps into the groove of the second molding when the moldings are rotated to a predetermined angle with respect to each other.
[0009] Some of the benefits of the present invention are:
An easier, safer and quicker installation. A “leading-outside-engagement feature” of the extrusions engages in a manner so that when the extrusions are rotated toward the permanent engagement position, the connection does not allow separation in the installation process. A secure connection between the door and fixed panels. Following the leading-outside-engagement feature connection, an “inside-engagement feature” then engages in a “snapping” function that locks and holds the panels permanently in the proper alignment. Upon permanent engagement, the relationship of the leading-outside-engagement feature and the inside-engagement feature reduces lateral or twisting action. The resulting strength of the fully assembled joint (i.e. “permanent” engagement) precludes the need of using fasteners to secure the panels together. Saving in material cost. The strength and stability of the fully assembled joint inherent in the moldings of the present invention reduces the amount of frame material required. Conventional frame moldings are thicker to accommodate fasteners, typically 3-5 screws per post, and access thereto. Since no fasteners are needed to assemble the moldings of the present invention, they can be substantially thinner. As a result, it is feasible to reduce the width of the frame material by up to 50%.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a prior art shower enclosure.
[0014] FIG. 2 is a detailed cross-sectional view of a pair of prior art moldings for forming a corner of a shower enclosure.
[0015] FIG. 3 is a detailed cross-sectional view of the moldings shown in FIG. 2 after being permanently attached.
[0016] FIG. 4 is a detailed cross-sectional view of a pair of moldings in accordance with an embodiment of the present invention.
[0017] FIG. 5 is a detailed cross-sectional view of the moldings shown in FIG. 4 after being permanently attached.
[0018] FIG. 6 is a magnified view of the inside engagement feature of the present invention.
[0019] FIG. 7 illustrates the reduction in material made possible with the present invention.
DETAILED DESCRIPTION
[0020] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0021] FIG. 1 is a perspective view of a typical Neo-Angle shower installation utilizing prior art extruded moldings. Enclosure 10 comprises a door and doorframe 12 and two fixed panels 14 , 16 on either side of the door. The fixed panels are attached to the walls and the doorframe is attached between the fixed panels along each side edge.
[0022] FIG. 2 is a cross-sectional view of the prior art extruded moldings that form the adjoining edges of panel 14 and door/doorframe panel 12 . During installation of a typical Neo-Angle shower joint design, the adjoining panels are initially brought together prior to the permanent fastening stage. To facilitate this initial alignment, panel edge molding 18 has a hook-shaped leading edge 20 that engages a rearward facing protrusion 26 on doorframe molding 24 . These features are referred to collectively as “leading-outside-engagement feature” 32 . This engagement feature, while helpful for initially aligning the panels, fails to positively engage the two moldings and therefore allows the panels to become easily disengaged, particularly when subjected to the tilting and twisting forces that are commonly applied during panel alignment. Notice, in particular, how the shape of the leading-outside-engagement feature 32 of extrusions 18 and 24 allows panel 14 to separate from doorframe 12 in any of the indicated directions during the initial assembly and adjustment process.
[0023] Prior art moldings 18 and 24 also incorporate an “inside-engagement feature” 34 comprising flange 22 on panel edge molding 18 and groove 28 in doorframe molding 24 . After the leading-outside-engagement feature 32 has been engaged, panel 12 is rotated counter-clockwise to engage flange 22 in groove 28 as shown in FIG. 3 . Note, however, that engagement of both the leading-outside-engagement feature 32 and the inside-engagement feature 34 is insufficient to lock panel 14 and doorframe 12 together into permanent engagement because it fails to hold the panel and doorframe under lateral or twisting forces. Thus, shower enclosures constructed with prior art moldings 18 and 24 require the use of a plurality of fasteners 30 (only one of which is seen in the figure) to “lock” the adjoining panels together. All of the existing connection systems require multiple fasteners, usually three to five screws per connection, to permanently join the frame edges of the door panel and stationary panel. Since these existing connection systems require the use of screws, larger frame sections, which require more raw material, are necessary to allow space both for the screws and for access to the screws during assembly.
[0024] Many prior art shower enclosure joint designs use both outside and inside engagement features similar to those described above; however, such engagement features nevertheless allow separation of the adjoining panels. Even with the use of screws 30 to fasten moldings 18 and 24 together, the assembly is still prone to gaps along the joints 32 and 34 due to the flexibility of the aluminum moldings. Note, in particular, that the leading-outside-engagement feature 32 does not positively lock together and therefore allows the moldings to separate as indicated by the arrows in FIG. 3 . The resulting gap is not only aesthetically displeasing, but the separation of the moldings also reduces the structural integrity of the shower enclosure. Typically, only 3-5 screws are used along the length of the moldings. The use of additional screws would reduce the severity of the gaps, but would increase the material and assembly costs. The present invention also uses outside and inside engagement features; however, the design of the engagement features differs from the prior art in form, fit and function to achieve a variety of benefits.
[0025] Referring now to FIG. 4 , a pair of extruded moldings in accordance with an embodiment of the present invention are shown in cross section. Doorframe molding 110 is attached to the edge of door/doorframe panel 101 . Molding 110 includes a channel 116 along the edge of front face 112 and a groove 118 in the rear face 114 . Panel edge molding 120 is attached to the edge of fixed panel 102 . Molding 120 includes tongue 126 extending along the edge of front face 122 and a flange 128 along the edge of rear face 124 . A leading-outside-engagement feature, designated generally as 105 , comprises channel 116 of doorframe molding 110 and tongue 126 of panel edge molding 120 . This is the first feature to be engaged during installation.
[0026] The leading-outside-engagement feature 105 becomes engaged as tongue 126 is captured within channel 116 . This first occurs when the door/doorframe panel 101 is at an angle of approximately 165° with respect to the fixed panel 102 . Once feature 105 is initially engaged, the door/doorframe panel's angle of orientation can be rotated slightly counter-clockwise (as viewed in FIG. 4 ) toward a permanent engagement position in which feature 105 is in contact along the entire vertical length. At this point, the two moldings are held securely together by the full-length capture of tongue 126 within channel 116 . Note how the shape of the leading-outside-engagement feature 105 of the extrusions engage in a manner so that once engaged, the connection does not allow separation in any direction. This greatly facilitates the initial assembly and adjustment process, when usually one installer must maneuver numerous panels and a doorframe at the same time prior to their “permanent” attachment. The stability of the multiple glass panels afforded by the present invention results in an easier, safer and quicker installation process.
[0027] With reference also to FIG. 5 , an inside-engagement feature, designated generally as 106 , comprises groove 118 of doorframe molding 110 and flange 128 of panel edge molding 120 . From the position shown in FIG. 4 , the door/doorframe panel 101 may be further rotated in a counter-clockwise direction to its permanent engagement position where flange 128 “snaps” into groove 118 to lock and hold the panels permanently in the proper alignment, providing a secure connection between the door/doorframe panel 101 and the fixed panel 102 without the use of fasteners. In the example shown, the flange snaps into the groove when the panels are at an angle of about 135°.
[0028] Referring also to FIG. 6 , the moldings 110 and 120 are configured so that molding 120 is “sprung” slightly when fully engaged with molding 110 , thereby urging the rear face 124 against rear face 114 and urging flange 128 into groove 118 . This self-locking feature of the joint obviates the need for additional fasteners to secure the panels together. Upon permanent engagement, the relationship of the leading-outside-engagement feature 105 and the inside-engagement feature 106 locks the panels together under any type of lateral or twisting force and thereby greatly reduces vibration and squeaking. The finished joint also allows for an aesthetically desirable flush mating of both the inside and outside surfaces of the shower enclosure, which is a major advantage of the present invention over the prior art.
[0029] As explained above, the strength and stability of the fully assembled joint inherent in the moldings of the present invention obviates the need for mechanical fasteners such as screws. This allows for substantially thinner moldings and reduces the amount of frame material required. FIG. 7 presents a comparison of the moldings of the present invention to those of the prior art to illustrate the reduction in material that can be achieved with the present invention.
[0030] The present invention has been described with reference to a particular example of a shower enclosure; however, the invention may be applied in any application requiring the connection of adjoining panels. For example, while the invention has been described in the context of panels joined at an angle of 135°, suitably modified moldings substantially similar to those described above may be provided for joining panels at any desired angle. Furthermore, the invention has been described with reference to a tongue and channel engagement feature on the front faces of the interlocking extrusions and a flange and groove engagement feature on the rear faces. However, these engagement features could be reversed, yet still provide similar functionality and benefits.
[0031] It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
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A set of extruded interlocking moldings joins together panels of framed glass and/or framed glass doors. A first molding has a channel along an edge of one face and a groove in the opposite face. A second molding has a tongue extending along an edge of one face and a flange along an edge of the opposite face. The channel of the first molding is configured to receive and hold the tongue of the second molding to secure the moldings together as the panels are aligned. The flange of the first molding snaps into the groove of the second molding when the moldings are rotated to a predetermined angle with respect to each other.
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[0001] The present application generally relates to paper towel dispensers, and more particularly, to a paper towel cabinet with paper towel module.
BACKGROUND
[0002] Paper towel dispensers are either dispensers that dispense individual paper towels from a roll, and dispensers that dispense paper towels from a folded stack of paper towels. The latter type of dispensers typically include a cabinet that is mounted on a wall at a height that allows dispensing of paper towels to a person standing next to the cabinet. A stack of paper towels is placed in the cabinet such that the stack is oriented vertically inside the cabinet. An opening at the bottom of the cabinet provides access to a paper towel at the bottom of the stack. Paper towels can be manually pulled out of the stack through the opening. The paper towels are folded on top of the each other to form the stack. The fold pattern can be a single-fold, C-fold or multi-fold. The opening is typically an oblong slot having a large center area in order to accommodate various fold configurations and sizes of paper towels.
[0003] The above-described paper towel dispensers have several problems associated with the dispensing of paper towels through the opening. When the height of the stack of paper towels is large, the weight of the stack may cause a bloating of the paper towels at the opening such that a cluster of paper towels are exposed. The bloating may also be caused when the bottom opening does not correspond with the size of paper towels being dispensed from the cabinet. The bloating may allow a user to pull out several paper towels at a time and waste paper towels. The bloating may also cause tearing of paper towels when a user is attempting to pull single paper towels from the stack. In addition to the noted functional disadvantages, bloating of paper towels at the opening is not aesthetically pleasing. When the stack of paper towels is low or almost depleted, the remaining paper towels in the stack may fall out of the opening. When the stack of paper towels is high, the paper towels can tear when being pulled out of the opening because of the friction between the paper towel being pulled out and the bottom of the cabinet at the opening. The tearing of the paper towels is particularly problematic when recycled paper towels are used or when a user's hands are wet.
[0004] The above-described paper towel dispensers also have a problem associated with the replacement and/or refilling of the paper towel stack. In order to refill the cabinet with paper towels, the face of the cabinet is hinged on one side in order to function as a door. The door can be swung open, thereby allowing a maintenance person to place one or more stacks of paper towels in the cabinet. The paper towel stack typically rests against the back wall of the cabinet. However, depending on the height of the stack, a possibly slight stagger in the paper towels in the stack, and/or the curvature of the paper towel tray, the paper towels may rest against the door of the cabinet. Accordingly, the paper towels can fall out of the cabinet when a maintenance person opens the door to replace the stack or refill the cabinet with one or more stacks of paper towels.
[0005] In view of the above, there is a need for a paper towel cabinet or a module for existing paper towel cabinets that can remedy one or more of the above described problems associated with current paper towel dispensers.
SUMMARY
[0006] In accordance with one aspect of the disclosure, a paper towel cabinet includes a first side wall and a second side wall, a pivotally mounted front wall defining a door, a back wall extending between the side walls, and a paper towel tray having an opening to provide access to paper towels. The cabinet also includes a module assembly including a first module having a front surface extending transversely relative to the first side wall toward the second side wall. When the door is in an open position, the front surface prevents paper towels leaning toward the door from falling out of the cabinet.
[0007] In accordance with another aspect of the disclosure, a paper towel cabinet includes a first side wall and a second side wall, a pivotally mounted front wall defining a door, a back wall extending between the side walls, and a paper towel tray having an opening to provide access to paper towels. The cabinet further includes a module assembly including a first module having a first side surface extending relative to the back wall toward the door, a second side surface generally parallel to the first side surface, a back surface extending between the first side surface and the second side surface, and a front surface extending transversely from the first side surface toward the second side surface. When the door is in an open position, the front surface prevents paper towels leaning toward the door from falling out of the cabinet.
[0008] In accordance with another aspect of the disclosure, a paper towel cabinet includes a first side wall and a second side wall, a pivotally mounted front wall defining a door, a back wall extending between the side walls, a paper towel tray having an opening to provide access to paper towels, a front surface extending transversely relative to the first side wall toward the second side wall, and a bar mounted proximate to the opening and having a length extending transversely relative to the side walls. The bar is disposed between the stack of paper towels and the opening when the stack of paper towels is placed on the paper towel tray. When the door is in an open position, the front surface prevents paper towels leaning toward the door from falling out of the cabinet.
[0009] Features and advantages of the present disclosure will become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates a side perspective view of a paper towel cabinet.
[0011] FIG. 2 is a perspective view of the cabinet of FIG. 1 and a module according to a first embodiment of the disclosure.
[0012] FIG. 3 is a perspective view of the cabinet of FIG. 1 and a module according to a second embodiment of the disclosure.
[0013] FIG. 4 is a perspective view of the cabinet of FIG. 1 and a module according to a third embodiment of the disclosure.
[0014] FIGS. 5A-5C are top, front and side elevational views of a module according to the third embodiment of the disclosure.
[0015] FIG. 6 is a view of a paper towel tray of the cabinet of FIG. 1 with the module of FIGS. 5A-5C .
[0016] FIG. 7 is a perspective view of the cabinet of FIG. 1 and a module according to a fourth embodiment of the disclosure.
[0017] FIGS. 8A-8C are views of a paper towel tray of the cabinet of FIG. 1 with a module according to the fifth embodiment of the disclosure.
DETAILED DESCRIPTION
[0018] Referring to FIG. 1 , a paper towel cabinet 10 is shown having a pair of side walls 12 a and 12 b , a back wall 14 , a top wall 16 , and a front wall connected to one of the side walls 12 a and 12 b with one or more hinges in order to function as a door 18 . The cabinet 10 further includes a paper towel tray 20 for supporting a stack of paper towels. The paper towel tray 20 has an opening 22 for dispensing paper towels. The side walls 12 a and 12 b , the back wall 14 , the top wall 16 , the door 18 and the paper towel tray 20 define the interior of the cabinet 10 in which a stack of paper towels can be housed and accessed from outside the cabinet 10 through the opening 22 . The paper towel cabinet 10 may include an adapter 24 (shown in FIG. 2 ) mounted therein for accommodating a stack of paper towels having a width that is smaller than the internal width of the cabinet 10 . The adapter 24 includes a pair of side walls 24 a and 24 b connected with a back wall 24 c . The adapter 24 can be mounted in the cabinet 10 by the back wall 24 c being mounted to the back wall 14 of the cabinet.
[0019] Referring to FIG. 2 , a module 30 according to the first embodiment of the disclosure is shown. The module 30 is in the form of an angle or a generally L-shaped bracket that can be attached to one of the side walls 12 a and 12 b and/or the back wall 14 of the cabinet or to one of the side walls 24 a and 24 b of the adapter 24 . In the example shown in FIG. 2 , the module 30 is attached to the side wall 24 a of the adapter 24 . When an adapter 24 is not used in the cabinet 10 , the module 30 can be attached to one of the side walls 12 a or 12 b and/or the back wall 14 . The module 30 can be attached to the cabinet 10 or adapter 24 by welding, with an adhesive, with fasteners, or by other known methods and devices that can provide a secure attachment of the module 30 to the cabinet. In the example shown in FIG. 2 , the module 30 includes a first side surface 32 extending generally parallel with the side wall 24 a and a front surface 34 extending generally transverse to the first side surface 32 and toward the side wall 24 b . The module 30 can be constructed in one piece with the adapter 24 . Accordingly, the module 30 may only include a front surface 34 that is in one piece with the side wall 24 a and extends transverse to the side wall 24 a . When a stack of paper towels is placed in the cabinet 10 , the paper towels are bound in a generally rectangular region defined by the module 30 , the back wall 24 a , the paper towel tray 20 and the side wall 24 b . The stack of paper towels can be placed in the cabinet 10 by first inserting one side of the stack at an angle relative to the front surface 34 inside the area defined by the module 30 and the back wall 24 . The opposite side of the stack is then moved toward the back wall 24 c or 14 to fully place the stack of paper towels in the cabinet 10 . The weight of the stack of paper towels is supported by the paper towel tray 20 . The stack of paper towels can lean on the front surface 34 to prevent the stack from falling out of the cabinet 10 when the door 18 is opened.
[0020] The front surface 34 can be configured to extend from the top wall 16 to the paper towel tray 20 . Alternatively, as shown in FIG. 2 , the height of the front surface 30 may be such that only a portion of the stack of paper towels can lean on the front surface 34 . In the latter configuration, the module 30 can be positioned in the cabinet 10 so that the front surface 34 provides direct leaning support for a portion of the stack of paper towels. However, this partial leaning support may be sufficient to prevent the entire stack of paper towels from falling out of the cabinet 10 when the door 18 is opened. In the example shown in FIG. 2 , the front surface 34 is closer to the paper towel tray 20 than to the top wall 16 . When a stack of paper towels extends above the front surface 34 , a portion of the stack that is above the front surface 34 most likely remains positioned with the rest of the stack and will not independently lean on the door 18 due to friction between the paper towels and the relative height of the portion extending above the front surface 34 as compared to the height of the entire stack. When the stack is depleted to a level such that the stack is below the front surface 34 , the likelihood of the stack leaning against the door 18 may be very slim to none because the center of gravity of the stack is very near the paper towel tray 20 . Accordingly, a module 30 having a front surface 34 that is shorter than the height of the cabinet and positioned so as to support only a portion of the paper towel stack can provide the function of preventing the entire stack of paper towels from falling out of the cabinet when the door 18 is opened.
[0021] Referring to FIG. 3 , a module 130 according to the second embodiment of the disclosure is shown. The module 130 includes a pair of side surfaces 132 a and 132 b , a front surface 134 that is connected to the side surface 132 a and extends toward the side surface 132 b , and a back surface 136 . The front surface 134 and the side surface 132 a form a generally L-shaped area for receiving a stack of paper towels. The back surface 136 and/or any of the side surfaces 132 a and 132 b can be attached to the cabinet 10 or the adapter 24 by welding, with an adhesive, with fasteners, or by other known methods and device that can provide a secure attachment of the module 130 to the cabinet 10 . The entire module 130 may be supported on the paper towel tray 20 without being attached to any part of the cabinet 10 .
[0022] When a stack of paper towels is placed in the cabinet 10 , at least a portion of the stack of paper towels is bound by the module 130 . The stack of paper towels can be placed in the module 130 by inserting one side of the stack in the region defined by the front surface 134 , the side surface 132 a and the back surface 136 . The opposite side of the stack is then placed in the module 130 . The stack of paper towels can lean on the front surface 134 to prevent the stack from falling out of the cabinet 10 when the door 18 is opened.
[0023] The front surface 134 may extend from the paper towel tray 20 to the top wall 16 to provide leaning support for the entire stack of paper towels. Alternatively, the front surface 134 may only extend partially between the paper towel tray 20 and the top wall 16 in order to provide leaning support to only a portion of the stack of paper towels placed in the cabinet. However, as described above with respect to the module 30 of the first embodiment, providing direct leaning support to a portion of the stack of paper towels may be sufficient to provide leaning support to the entire stack of paper towels.
[0024] Referring to FIG. 4 , a third embodiment of the disclosure is shown to have a first module 230 a , which is similar to the module 30 of the first embodiment, and a second module 230 b . Accordingly, parts of the first module 230 a are referred to with the same reference numbers as the same parts of module 30 . Referring also to FIGS. 5A-5C , the second module 230 b includes a pair of side surfaces 232 a and 232 b and a bar 233 that is fixedly or rotationally mounted to the side surfaces 232 a and 232 b and extends therebetween. The bar 233 may be mounted to the side surfaces 232 a and 232 b with fasteners 235 so as to enable a maintenance person to remove the bar 233 for repair or replacement with another bar. Each of the side surfaces 232 a and 232 b can be connected to a corresponding side wall 24 a and 24 b of the adapter 24 or to the corresponding side wall 12 a and 12 b of the cabinet 10 . Alternatively, the second module 230 b may also include a back surface 234 that connects the side surfaces 232 a and 232 b and can be attached to the back wall 24 c of the adapter 24 or the back wall 14 of the cabinet 10 . The module 230 b is mounted inside the cabinet 10 near the opening 22 such that the bar 233 is positioned above the opening 22 . The distance between the bar 233 and the opening 22 may be determined based on a variety of factors, such as the weight, size, thickness, and texture of each paper towel. The module 230 b can be mounted in the cabinet without the module 230 a.
[0025] Referring to FIG. 6 , the paper towel tray 20 of the cabinet 10 is shown with the module 230 b . The opening 22 is defined by a first edge 40 and a second edge 42 that are spaced apart from a first side 44 of the paper towel tray 20 to a second side 46 of the paper towel tray 20 . The bar 233 is positioned so as to extend along the opening 20 from the first side 44 to the second side 46 and between the first edge 40 and a the second edge 42 . In the example shown in FIG. 6 , the bar 233 is shown to be approximately half way between the first edge 40 and the second edge 42 . Preferably, the opening 20 is divided by the bar 233 into two substantially similar sized smaller openings from which each paper towel can be pulled out the stack of paper towels housed in the cabinet 10 . If the bar 233 is placed too close to the first edge 40 , the portion of the opening 22 that will be between the bar 233 and the first edge 40 may be too small for pulling out a paper towel. The small opening may cause tearing in the paper towels and prevent the edge of the next paper towel in the stack to be pulled out from the opening 22 . Furthermore, the portion of the opening 22 between the bar 233 and second edge 42 may be too large such that a user can intentionally or unintentionally pull a large number of paper towels from the opening 22 . Similarly, if the bar 233 were placed too close to the second edge 42 , the portion of the opening 22 between the bar 233 and the second edge 42 may be too small for pulling paper towels out of the opening 22 . Additionally, the portion of the opening 22 between the bar 233 and the first edge 42 may be too large so that a user can intentionally or unintentionally pull a large number of paper towels from the opening 22 .
[0026] When the stack of paper towels is placed in the cabinet 10 , the stack may at least partially rest on the bar 233 . Accordingly, the weight of the stack may be at least partially supported by the bar 233 . The weight of the stack of paper towels may also be partially supported by the paper towel tray 20 . The bar 233 may be generally circular or have a curved cross-section so as to provide a curved contact surface between itself and each paper towel at the bottom of the stack of paper towels. The curved surface of the bar 233 can reduce the resistance encountered by a user when pulling a paper towel out of the stack of paper towels. The bar 233 may be fixed to the side surfaces 232 a and 232 b such that it cannot rotate when each paper towel is being pulled out of the opening 22 . Accordingly, each paper towel slides over the bar 233 while being pulled out of the stack of paper towels. However, the bar 233 may be rotational relative to the side surfaces 232 a and 232 b so that it freely rotates when each paper towel is being pulled out of the opening 22 .
[0027] As described above, the weight of the stack of paper towels may be partially supported by the bar 233 . The weight of the stack of paper towels, however, depends on the number of paper towels that are in the stack. As the stack of paper towels is depleted, the weight of the stack is reduced. Accordingly, the frictional force between the paper towel at the bottom of the stack and the bar 233 is reduced and may cause more than one paper towel to fall out or be pulled out of the opening 22 . Additionally, when the stack is nearly depleted, the stack becomes light relative to the force by which a user pulls out a paper towel from the bottom of the stack. Accordingly, pulling a single paper towel may lift, flip, and/or move the stack so as to disorient the stack relative to the opening 22 . The disorientation of the stack may cause the entire stack to fall out of the opening 22 , or position the stack such that the remaining paper towels of the stack can be pulled out together. To prevent the stack from being disoriented in the cabinet 10 when nearly depleted, a weight (not shown) that can be placed on top of the stack of paper towels. Accordingly, as the stack of paper towels is depleted, the change in the total weight of the stack of paper towels and the weight may not be significant. Thus, even when the stack of paper towels is nearly depleted, the action of pulling a paper towel from the stack may not disorient the stack inside the cabinet 10 . Instead of using a weight, known biasing mechanisms such as a spring-loaded plate can be used to press down on the stack of paper towels.
[0028] Referring to FIG. 7 , a module 330 according to the fourth embodiment of the disclosure is shown. The module 330 is similar to the module 130 except that it includes a bar 333 extending between the side surfaces 132 a and 132 b . Accordingly, parts of the module 330 are referred to with the same reference numbers as the same parts of module 130 . The bar 333 may be directly connected to the side surfaces 132 a and 132 b . Alternatively, as shown in FIG. 7 , the module 330 includes support surfaces 335 a and 335 b extending below side surfaces 132 a and 132 b , respectively. The bar 333 is rotationally or fixedly attached to the brackets 335 a and 335 b with fasteners so as to enable a maintenance person to remove the bar 333 for repair or replacement with another bar. The function of the bar 333 is similar to the function of the bar 233 of the third embodiment discussed above.
[0029] Referring to FIGS. 8A-8C , a module 430 according to a fifth embodiment of the disclosure is shown. The module 430 includes a bar 433 for mounting near the opening 22 of the paper towel tray 20 as described above. Referring to FIG. 8A , the bar 433 may be positioned at the opening 22 . The bar 433 may rest on the paper towel tray 20 . Alternatively, the bar may be maintained by a groove or an indentation (not shown) in the paper towel tray 20 that is configured to receive all or a portion of the bar 433 . Referring to FIG. 8B , the bar can be fixedly or rotationally mounted to the side walls 12 a and 12 b of the cabinet by using brackets or known mounting hardware such as a variety of fasteners. The noted mounting hardware is generally shown in FIG. 8B with reference number 435 . For configurations where the bar is fixedly mounted to the cabinet and is not to be removed, the bar 433 can be welded or mounted with adhesives to the side walls 12 a and 12 b of the cabinet (not shown). Referring to FIG. 8C , the bar 433 can be rotationally or fixedly mounted to the paper towel tray 20 by using brackets or known mounting hardware such as a variety of fasteners, which are generally shown in FIG. 8C with reference number 437 . Although not shown, the bar 433 can also be welded to the paper towel tray 20 or fixedly attached thereto with an adhesive. Similarly, the bar 433 can be mounted to the back wall 14 by the devices and methods described above.
[0030] Although the above embodiments are described separately, they can be used in combination if desired. For example, the module 130 of the second embodiment and the module 230 b of the third embodiment can be mounted together in a paper towel cabinet. In another example, the module 30 of the first embodiment can be provided with a lower support surface similar to the support surfaces 335 a and 335 b of the module 330 for supporting a bar that extends along the opening as described above. In yet another example, the module 430 of the fifth embodiment, which includes a bar 433 and may include mounting hardware 435 or 437 , can be mounted inside the cabinet either alone or with one of the modules 30 , 130 or 230 a.
[0031] The cabinet 10 is described has optionally having the adapter 24 to accommodate paper towels that have a smaller width than the width of the cabinet. However, the cabinet 10 may not require the adapter 24 in cases where the paper towels are size to properly fit in the cabinet 10 . Accordingly one of ordinary skill in the art will recognize that the components of the disclosed modules that couple, connect or engage with the certain parts of the cabinet can similarly couple, connect or engage to similar parts of the adapter.
[0032] The orientation of the various surfaces of the above-described modules may vary depending on the type of cabinet or application of the module. For example, the front surface of each module may be oriented at a right angle relative to the side surface to which it is connected. Alternatively the front surface may be oriented at a different angle relative to the side surface depending on the size, shape and internal angles of various parts of the cabinet. Furthermore, although the terms “surface” and “walls” are used herein to describe the components of the cabinet and the modules, any of the surfaces and walls may be formed by a flat or curved surface and may be constructed from a mesh, a plurality of rods or elongated elements forming a lattice, woven strings, wires, or any other geometrical and material configuration that can provide the functionality of the surfaces and walls described herein. For example, the front surface of each of the above described modules can be formed by a wire mesh. In another example, the front surface of each of the above described modules can be formed by one or more vertically, horizontally or diagonally oriented rods that provide leaning support to a stack of paper towels.
[0033] The modules described above which include a front surface for providing leaning support to an end portion of a stack of paper towels may include a second front surface located laterally opposite to the first front surface to also provide leaning support to the opposite end portion of the stack of paper towels. However, having a second front surface may make the loading of paper towels difficult as the paper towels would have to be inserted in the module from a narrow opening in front of the module. Accordingly, the second front surface may be narrower than the first surface or not provided at all.
[0034] The above-described modules can be mounted inside existing paper towel cabinets in order to prevent the stack of paper towels from falling out of the cabinet when the front door of the cabinet is opened. Furthermore, new paper towel cabinets can be constructed with the disclosed modules separately incorporated therein or constructed integrally therewith.
[0035] While a particular form of the disclosure has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the disclosure. Accordingly, it is not intended that the disclosure be limited, except as by the appended claims.
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A paper towel cabinet includes a first side wall and a second side wall, a pivotally mounted front wall defining a door, a back wall extending between the side walls, and a paper towel tray having an opening to provide access to paper towels. The paper towel cabinet also includes a module assembly comprising a first module having a front surface extending transversely relative to the first side wall and toward the second side wall. When the door is in an open position, the front surface prevents paper towels leaning toward the door from falling out of the cabinet. The cabinet also includes a bar mounted proximate to the opening and having a length extending between the side walls. The bar is positioned between a stack of paper towels and the opening when the stack of paper towels is placed on the paper towel tray.
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BACKGROUND OF THE INVENTION
The present invention relates to means for attaching pet tags to pet collars and more particularily to a holder adapted for attaching one or more tags while preventing rattling of the tags.
Domesticated pets such as dogs and cats are generally required by statute to be licensed and vaccinated. Tags indicating the payment of license fees and appropriate vaccination are required to be attached to the pet's collar to indicate that the statutory requirements have been complied with. In addition most pet owners choose to provide at least one additional tag carrying identifying information such as the owner's name and address and the pet's name to aid in recovery of the pet if it should be lost. Thus at least two and sometimes three tags are attached to the pet's collar. These tags are generally made of some type of metal to provide the desired strength and durability. But the metal tags invariably rattle whenever the pet moves and thereby generate an objectionable noise. It would therefore be desireable to provide a means for attaching the required tags to a pet's collar while preventing rattling between the tags and also to provide an identifying tag without adding to the rattling problem.
Most pet owners do not consider the licensing and vaccination tags to be particularly attractive. At professional pet shows these tages must usually be removed during judging. An attractive identifying tag with, for example, a pet's name is desireably left attached to the pet's collar during the judging process. Thus it would be desireable to also provide means for conveniently attaching and removing the required metal tags from the pet's collar while also providing an attractive identification tag for the pet.
SUMMARY OF THE INVENTION
Accordingly an object of the present invention is to provide a pet tag holder for supporting one or more pet tags from a pet's collar while preventing rattling of the tags.
Another object of the present invention is to provide a pet tag holder which may be used as a support for indicia identifying the pet.
Yet another object of the present invention is to provide a pet tag holder which allows required tags to be quickly and easily attached and removed from the pet's collar.
These and other objects of the present invention are achieved by providing a pet tag holder comprising a base member having attachment means on one end for connection to a pet collar, a post carried on a second end extending from the base to engage a hole in one or more pet tags, and a pair of spring arms supported by the base member and each having a free end positioned on opposite sides of the post member for urging pet tags carried on the post against the base member to prevent rattling. In a preferred form the base member comprises a flat plate of sufficient dimensions to receive indicia identifying a pet or its owner.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood by reading the following detailed description of the preferred embodiments with reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a preferred embodiment of the present invention;
FIG. 2 is a side sectional view of the FIG. 1 embodiment with a pair of pet tags installed;
FIG. 3 is a perspective view of a second embodiment of the present invention;
FIGS. 4 and 5 are perspective views of alternate attaching posts for use with the various embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to FIG. 1 a preferred embodiment of the present invention is shown in perspective view designated generally 10. The pet tag holder 10 in the preferred embodiment is constructed from two generally square sheets of somewhat flexible plastic with one forming a base plate 12 having dimensions of about one inch square on which the rest of the tag holder is assembled. A pair of spring arms 14 are formed from the second sheet by cutting out a rectangular window 16 thereby leaving arms 14 connected by a bight portion 18. In this preferred embodiment, the bight portion 18 is bonded to base plate 12 permanently by gluing or heat fusing. A hole 20 is provided through bight portion 18 and base plate 12 for engagement with one or more metal rings 22 for connection to a pet collar. The appropriate number of rings 22 is selected according to the type of pet collar to which the holder is to be attached and a desired orientation of the holder and tags. The final element of the preferred embodiment is a post 24 which extends from a back surface of plate 12 at essentially a right angle and is positioned near a bottom edge 26 opposite the supporting rings 22. One end of post 24 is embedded into the plate 12 by any suitable means. In a preferred form a nail head 28 is formed as an integral part of post 24 and provides a fairly large flat surface which may be bonded to plate 12. For greatest strength the post 24 is inserted through a hole in plate 12 and nail head 28 is bonded to a recess in a front surface 30 of plate 12. In this preferred embodiment post 24 is made from steel and is of sufficiently small diameter to fit through the holes normally provided in license and vaccination tags. A tag retaining arrangement is formed integrally with post 24 and comprises an arcuate extension 31 of the upper end of post 24 which curves back toward the back surface of plate 12 so that an end 32 thereof contacts plate 12 near the hole 20. In this preferred form a small window or recess 34 is provided in bight portion 18 to accomodate the end 32 of the tag retaining arm 30. If desired, the end 32 may be allowed to simply rest upon the bight portion 18 but this form is not preferred since there is some chance of snagging the free end 32.
More details of the FIG. 1 embodiment are illustrated in FIG. 2 where a side sectional view of tag holder 10 is provided with a pair of tags installed in the holder. Elements which are also illustrated in FIG. 1 carry the same designation numbers. As illustrated in FIG. 2 a pair of tags 36 may be installed back to back so that the printed material thereon is completely readable. When two tags 36 are installed on a tag holder 10 as illustrated the post 24 passes through normal holes in the tags to firmly support the tags. In addition the spring arms 14 overlie the upper edges of the tags 36 and force them against the plate 12 greatly reducing motion of tags 36 relative to plate 12 and to each other. The tags 36 are therefore firmly held on the holder 10 by the post 24 and prevented from rattling by arms 14. It can be seen that the arms 14 also act to prevent removal of tags 36 from post 24. But in the preferred embodiment the tag retaining arm 31 is also provided to prevent loss of the tags should they work free of the arms 14. It can be seen that even if tags 36 are positioned above arms 14 some intentional effort is required to remove the tags entirely from the holder. That is, the tags must be moved along the length of retaining arm 31 and the end 32 of the arm 31 must be lifted away from plate 12 to provide sufficent clearance for complete removal of tags 36.
As noted above tag holder 10 is constructed primarily from two flexible plastic sheets, forming base 12 and the other the spring arms 14. Plastic material aids in damping sound which may be generated by contact of the tag holder with other objects. Such material also provides a good surface 30 for receiving printed material identifying the pet or its owner. Surface 30 could also be used to print advertising material for pet products manufacturers who would distribute the tag holders for promotional purposes. For individuals the tag holder 10, or at least base plate 12, may preferably be manufactured from sheet metal stampings. A metal base plate 12 would provide a surface 30 into which identifying information could be stamped in a conventional manner.
In light of the above description the installation of tags to the position shown on FIG. 2 is apparent. The two tags are preferrably placed back to back with their holes in alignment. The arm 31 is then raised from plate 12 and tags 36 are placed onto the arm 31. The tags are then slid down to the post 24 and rotated to the position illustrated in FIG. 2. The tags are then turned about the axis of post 24 to one side so that a first spring arm 14 may be raised and the tags slid thereunder. Tags 36 are then rotated to the second side and the second spring arm 14 is raised so that when the tags 36 are returned to a centered position they lie under both spring arms 14. When thus assembled information on both tags 36 is visible, one from the front and one from the back. In addition any identifying information on the front surface 30 of the holder 10 is also visible. The tag holder is preferrably attached to a pet collar by one or more rings 22 in such a manner that the surface 30 is visible when facing the pet.
With reference now to FIG. 3 an alternate embodiment of the pet tag holder of the present invention is generally designated 38. In this embodiment the holder is assembled on a generally elongated base member 40 which may have a ring 42 formed integrally at a first end thereof. Member 40 carries a post 44 at a second end opposite ring 42. Member 40 is preferably wider at the second end to provide wings 46 on opposite sides of the post 44. A pair of spring arms 48 each have a first end connected to the base member 40 near connecting ring 42 and a second end overlying each of the wings 46. Tag holder 38 may be constructed from metal stampings joined together by a rivet 50. Thus the spring arms 48 may be stamped from a single piece of metal in a U-shape while base member 40 is stamped in a T-shape with the ring 42 formed from the central leg of the T. Post 44 may be formed from metal and riveted to base member 40. The post 44 may be simply a straight section of a cylinder for holding pet tags in the manner described above while the spring arms 48 prevent the tags from being disengaged from the post. Alternately an arcuate retaining arm may be formed as an extension from the upper end of post 44 in exactly the same fashion as arm 31 of FIGS. 1 and 2. If desired the entire tag holder 38 may be formed from one or two plastic moldings.
While the post 44 in FIG. 3 is shown as a simple cylinder on which pet tags may be easily installed, various modifications to the post would provide other retaining means to prevent the tags from easily slipping off. FIG. 4 is a perspective view of a post 52 which may be used in place of either post 24 in FIG. 1 or post 44 in FIG. 3. A base portion 54 of this post is attached to base 12 or 40 in any suitable manner including the molding of the post 52 integrally with the support member. The base 54 is of sufficiently small diameter to fit within the holes in the pet vaccination or license tags. Post 52 further has a generally conically shaped upper end 56 and is split along its length at 58 so that an upper portion 60 of post 52 is of diameter larger than the holes in the pet tags 36. When the pet tags 36 are placed on the upper end of posts 52 and pressed downward the conical area 56 forces the two halves of post 52 together so the tag may slip over the portion 60. As the tag is then pushed down towards the base 54, the post reopens and thereby holds the tag on the post 52 in a positive manner. This retaining arrangement is intended only as a safety feature to act in addition to the spring arms 14 or 48.
With reference now to FIG. 5 post 62 is illustrated as an alternate to posts 24 or 44. Post 62 has a constant diameter along most of its length and is generally small enough to fit within the holes in pet tags 36. Ears 64 are provided on two sides of post 62 at its upper end and are of sufficient size to prevent a tag carried on post 62 from being easily lifted therefrom. Post 62 is bifurcated, having a slot 66 extending from the upper end to a point near the lower end of post 62. Pet tags 36 may be installed on or removed from the posts 62 by forcing the ears 64 toward each other thereby closing the slot 66 and reducing the diameter of the upper end to the point where it will fit through the holes in the tags. Once installed, the post 62 springs back to the shape illustrated in FIG. 5 so that the ears 64 prevent a tag from falling from post 62. This tag retaining arrangement is again intended to be only a safety feature to prevent loss of tags 36 should they in some manner work free from the spring arms 14 or 48. As with post 52 the post 62 is preferably made from plastic and preferably molded integrally with a base member, such as plate 40.
Various modifications in the apparatus of the present invention will be apparent to those skilled in the art. For example in the FIG. 1 embodiment it may be desireable to anchor post 24 to the base 12 by means of end 32 of the retaining arm 31. The lower end of post 24 would then be fitted within a recess in the base 12 and held there by a spring tension in the arm 31. With such an arrangement the tags 36 could be installed in the position illustrated in FIG. 2 by simply slipping upwards between the base 12 and arms 14 while the spring arm 31 is lifted to take the post 24 out of engagement with the base 12. Then the tags 36 would be positioned to align the tag holes with the recess in base 12 and the arm 31 would be released so that the post 24 would drop through the pet tags and lock into the base 12. With this arrangement the post 24 could be somewhat shorter since the tags 36 would not need to be rotated after being positioned on the spring arm 31. Various other modifications and changes to the present invention can be made within the scope of the appended claims.
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A holder for supporting a pair of pet tags while preventing rattling therebetween comprising an elongated base member having means at one end for connection to a pet collar and carrying a post on a second end for engaging a hole in pet tags. A pair of spring arms are carried by the base member and have free ends spaced in opposition about the post to urge the tags against the base member to thereby prevent rattling. In a preferred form the base member comprises a flat plate having dimensions comparable to a pet tag and providing a surface for carrying identifying indicia.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present application relates generally to a tool for applying torque to an object. More particularly, the present application relates to a roller clutch mechanism for a reversible ratchet-type tool.
BACKGROUND OF THE INVENTION
[0002] Reversible ratchet tools, such as socket wrenches and drivers, are commonly used in automotive, industrial and household applications to install and remove threaded fasteners and to apply an amount of torque and/or angular displacement to work pieces, such as a threaded fasteners, for example. Various mechanisms within ratchet tools are configured to prevent rotation of a ratchet drive head relative to the tool handle in one direction and to allow rotation of the ratchet head relative to the tool handle in the opposite direction. This allows the drive head to apply torque to a fastener through large angles by repeating smaller angular movements of the tool handle and without disengaging the tool head from the fastener after each movement. For conventional ratchet tools, the smaller angular movements on each stroke must reach at least a minimum angular displacement to overcome backlash and cumulative dimensional variations of the tool components within manufacturing tolerances. Backing the handle of a ratchet tool through some minimum angular displacement after each movement provides sufficient rotation of the ratchet body relative to a drive member to overcome the backlash and dimensional variations to configure the tool for applying a torque on a following movement.
[0003] Ratchet tools which require an excessive angular displacement of the handle may not be usable in confined spaces. It is thus desirable to reduce or eliminate the minimum angular displacement constraint, i.e., ratchet angle, of conventional ratchet tools in order to allow use of the tool in locations where angular displacements of the handle may be obstructed.
SUMMARY OF THE INVENTION
[0004] Aspects of the present application include a roller clutch mechanism of a reversible ratchet tool that reduces relative rotation between the ratchet body and a drive head. The reversible ratchet tool includes a biasing and reversing mechanism for a roller clutch. A cage member of the roller clutch mechanism locates rollers in either a clockwise or counterclockwise position based on a position of the reversing mechanism. The reverser mechanism applies a constant bias to the cage member so that the rollers are biased to quickly engage between the ratchet body and the drive head. The constant bias applied to the cage member reduces the ratcheting angle for improved performance of the reversible ratchet tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated.
[0006] FIG. 1A is a front, perspective exploded view illustrating a reversible ratchet apparatus in accordance with an embodiment of the present application.
[0007] FIG. 1B is a rear, perspective exploded view illustrating a reversible ratchet apparatus in accordance with an embodiment of the present application.
[0008] FIG. 2 is an enlarged plan view illustrating rollers binding between a drive member an a ratchet body according to an aspect of the present application.
[0009] FIG. 3A is a plan view of a reversible ratchet apparatus configured to apply torque in a first direction according to an aspect of the present disclosure.
[0010] FIG. 3B is a plan view of the reversible ratchet apparatus of FIG. 3A configured to apply torque in a second direction according to an aspect of the present disclosure.
[0011] FIG. 4 is a plan view of biasing members engaged between a reverser sleeve and a cage member in a reversible ratchet apparatus according to aspects of the present disclosure.
[0012] FIG. 5 is a flow chart depicting a method of configuring a ratchet drive according to aspects of the present disclosure.
[0013] It should be understood that the comments included in the notes as well as the materials, dimensions and tolerances discussed therein are simply proposals such that one skilled in the art would be able to modify the proposals within the scope of the present application.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings, and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present application is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated.
[0015] An illustrative embodiment of a reversible ratchet tool according to aspects of the present disclosure is described with reference to FIGS. 1A and 1B . In an embodiment, a reversible ratchet tool 100 includes a ratchet body 102 , a cage member 108 sized to fit and disposed within the ratchet body 102 , a reverser sleeve 116 sized to fit coaxially disposed within the cage member 108 , and a drive member 104 including an axle portion 105 sized to be rotatably contained by the reverser sleeve 116 . A number of rollers 106 are constrained by the cage member 108 between an inner surface 118 of the ratchet body 102 and the drive member 104 . According to an aspect of the present disclosure, the drive member 104 and the reverser sleeve 116 are selectively constrained in either of a first angular displacement or a second angular displacement relative to each other. At least one biasing member 110 is configured to exert a substantially continuous rotational biasing force between the reverser sleeve 116 and the cage member 108 .
[0016] In one example, the biasing member 110 may consist of a pair of compression springs 110 , 111 as shown in FIGS. 1A and 1B . According to an aspect of the present disclosure, the cage member 108 is configured to shift the rollers 106 from a corresponding first position on the drive member 104 to a corresponding second position on the drive member 104 when an angular displacement between the drive member 104 and the reverser sleeve 116 is shifted from the first angular displacement to the second angular displacement. A reverser lever (not shown) may be coupled to the reverser sleeve 116 or may be formed together with the reverser sleeve 116 as a single component, for example.
[0017] The rollers 106 are cylindrically shaped and sized to selectively prevent relative motion between the ratchet body 102 and the drive member 104 only in a first direction of rotation when the rollers are in their corresponding first positions, and to prevent relative motion between the ratchet body 102 and the drive member 104 only in a second direction of rotation opposite the first direction of rotation when the at rollers are in the corresponding second positions.
[0018] According to aspects of the present disclosure, the ratchet body 102 includes an inner surface 118 defining an inner wall of a circular aperture 120 . In the illustrative embodiment, the cage member 108 includes an annular base 122 and a plurality of axial fingers 124 extending from one side of the annular base 122 . The annular base 122 is sized to fit and be coaxially disposed within the circular aperture 120 , wherein the fingers 124 substantially avoids contact with the inner surface 118 , to cooperatively define a cage aperture 126 . In this embodiment, a tab 134 extends radially from the annular base into the cage aperture 126 .
[0019] In an illustrative embodiment, the reverser sleeve 116 is a semi-annular reverser sleeve including an outer semi-annular wall 128 sized to fit coaxially within the cage aperture 126 and including an inner semi-annular wall 130 defining a first portion of a central aperture 132 . The reverser tab 134 defines a second portion of the central aperture 132 having a same diameter as the first portion of the central aperture 132 . In one example, according to an aspect of the present disclosure, the semi-annular reverser sleeve 116 includes a first end 136 and a second end 138 . A first biasing member 110 is engaged between the first end 136 and the tab 134 . A second biasing member 111 is engaged between the second end 138 and the tab 134 .
[0020] In the illustrative embodiment, the drive member 104 includes the axle portion 105 sized to be rotatably contained by the central aperture 132 and a drive body coaxial with the axle portion. According to an aspect of the present disclosure, the drive body 140 includes a scalloped outer surface 142 . The drive member 104 may also include a drive lug 144 extending from the drive body 104 and coaxial with the axle portion 105 . In one example, the drive lug 144 may be configured as a square socket drive. In other embodiments, the drive lug 144 may be any of various commonly known ratchet drive configurations, such as a screw driver head, for example. Other embodiments may be configured with a drill chuck, box end wrench head or a socket in place of the drive shaft 144 , for example, without departing from the scope and spirit of the present application.
[0021] According to an aspect of the present disclosure, at least one engagement member is engaged between the drive member 104 and the reverser sleeve 116 . The engagement member is configured to constrain the drive member 104 and the reverser sleeve 116 in either of a first angular displacement or a second angular displacement relative to each other. For example, in the illustrative embodiment, the drive member 104 includes a shoulder 146 (see FIG. 1B ) facing the reverser sleeve 116 . The shoulder 146 includes a pocket 148 sized to retain a detent spring 112 . The reverser sleeve 116 includes at least two detent cavities 150 facing the shoulder 146 and angularly displaced from each other. The engagement member consists of a detent ball 114 sized to fit in either one of the detent cavities 150 and the detent spring 112 . The detent spring 112 is at least partially retained in the pocket 148 and compressed between the detent ball 114 and the drive member 104 .
[0022] Engagement between the ratchet body 102 , the rollers 106 and the drive member 102 is described with reference to FIG. 2 . In order for the ratchet tool 100 to apply a torque from the ratchet body 102 to the drive member 104 , the rollers 106 are frictionally wedged between the inner surface 118 of the circular aperture 120 . In the arrangement shown in FIG. 2 , the drive member 104 is allowed to freely rotate counter-clockwise with respect to the ratchet body 102 , but locks-up when rotated in a clockwise direction with respect to the ratchet body 102 , thus imparting torque from the ratchet body 102 .
[0023] According to aspects of the present disclosure, the rollers 106 are each constrained between a corresponding pair of fingers 124 of the cage member 108 . The rollers 106 are also constrained between the inner surface 118 of the circular aperture 120 and the scalloped surface 142 of the drive member 104 . The fingers 124 are configured to shift the rollers 106 from a corresponding first ramp 152 on the scalloped surface to a corresponding second ramp 154 on the scalloped surface when an angular displacement between the drive member 104 and the semi-annular reverser sleeve 116 is shifted from the first angular displacement to the second angular displacement. The fingers 124 of the cage member 108 keep each roller 106 in contact with the inner surface 118 and with either the corresponding first ramp 152 or the corresponding second ramp 154 .
[0024] According to an aspect of the present disclosure, the rollers 106 are sized to respectively bind between the first ramps 152 and the inner surface 118 of the ratchet body 102 to prevent relative motion between the ratchet body 102 and the drive member 104 only in a first direction of rotation when the rollers 106 respectively engage and bind the corresponding first ramps 152 , and to respectively bind between the second ramps 154 and the inner surface 118 of the ratchet body 102 to prevent relative motion between the ratchet body 102 and the drive member 104 only in a second direction of rotation opposite the first direction of rotation when the rollers 106 respectively engage and bind the corresponding second ramp 154 .
[0025] To reverse the free-spinning and driving directions of the roller clutch mechanism in the reversible ratchet tool 100 , the cage member 108 is rotated clockwise with respect to the drive member 104 so fingers 124 keep the rollers 106 in contact with the inner surface 118 of the ratchet body 102 and the second ramp 154 .
[0026] FIG. 3A is an illustration of a reversible ratchet apparatus 100 configured to apply torque in a first direction according to an aspect of the present disclosure. As shown in FIG. 3A , the drive member 104 is prevented from rotating clockwise with respect to the ratchet body 102 . Thus, torque may be transmitted from the ratchet body 102 to the drive member 104 by counterclockwise motion of the ratchet body.
[0027] FIG. 3B is an illustration of a reversible ratchet apparatus 100 configured to apply torque in a second direction according to an aspect of the present disclosure. As shown in FIG. 3B , the drive member 104 is prevented from rotating counterclockwise with respect to the ratchet body 102 . Thus, torque may be transmitted from the ratchet body 102 to the drive member 104 by clockwise motion of the ratchet body.
[0028] FIG. 4 is an illustration of the reversible ratchet apparatus 100 showing biasing members 110 , 111 engaged between a reverser sleeve 116 and a cage member 108 according to aspects of the present disclosure. In FIG. 4 , the drive member 104 is hidden for clarity.
[0029] Although a reverse lever could be coupled in direct contact with the cage member 108 to facilitate selectively switching between the two cage positions, normal manufacturing tolerances would lead to a “sloppy” action with an unacceptable amount of handle travel between ratcheting strokes. In the disclosed embodiments, a bias member 110 , 111 , such as a spring, is configured to provide a continuous rotational bias between the reverser sleeve 116 and cage member 108 .
[0030] The reverser sleeve 116 may be selectively engaged in one of two detent positions defined by the detent ball 114 and detent spring 112 being disposed in either of the two detent cavities 150 in the reverser sleeve 116 . The biasing members 111 , 110 push against the reverser sleeve 116 and cage member 108 to provide positive pressure between fingers 124 of the cage member 108 and rollers 106 . This reduces or minimizes excessive free movement or “slop” in the ratcheting action.
[0031] Another aspect of the present disclosure includes a method for reducing backlash in a reversible ratchet tool. Referring to FIG. 5 , in block 502 , the method includes configuring a circular array of rollers within a circular roller cage member for rotation around an axis within a ratchet body. In block 504 , the method includes configuring a semi-annular reverser sleeve within the ratchet body for rotation around the axis. In block 506 , the method includes configuring at least one biasing member to exert a continuous rotational biasing force between the reverser sleeve and the cage member and about the axis. At block 508 , the method includes configuring the semi-annular reverser sleeve in one of two positions angularly displaced from each other about the axis. At block 510 , the method includes configuring a drive member within the reverser sleeve for rotation about the axis. At block 512 , the method includes engaging the semi-annular reverser sleeve to a drive member to prevent relative angular displacement between the semi-annular reverser sleeve and the drive member.
[0032] As used herein, the term “coupled” or “communicably coupled” can mean any physical, electrical, magnetic, or other connection, either direct or indirect, between two parties. The term “coupled” is not limited to a fixed direct coupling between two entities.
[0033] The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants′ contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A roller clutch mechanism of a reversible ratchet tool is configured to include a biasing and reversing mechanism for biasing rollers in the roller clutch mechanism. A cage member of the roller clutch mechanism locates rollers in either a clockwise or counterclockwise position based on a selective position of the reverser mechanism. The reverser mechanism applies a constant bias to the cage member so that the rollers are constantly biased and quickly engage between the ratchet body and the drive head. The constant bias applied to the cage member reduces the ratcheting angle for improved performance of the reversible ratchet tool.
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CROSS-REFERENCE TO PRIOR APPLICATION
This application claims priority to Swedish Application No. 0900847-5 filed Jun. 23, 2009, which is incorporated by reference herein.
TECHNICAL FIELD
This disclosure relates to a drilling tool intended for chip removing machining and of the type that includes a basic body having front and rear ends, between which a first center axis extends around which the basic body is rotatable in a given direction of rotation. Further, the drilling tool includes a loose top having front and rear ends, between which a second centre axis extends. The front end of the loose top includes one or more cutting edges. The front end of the basic body includes a jaw between two axially protruding, peripherally situated branches that are elastically bendable and have the purpose of resiliently clamping the loose top in the jaw. Specifically, a pair of inner support surfaces of the branches resiliently presses against a pair of external side contact surfaces of the loose top. Further, the branches have the purpose of transferring torque to the loose top via tangential support surfaces of the branches and cooperating tangential contact surfaces of the loose top. The inner support surface of the individual branch extends between first and second, tangentially separated side borderlines. The first tangentially separated borderline is heading and the second tangentially separated borderline is trailing during rotation of the tool. The individual side contact surface extends between first and second side borderlines. The second side borderline is rotationally trailing and is included in an edge to a trailing part surface, besides which the loose top is axially insertable into the jaw and turnable into and out of an operative engagement with the branches.
Drilling tools of the kind in question are suitable for chip removing or cutting machining, especially hole making of workpieces of metal, such as steel, cast iron, aluminium, titanium, yellow metals, etc. The tools may also be used for the machining of composite materials of different types.
BACKGROUND ART
In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art.
Drilling tools have been developed that, contrary to solid drills, are composed of two parts, including a basic or drill body and a head detachably connected with the same and thereby being replaceable. The head includes the requisite cutting edges. In such a way, the major part of the tool can be manufactured from a comparatively inexpensive material having a moderate modulus of elasticity, such as steel, while a smaller part, the head, can be manufactured from a harder and more expensive material, such as cemented carbide, cermet, ceramics and the like, which gives the cutting edges a good chip-removing capacity, a good machining precision and a long service life. The head forms a wear part that can be discarded after wear-out, while the basic body can be re-used several times, for example, 10 to 20 replacements. A now recognized term for these cutting edge-carrying heads is “loose tops”, which henceforth will be used in this document.
Loose top type drilling tools have a plurality of desired capabilities, one of which is that torque should be transferable in a reliable way from the rotatable, driven basic body to the loose top. Furthermore, the basic body should without problems be able to carry the rearwardly directed axial forces that the loose top is subjected to during drilling. Further, the loose top should be held centered in an exact and reliable way in relation to the basic body. Also, the loose top is clamped to the basic body not only during drilling of a hole, but also during retraction of the drilling tool out of the same. A user further desires that the loose top should be mountable and dismountable in a rapid and convenient way without the basic body necessarily having to be removed from the driving machine. In addition, the tool, and in particular the loose top manufactured from expensive materials, should be capable of low cost manufacture.
A loose-top tool intended for drilling and of the initially generally mentioned kind is previously known by EP 1013367. In this case, the two branches of the basic body are arranged to be turned into arched pockets, which are recessed in the rear part of convex envelope surfaces of two bars included in the loose top and separated by chip flutes, and which have a limited axial extension that in turn limits the maximally possible length of the branches. The internal support surfaces of the branches and the external side contact surfaces of the loose top, which are pressed against each other in order to resiliently and securely pinch the loose top in the jaw between the branches, have a rotationally symmetrical basic shape. The external side contact surfaces of the loose top generally have a larger diametrical dimension than the inner support surfaces of the branches in order to bend out the branches elastically or resiliently. In their angle-wise end position of turning, the rotationally heading, torque-transferring tangential support surfaces of the branches should be pressed into close contact against two tangential contact surfaces that form end surfaces in the two pockets in the loose top.
The tool of EP 1013367 is meritorious in several respects, one of which is that the axial support surface that is situated between the branches and forms a bottom in the jaw of the basic body does not need to be intersected by any slot or cavity in which chips could get caught. Another merit is that the loose top can be made fairly short in relation to its diameter, something that is material-saving and cost-reducing. In addition, the axial contact surface of the loose top as well as the axial support surface of the basic body extends between ends that are peripherally situated. In such a way, these surfaces become ample and thereby suitable to transfer great axial forces.
A disadvantage of the known tool is, however, that the mounting of the loose top in the jaw of the basic body risks becoming unreliable and cumbersome to carry out. Already when the two branches initially begin to be turned into the appurtenant pockets in the loose top, the branches are subjected to a clamping force that from then on becomes equally great during the entire rotary motion up to the end position in which the branches are pressed against the end surfaces of the pockets. Because the mounting is carried out in a manual way and the branches are held resiliently clamped against the side contact surfaces of the loose top by a force that is equally great during the entire rotary motion, it may become difficult for the operator to determine whether the loose top has reached its end position or not. This decision is made more difficult by the fact that the uniform clamping force has to be fairly great in order for the loose top to be clamped reasonably reliably. This means that the work with the turning-in becomes laborious, and therefore the operator, particularly when in a hurry, may unintentionally finish the turning-in too early, before the loose top has reached its end position in the jaw. Incorrect mounting of the loose top may, among other things, manifest itself in lost centering of the drilling tool in connection with the entering of a workpiece.
SUMMARY
The present disclosure aims at obviating the above-mentioned disadvantages of the known drilling tool and at providing an improved drilling tool. An object is accordingly to provide a drilling tool, in which the loose top and the cooperating jaw of the basic body are formed in such a way that the operator, in a tactile and/or auditory way, clearly perceives when the loose top reaches its end position during the turning-in. Another object is to provide a drilling tool, the loose top of which can be turned into the jaw of the basic body without the branches constantly subjecting the loose top to a great clamping force and thereby a great, uniform resistance during the entire turning-in operation. Still another object is to provide a drilling tool, the loose top of which is held reliably clamped in the jaw of the basic body, for example, by utilizing the inherent elasticity of the branches in such a way that an optimal grip on the loose top is provided. A further object is to provide a drilling tool, the loose top of which has a minimal length, and thereby a minimal volume, in relation to its diameter, all with the purpose of reducing the consumption of expensive material to a minimum in connection with the manufacture of the loose top. It is also an object to provide a drilling tool where the basic body can transfer great torques to the loose top. Still another object is to provide a drilling tool in which the loose top is centered and retains its centricity in an accurate way in relation to the basic body.
An aspect of the invention provides a drilling tool for chip removing machining, including a basic body having front and rear ends, between which a first center axis extends around which the basic body is rotatable in a given direction of rotation, and a loose top having front and rear ends, between which a second center axis extends, the front end including one or more cutting edges. The front end of the basic body comprises a jaw between two axially protruding, peripherally situated branches that are elastically bendable. The branches are capable of resiliently clamping the loose top in the jaw by inner support surfaces of the branches being resiliently pressed against external side contact surfaces of the loose top, and capable of transferring torque to the loose top via tangential support surfaces of the branches and cooperating tangential contact surfaces of the loose top. The inner support surface of the individual branch extends between first and second tangentially separated side borderlines, the first tangentially separated side borderline is heading and the second tangentially separated side borderline is trailing during rotation of the tool. The individual side contact surface extends between first and second side borderlines, the second side borderline that is rotationally trailing is included in an edge to a trailing part surface, besides which the loose top is axially insertable into the jaw and turnable into and out of an operative engagement with the branches. A second imaginary diametrical line, which extends perpendicular to the second center axis of the loose top between abutting edges that abut the second side borderline of each of the two side contact surfaces, has a length that is greater than the length of an analogous first diametrical line, which extends the shortest possible distance between the inner support surfaces when the branches are unloaded, and has opposite end points located at tangential distances from the first tangentially separated side borderline and the second tangentially separated side borderline of the respective inner support surface.
The side contact surfaces of the loose top with edges, in combination with a suitably selected distance between the inner support surfaces of the branches, upon the turning-in provides a successively increasing deflection of the branches up to a predetermined dead or intermediate position. At the predetermined dead or intermediate position the clamping force is maximal, so as to then decrease during the continued turning a short distance further until the end position is reached. During the final phase of the rotary motion between the dead position and the end position, the clamping force in the branches assists in rapidly bringing the loose top to the end position. This may manifest itself in either a tactile perception in the fingers of the operator or a click sound being audible to the ear, or a combination of these manifestations.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
Particular embodiments of the invention will be described in more detail below, reference being made to the appended drawings, on which:
FIG. 1 is a sectioned perspective view showing the basic body and loose top of an embodiment of the drilling tool in the composed state,
FIG. 2 is an exploded perspective view showing the drilling tool of FIG. 1 where the loose top is separated from the basic body,
FIG. 3 is an enlarged exploded view showing the drilling tool of FIG. 1 where the loose top is shown in a bottom perspective view and the front end of the basic body is shown in a top perspective view,
FIG. 4 is an exploded view showing the basic body and the loose top of FIG. 1 in side elevation,
FIG. 5 is an end view V-V in FIG. 4 showing the front end of the loose top,
FIG. 6 is an end view VI-VI in FIG. 4 showing the basic body from the front,
FIG. 7 is an end view VII-VII in FIG. 4 showing the loose top from behind,
FIG. 8 is an enlarged side view of the loose top of FIG. 1 ,
FIG. 9 is a cross section IX-IX in FIG. 8 ,
FIG. 10 is a partial perspective view showing the loose top of FIG. 1 inserted into the jaw of the basic body of FIG. 1 in a state when the turning-in of the same is to be started,
FIG. 11 is a section XI-XI in FIG. 4 ,
FIG. 12 is a cross section XII-XII in FIG. 4 ,
FIGS. 13-16 are a series of pictures showing the different positions of the loose top of FIG. 1 in connection with the turning-in of the same into the jaw of the basic body,
FIG. 17 is a cross section XVII-XVII in FIG. 4 , the loose top being shown in an intermediate position between the branches,
FIG. 18 is a cross section corresponding to FIG. 17 in which the loose top is shown in its end position of turning,
FIG. 19 is an extremely enlarged, schematic picture showing different positions of the edge of the loose top of FIG. 1 that bends out a cooperating branch,
FIG. 20 is an enlarged perspective view of the jaw of the basic body of FIG. 1 ,
FIG. 21 is a perspective exploded view illustrating an alternative embodiment of the invention,
FIG. 22 is a cross section showing the loose top according to FIG. 21 in an initial position before turning-in into the jaw of the basic body, and
FIG. 23 is a cross section showing the loose top according to FIG. 21 in its turned-in, operative position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description and the claims, a number of cooperating pairs of surfaces of the basic body and the loose top, respectively, will be described. When these surfaces are present on the basic body, the surfaces are denominated “support surfaces”, while the corresponding surfaces of the loose top are denominated “contact surfaces” (for example, “axial support surface” and “axial contact surface”, respectively). Furthermore, it should be pointed out that the loose top includes a rear end in the form of a plane surface, which in the example serves as an axial contact surface for pressing against an axial support surface in the basic body. Depending on the context, this surface will be denominated either “rear end” or “axial contact surface”. Furthermore, an inner support surface of a branch and a side contact surface of the loose top are defined by a pair of side borderlines, one of which moves ahead of the other one during rotation. The borderlines are denominated “heading” and “trailing”, respectively, in order not to be mistaken for the concepts “front” and “rear”. In the drawings, the cooperating surfaces contacting each other in the operative state of the drilling tool are shown by similar surface patterns.
The drilling tool shown in FIGS. 1 and 2 is in the form of a so-called twist drill and includes a basic body 1 as well as a loose top 2 in which the requisite cutting edges 3 are included. In its composed, operative state according to FIG. 1 , the drilling tool is rotatable around a center axis indicated by C, more precisely in the direction of rotation R.
In FIG. 2 , it is seen that the basic body 1 includes front and rear ends 4 , 5 , between which a centre axis C 1 specific to the basic body extends. In the backward direction from the front end 4 , a cylindrical envelope surface 6 extends, in which two chip flutes 7 are countersunk that in this embodiment are helicoidal, but that also could be straight as in tap borers. In the example, the chip flutes 7 end in the vicinity of a collar 8 included in a rear part 9 that is intended to be attached to a driving machine (not shown).
Also the loose top 2 includes front and rear ends 10 , 111 and a center axis C 2 with which two parts 12 of an envelope surface are concentric. The envelope part surfaces 12 are separated by two helicoidal chip flute sections 13 (see also FIG. 3 ), which form extensions of the chip flutes 7 of the basic body 1 when the loose top is mounted onto the basic body. If the loose top 2 is centered correctly in relation to the basic body 1 , the individual centre axes C 1 and C 2 coincide with the centre axis C of the composed drilling tool.
Reference is now made to FIG. 3 and other drawing figures. In FIG. 3 , it is seen that the basic body 1 in the front end thereof includes a jaw 14 that is delimited between two identical branches or shanks 15 and an intermediate bottom that forms an axial support surface 16 for the loose top. Each branch 15 includes an inner support surface 17 that extends axially rearward from a front end surface 18 of the branch. Furthermore, the individual branch 15 includes a tangential support surface 19 that is facing forward in the direction of rotation, and thus is heading. An opposite, trailing tangential support surface 20 a is included as a front part of the concave surface 20 that is present between two helicoidal borderlines 21 , 22 and delimits the chip flute 7 . In a known way, the individual branch 15 is elastically bendable to be resiliently clampable against the loose top 2 . This is realized by the fact that the material in at least the front portion of the basic body 1 has a certain inherent elasticity, for example, lower modulus of elasticity than the material in the loose top 2 . The material in at least the front portion can include steel. The material in the loose top may, in a traditional way, include cemented carbide, which is hard carbide particles in a binder metal, cermet, ceramics or the like. Advantageously, the axial support surface 16 is plane and extends perpendicular to the center axis C 1 . In addition, the axial support surface 16 extends diametrically between the two part surfaces that together form the envelope surface 6 . Generally the axial support surface has a §-like contour shape.
As is further seen in FIG. 3 , the rear end of the loose top is represented by an axial contact surface 11 that, like the axial support surface 16 , can be plane and extends perpendicular to the center axis C 2 . The axial contact surface 11 extends between diametrically opposed envelope part surfaces 12 and has a §-like contour shape. Furthermore, the loose top 2 includes a pair of external, diametrically opposed side contact surfaces 23 , against which the inner support surfaces 17 of the branches can be resiliently clamped. In certain embodiments, the contour shape of the surfaces 11 and 16 is identical, whereby complete surface contact is established in the operative state of the tool.
The front end 10 of the loose top 2 , in which the cutting edges 3 are included, is represented by an end surface that is composed of a plurality of part surfaces (see FIGS. 5 and 8 ), which in this embodiment are identical in pairs and therefore not described individually. Behind the individual cutting edge 3 , as viewed in the direction of rotation, a primary clearance surface 24 is formed, which has a moderate clearance angle and transforms into a secondary clearance surface 25 having a greater clearance angle, via a borderline 26 . Via an additional borderline 27 , the secondary clearance surface 25 transforms into a third clearance surface 28 , which in turn, via an arched borderline 29 , transforms into a chip flute 13 . As may be best seen in FIG. 8 , the concave surface 30 that delimits the chip flute section 13 extends partly up to the individual cutting edge 3 and forms a chip surface for the cutting edge 3 . In the chip surface of the cutting edge, also a convex part surface 31 is included. The design of the front end of the loose top may be modified in miscellaneous ways and is therefore incidental provided that the loose top can carry out chip removing machining.
Furthermore, it should be observed that adjacent to the envelope part surface 12 , a guide pad 32 (see FIGS. 3 and 5 ) is formed, the main task of which is to guide the drilling tool. The diameter of the drilled hole is determined by the diametrical distance between the peripheral points 33 where the cutting edges 3 meet the guide pads 32 . Also the two cutting edges 3 converge into a tip 34 , which forms the very foremost part of the loose top, and in which there may be included a so-called chisel edge and a minimal centering punch (lack designations).
Reference is now made to FIG. 8 , from which it is seen that the individual side contact surface 23 of the loose top 2 is laterally delimited between first and second side borderlines 35 , 36 , the first side borderline 35 is heading and the second side borderline 36 is trailing during rotation of the tool. Rearward (downward in the drawing), the side contact surface 23 is delimited by a transverse, rear borderline 37 , while its front limitation includes two oblique borderlines 38 , 39 , the first oblique borderline borders on the secondary clearance surface 25 and the second oblique borderline borders on the third clearance surface 28 . The second side borderline 36 is included in (or forms) an edge, designated 40 , that constitutes a transition between the side contact surface 23 and a rotationally trailing part surface 41 . Although it is feasible to form the edge 40 sharp, most embodiments manufacture the edge 40 as a radius transition, including, for example a convexly rounded, long narrow surface in the transition between the side contact surface 23 and trailing part surface 41 . Also, the trailing part surface 41 in this embodiment is wedge-shaped and borders on the trailing chip flute surface 30 . In particular, the trailing part surface 41 is delimited between the edge 40 and an acute borderline 42 that forms an acute angle with the edge 40 . The edge 40 and the acute borderline 42 diverge in the backward direction.
At the first side borderline 35 thereof, the side contact surface 23 transforms into a concave recess surface 43 that in turn borders on a tangential contact surface 44 (see FIG. 3 ), against which the individual branch 15 is pressed, in order to transfer torque to the loose top.
In the illustrated embodiment, the side contact surfaces 23 , like the inner support surfaces 17 of the branches 15 , are essentially plane. As is further seen from the cross section in FIG. 9 , the two opposite side contact surfaces 23 of the loose top 2 diverge at a certain angle α in the direction from the rear end toward the front end. In the reference plane RP 1 , which is situated on a level with the front end 40 a of the edge 40 , the loose top has accordingly a width W 1 that is somewhat greater than the width W 2 in the reference plane RP 2 , which is situated on a level with the rear borderline 37 of the side contact surface. The difference between the width measures W 1 and W 2 can be very moderate, where the angle of divergence α is small. In the illustrated embodiment, W 1 is about 8.00 mm and W 2 is about 7.97 mm, the angle α is about 0.86° (α/2=0.43°). Although this angle of divergence is diminutive, the angle is, however, fully sufficient for bending out the branches 15 so much that the branches subject the loose top to a considerable clamping force.
In this connection, it should be pointed out that the angle of divergence α may vary upward as well as downward from about 0.86°. However, the angle of divergence α should amount to at least about 0.20° and at most about 2°. In certain embodiments, the angle of divergence α should be within the range of 0.60-1.20°. The size of the angle α depends on the axial length of the inner support surface 17 and side contact surface 23 . Specifically, the angle should be adapted to the length of the surfaces in such a way that surface contact is attained in the operative state of the loose top.
Because the side contact surfaces 23 diverge in the way described above, the front end 40 a of the edge 40 is located at a greater radial distance from the center axis C 2 of the loose top than the rear end 40 b of the edge 40 . In other words, the front end 40 a will first contact the inner support surface 17 of the individual branch in connection with the turning-in of the loose top into the jaw 14 . Also, the edge 40 in this embodiment is straight.
Reference is now made to FIG. 20 , which shows that the inner support surface 17 of the individual branch 15 , like the cooperating side contact surface 23 of the loose top, is delimited between first and second side borderlines 51 , 52 . The first borderline 51 is heading and the second borderline 52 is trailing during rotation. Between the inner support surface 17 and the tangential support surface 19 , there is a concave clearance surface 53 having a radius that is greater than the radius of the recess surface 43 .
In FIG. 10 , the loose top 2 is shown in an initial position in which the loose top has been inserted axially into the jaw between the branches 15 , but has not been turned into its operative end position. In order to coarse-center or provisionally retain the loose top in a reasonably, but not exactly, centered position during the subsequent turning-in, the rear part of the loose top and the inner parts of the branches are formed with cooperating guide surfaces. Each side contact surface 23 (see FIGS. 3 and 4 ) transforms into a convex guide surface 45 being axially behind via an intermediate surface 46 . Between the guide surface 45 and the axial contact surface 11 of the loose top, a clearance surface 47 is present. As is seen in FIG. 7 , the two guide surfaces 45 , which are formed on diametrically opposed sides of a central portion of the loose top, have a rotationally symmetrical shape. The surfaces follow a circle S 2 , the diameter of which is designated D 2 . The circle S 2 , and thereby also the surfaces 45 , are concentric with the centre axis C 2 of the loose top. In the illustrated embodiment, the surfaces 45 are cylindrical, although they could also be conical.
As is seen in FIG. 3 , in combination with FIGS. 6 and 20 , the two branches 15 are, at the rear ends thereof, formed with a pair of concave, internal guide surfaces 48 , which cooperate with the convex, external guide surfaces 45 of the loose top. Each such guide surface 48 transforms into an inner support surface 17 via an intermediate surface 49 , which is inclined in the inward/rearward direction from the inner support surface 17 . Also the two internal guide surfaces 48 are cylindrical, or alternatively conical, and are defined by an imaginary circle S 1 (see FIG. 6 ), the diameter of which is designated D 1 . The diameter D 1 of the circle S 1 is somewhat greater than the diameter D 2 of the circle S 2 , which means that the guide surfaces 45 , 48 do not contact each other when the loose top is operatively clamped in the jaw of the basic body. The difference in diameter may in practice amount to one or a few tenth of a millimeter. However, it is guaranteed that the loose top is coarse centered and retains an approximate intermediate position between the branches during the turning-in that is carried out from the initial position shown in FIG. 10 . The fact that the diameters D 1 and D 2 are differently great means that the guide surfaces 45 , 48 do not impose requirements of dimensional accuracy in connection with the manufacture.
The guide surface 45 (see FIG. 8 ) is partially displaced in the tangential direction in relation to the side contact surface 23 , in such a way that the borderline 45 a to the chip flute 13 is displaced rearward in the direction of rotation R in relation to the limiting edge 40 of the side contact surface, which is toward the left in FIG. 8 . During the turning-in of the loose top in the turning direction V, the borderline 45 a will therefore move before the limiting edge 40 . The practical consequence of this will be that the guide surfaces 45 can start to co-operate with the guide surfaces 48 with the purpose of provisionally coarse centering the loose top already before the limiting edges 40 get in contact with the inner support surfaces 17 of the branches 15 .
Reference is now made to FIG. 11 , in which DL 1 designates a straight, first diametrical line that intersects the centre axis C 1 and extends the shortest possible distance between the inner support surfaces 17 of the branches 15 facing each other, and forms a right angle with the inner support surfaces. The ends of this shortest possible diametrical line DL 1 are designated Ea, Eb. It is evident that any other imaginary diametrical line (lacks designation) drawn between the inner support surfaces 17 and intersecting the centre axis C 1 becomes longer than the shortest diametrical line DL 1 . This applies irrespective of whether the imaginary, longer diametrical line is turned clockwise or counter-clockwise around C 1 in relation to the diametrical line DL 1 shown in FIG. 11 .
In FIG. 12 , DL 2 designates a second, likewise straight diametrical line that extends between the edges 40 of the two opposite side contact surfaces 23 and intersects the centre axis C 2 of the loose top. The diametrical line DL 2 extends between the front end points 40 a of the edges 40 (see FIG. 8 ). The individual side contact surface 23 forms an acute angle with the diametrical line DL 2 . In the example, the angle β amounts to about 85°. In certain embodiments, the angle β amounts to at least about 75° and at most about 88°. In yet more certain embodiments, the angle amounts are within the range of 80-86°. From the enlarged detailed section in FIG. 12 , it is furthermore seen that the side contact surface 23 and the trailing part surface 41 form an obtuse angle γ with each other. In the example, γ amounts to about 152°. By the fact that the angle γ is obtuse, rather than acute, which would also be feasible, the portion of the loose top that surrounds the edge 40 will become robust and endure forces that act against the edge.
In certain embodiments, the diametrical line DL 2 is somewhat longer than the diametrical line DL 1 . Because the length difference is small, for example, some hundredths of a millimeter, and not visible to the naked eye, reference is now made to the series of pictures in FIGS. 13-16 , as well as to the enlarged, schematic picture in FIG. 19 . In FIG. 13 , the loose top 2 is shown in an initial position P 1 according to FIG. 10 . FIG. 13 shows how the loose top in this position can be freely inserted axially into the jaw by the fact that the side contact surfaces thereof have no contact with the branches 15 . In this position, the convex guide surfaces 45 of the loose top are partially located between the concave guide surfaces 48 of the branches 15 . In a first step, the loose top is turned into the position P 2 according to FIG. 14 , where the two opposite edges 40 get in contact with the inner support surfaces of the branches. After further turning, the loose top 2 reaches the position P 3 shown in FIG. 15 where the diametrical lines DL 1 and DL 2 coincide. In this position, the edges 40 have reached a dead or intermediate position, in which the clamping force of the branches 15 is maximal. From this dead position P 3 , the loose top is turned further a short distance to reach its end position P 4 according to FIG. 16 . In this position, the edges 40 have passed the dead position P 3 according to FIG. 15 , but without the spring force or tensile capacity of the branches 15 having been exhausted. In the end position P 4 according to FIG. 16 , the side contact surfaces 23 abut against the inner support surfaces 17 at the same time as the torque-transferring tangential support surfaces 19 of the branches are pressed in close contact against the tangential contact surfaces 44 of the loose top.
In FIG. 19 , the different positions of the edge 40 in relation to the individual branch 15 are illustrated more clearly. In the position P 1 according to FIG. 13 , the edge 40 lacks all contact with the inner support surface 17 of the branch. In the position P 2 , contact has been established with the inner support surface 17 . From this position and on, the edge 40 of the loose top starts to bend out the branch 15 while applying a successively increasing clamping force to the loose top. In the dead position P 3 according to FIG. 15 , the clamping force in the branch has grown to a maximum, because here, the diametrical lines DL 1 and DL 2 coincide. In order to reach its end position P 4 , the loose top is turned further a short distance clockwise around the centre axis C 1 . During the comparatively short move between the positions P 3 and P 4 , when the edge 40 has passed the dead position P 3 , the continued turning of the loose top will entirely or partly be overtaken by the branches 15 as a consequence of the fact that the clamping force in the branches now aims to bring the loose top to the end position in which it no longer can be turned further as a consequence of the fact that the pairs of surfaces 23 , 17 and 19 , 44 are held pressed in close contact against each other. Practical tests carried out using the tool have shown that the concluding turning between the positions P 3 and P 4 is followed by a pronounced tactile sensation in the fingers of the operator, and at times an audible click sound, which confirms to the operator that the loose top has reached its operative end position.
The exact centering of the loose top in relation to the basic body is initiated in the position P 2 , when the edges 40 of the loose top first get in contact with the inner support surfaces 17 of the branches 15 . As the edges are turned toward their end position P 4 , the centering will become increasingly distinct and exact as a consequence of the increasing clamping force in the branches. The branches 15 retain an ample clamping force in the end position P 4 , even if the clamping force to a certain extent has been reduced in relation to the maximal clamping force in the position P 3 . By suitably adjusting such geometrical factors as the amount of rotary motion between P 3 and P 4 in relation to the selected difference in length between DL 1 and DL 2 , the clamping force in the operative end position can be predetermined. For instance, the clamping force in the end position P 4 can be determined to 50% of the maximal clamping force in the dead position P 3 .
In FIGS. 17 and 18 , it is illustrated how narrow, although pronounced slits 50 arise between the pairs of cooperating guide surfaces 45 , 48 of the loose top 2 and of the branches 15 , respectively, when the loose top is turned toward its operative end position.
Further, the drilling tool includes that the side contact surfaces 23 of the loose top 2 are situated near the front end 10 of the loose top, and that the corresponding inner support surfaces 17 of the branches 15 are situated far in front on the branches. Accordingly, the side contact surfaces 23 extend rearward from the two clearance surfaces 25 , 28 that are included as part surfaces in the front end 10 of the loose top. In an analogous way, the inner support surfaces 17 of the branches extend rearward from the edge lines that form transitions to the front end surfaces 18 of the branches. By this location of the side contact surfaces and the inner support surfaces, respectively, there is provided a powerful grip or pinch along the front portion of the loose top adjacent to the cutting edges, because the branches have their greatest bending capacity, and thereby their optimal gripping capacity, in the area of the free, front ends thereof rather than in the vicinity of the rear ends.
In FIG. 8 , 44 a designates the straight borderline that forms a transition between the part envelope surface 12 and the tangential contact surface 44 of the loose top (see also FIG. 3 ). Said tangential contact surface 44 is inclined in relation to the axial contact surface 11 of the loose top at an angle δ, which in the example amounts to about 76°. The tangential support surface 19 (see FIGS. 10 and 20 ) that cooperates with the individual tangential contact surface 44 is correspondingly inclined. By this inclination of the respective surfaces, a locking element is provided that, in combination with the pinching effect of the branches 15 , counteracts unintentional axial retraction of the loose top out of the jaw 14 , for example, in connection with the retraction of the drilling tool out of a drilled hole. The angle δ may vary upward as well as downward. In certain embodiments the angle amount is at least about 65° and at most about 85°.
In FIGS. 4 and 5 , it is seen that the loose top 2 includes a key grip in the form of a pair of peripherally situated notches or seats 55 .
Embodiments of the invention enable the operator to obtain an apparent confirmation of the loose top having reached its operative end position during the turning-in. Further, the resistance of the bendable branches to the turning-in is not constantly great, but maximal only during the short moment when the edges are turned past the dead position. Furthermore, the inherent elasticity of the branches assumes entirely or partly the final turning-in from the dead position to the end position during the final phase of the rotary motion. In other words, the risk that the operator, for example, when in a hurry, unintentionally fails to finish the manual turning all the way up to the absolute end position is counteracted. Additionally, the loose top is securely pinched between the front ends of the branches, where the branches are most bendable and give an optimal clamping force. Furthermore, the loose top may be given a minimal volume in relation to its diameter, whereby the consumption of expensive material in the same is reduced to a minimum. Yet further, the basic body can transfer considerable torques to the loose top because the tangential support surfaces of the branches can be given an optimized length within the scope of the available axial length of the loose top. Furthermore, the loose top can be mounted and dismounted in a simple way with use of a simple key. In addition, the two side contact surfaces of the loose top are well exposed and easy to access if the two side contact surfaces would need to be ground in order to guarantee good centering.
Reference is now made to FIGS. 21-23 , which illustrate an alternative embodiment in which the inner support surface 17 of each individual branch 15 is formed with a plurality of part surfaces or surface sections 17 a , 17 b and 17 c . The first surface section 17 a extends between the rotationally trailing borderline 52 and the surface section 17 c , which is a concave radius transition to the second surface section 17 b , which in turn connects to the borderline 51 . Via a transition surface 53 that includes three facet surfaces, the surface section 17 b transforms into the tangential support surface 19 . In the embodiment shown, the surface section 17 b has a concave, more precisely part-cylindrical shape, while the surface section 17 a is plane, or possibly slightly cambered.
Axially behind the inner support surface 17 there is, in the same way as in the previous embodiment, a cylindrical or otherwise rotationally symmetrical guide surface 48 that is included in a thickened, rear portion of the branch 15 , and is separated from the inner support surface 17 via an intermediate surface 49 .
In analogy with the inner support surface, the cooperating side contact surface 23 of the loose top 2 includes two surface sections 23 a , 23 b , the first surface section 23 a of which is rotationally trailing in relation to the second surface section 23 b . The surface section 23 a extends between a borderline 23 c to the surface section 23 b and between the edge 40 that forms a transition to the rotationally trailing part surface 41 . The surface section 23 b is convex and has the same rotationally symmetrical shape as the concave surface section 17 b of the branch 15 . In certain embodiments, the surface section 23 b has a cylindrical shape. Via the borderline 35 , the surface section 23 b transforms into the recess surface 43 , which in turn transforms into the tangential contact surface 44 . The surface section 23 a is plane, or slightly cambered, like the surface section 17 a included in the inner support surface 17 . Axially behind the two surface sections 23 a , 23 b , there is a convex, cylindrical or otherwise rotationally symmetrical guide surface for cooperation with the concave guide surface 48 .
In FIG. 22 , the loose top 2 is shown in an initial position before turning-in (P 1 ) into the jaw between the branches 15 , which is similar to the position of the first embodiment shown in FIG. 13 . The two plane surface sections 17 a that are included in the two inner support surfaces of the branches are mutually parallel. A diametrical line DL 1 that intersects the center axis C and is perpendicular to the surface sections 17 a represents the shortest distance between the surface sections 17 a . Said diametrical line DL 1 contacts the surface sections 17 a in points that are situated between their side limitations 17 c and 52 , respectively. DL 2 designates a second diametrical line that extends between the edges 40 along the surface sections 23 a that are included in the two opposite side contact surfaces 23 of the loose top. The second diametrical line DL 2 is some hundredths of a millimeter longer than the first diametrical line DL 1 . However, the radial distance between the center axis C and the edge 40 that forms an end of the diametrical line DL 2 is somewhat smaller than the radial distance between the center axis C and the concave surface section 17 b . This means that the edges 40 of the loose top will clear the concave surface sections 17 b when the turning-in of the loose top is started.
When the loose top 2 is turned in from its initial position (P 1 ) according to FIG. 22 to the operative end position (P 4 ) according to FIG. 23 , the following occurs. Initially, the edges 40 will freely pass the surface sections 17 b without affecting the branches 15 . When the edges 40 have passed the radius transitions 17 c , the edges 40 will contact the surface sections 17 a and successively start to bend out the branches. When the pair of edges 40 reaches the rotation angle position in which the diametrical lines DL 1 and DL 2 coincide with each other, which is similar to position P 3 in FIG. 15 of the first embodiment, the deflection and thereby the spring forces becomes maximal, as a dead position is passed. In this state, the convex surface section 23 b of the loose top has started to overlap the concave surface section 17 b of the inside of the individual branch 15 . From said dead position, the turning-in of the loose top continues primarily by the spring force in the branches up to the operative end position, which is shown in FIG. 23 and in which the tangential contact surfaces 44 of the loose top have been pressed against the tangential support surfaces 19 of the branches. In the final stage of the turning-in, which includes turning-in between the dead position and the end position, the convex surface sections 23 b of the loose top will be located opposite the concave surface sections 17 b . The spring force in the branches will be transferred to the loose top by surface contact between the surface sections 17 b and 23 b . Simultaneously, the plane surface sections 17 a clear somewhat from the internal, plane surface sections 23 a of the loose top. In other words, the fastening force that the branches exert will be located along an axial plane AP that extends diametrically between the surface pairs 17 b , 23 b according to FIG. 23 .
The embodiment according to FIGS. 21-23 includes an alternative type of axial locking element for the loose top that includes two seats 54 formed in the rear ends of the branches 15 and two male members 55 on the loose top. The seat 54 is, in this embodiment, a chute that is recessed in the individual branch 15 and situated between tangential support surface 19 thereof and the axial support surface 16 of the basic body. The individual male member 55 is in turn a ridge that is situated axially behind the tangential contact surface 44 of the loose top and connects to the axial contact surface 11 . In other words, the ridge 55 projects laterally in relation to the tangential contact surface 44 , the rear part thereof transforming into the axial contact surface 11 . When the loose top is turned into its operative position, the ridges 55 engage the chutes 54 without the ridges getting surface contact with the chutes. The ridges 55 are therefore activated only if the negative axial forces on the loose top overcome the spring force in the branches.
Further, the side contact surfaces of the loose top do not necessarily need to be plane. For instance, the side contact surfaces may be slightly cambered or markedly convex and arranged to cooperate with inner support surfaces that have been given a more or less markedly concave shape.
Although described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departure from the spirit and scope of the invention as defined in the appended claims.
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A drilling tool of the loose top type includes a basic body having two bendable branches having inner support surfaces that are resiliently pressable against side contact surfaces of a replaceable loose top. The mounting of the loose top is affected by turning-in from an initial position to an operative end position. An abutting edge along each side contact surface then bends out the branches and subjects the branches to a spring force that reaches a maximum in a dead position so as to then decrease somewhat up to the operative end position. During the final phase of the rotary motion, the operator obtains, in a tactile and/or auditory way, confirmation of the loose top indeed reaching its operative end position.
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This application is a continuation-in-part of Ser. No. 653,997, filed on Sept. 24, 1984, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a novel drug delivery system. More particularly, the present invention relates to a product in which a biologically active material is present in a multiphase system, i.e., (a) captured in multilamellar lipid vesicles (MLV); (b) dissolved in the solvent components of the system; and (c) in a solid crystalline or amorphous state.
Liposomes are lipid vesicles composed of membrane-like lipid layers surrounding aqueous compartments. Liposomes are widely used to encapsulate biologically active materials for a variety of purposes, but particularly they are used as drug carriers. Depending on the number of lipid layers, size, surface charge, lipid composition and methods of preparation various types of liposomes have been utilized.
Multilamellar lipid vesicles (MLV) were first described by Bangham, et al., (J. Mol. Biol. 13: 238:252, 1965). A wide variety of phospholipids form MLV on hydration. MLV are composed of a number of bimolecular lamellae interspersed with an aqueous medium. The lipids or lipophilic substances are dissolved in an organic solvent. The solvent is removed under vacuum by rotary evaporation. The lipid residue forms a film on the wall of the container. An aqueous solution generally containing electrolytes and/or hydrophilic biologically active materials are added to the film. Agitation produces larger multilamellar vesicles. Small multilamellar vesicles can be prepared by sonication or sequential filtration through filters with decreasing pore size. Small unilamellar vesicles can be prepared by more extensive sonication. An improved method of encapsulating biologically active materials in multilamellar lipid vesicles is described in U.S. Pat. No. 4,485,054.
Unilamellar vesicles consist of a single spherical lipid bilayer entrapping aqueous solution. According to their size they are referred to as small unilamellar vesicles (SUV) with a diameter of 200 to 500 Å; and large unilamellar vesicles (LUV) with a diameter of 1000 to 10,000 Å. The small lipid vesicles are restricted in terms of the aqueous space for encapsulation, and thus they have a very low encapsulation efficiency for water soluble biologically active components. The large unilamellar vesicles, on the other hand, encapsulate a high percentage of the initial aqueous phase and thus they can have a high encapsulation efficiency. Several techniques to make unilamellar vesicles have been reported. The sonication of an aqueous dispersion of phospholipid results in microvesicles (SUV) consisting of bilayer or phospholipid surrounding an aqueous space (Papahadjopoulos and Miller, Biochem. Biophys. Acta., 135: 624-238, 1968). In another technique (U.S. Pat. No. 4,089,801) a mixture of a lipid, an aqueous solution of the material to be encapsulated, and a liquid which is insoluble in water, is subjected to ultrasonication, whereby liposome precursors (aqueous globules enclosed in a monomolecular lipid layer), are formed. The lipid vesicles are then prepared by combining the first dispersion of liposome precursors with a second aqueous medium containing amphiphilic compounds, and then subjecting the mixture to centrifugation, whereby the globules are forced through the monomolecular lipid layer and forming the bimolecular lipid layer characteristic of liposomes.
Alternate methods for the preparation of small unilamellar vesicles that avoid the need of sonication are the ethanol injection technique (S. Batzri and E. D. Korn, Biochem. Biophys. Acta. 298: 1015-1019, 1973) and the ether injection technique (D. Deamer and A. D. Bangham, Biochem. Biophys. Acta. 443: 629-634, 1976). In these processes, the organic solution of lipids is rapidly injected into a buffer solution where it spontaneously forms liposomes--of the unilamellar type. The injection method is simple, rapid and gentle. However, it results in a relatively dilute preparation of lipsomes and it provides low encapsulation efficiency. Another technique for making unilamellar vesicles is the so called detergent removal method (H. G. Weder and O. Zumbuehl, in "Liposome Technology" ed. G. Gregoriadis, CRC Press Inc. Boca Raton, Fla., Vol. I, Ch. 7, pg 79-107, 1984). In this process the lipids and additives are solubilized with detergents by agitation or sonication yielding defined micelles. The detergents are then removed by dialysis.
Multilamellar vesicles can be reduced both in size and in number of lamellae by extrusion through a small orifice under pressure, e.g., in a French press. The French press (Y. Barenholz; S. Amselem and D. Lichtenberg, FEBS Lett. 99: 210-214, 1979), extrusion is done at pressures of 20,000 lbs/in at low temperature. This is a simple, reproducible, nondestruction technique with relatively high encapsulation efficiency, however it requires multilamellar liposomes as a starting point, that could be altered to oligo- or unilamellar vesicles. Large unilamellar lipid vesicles (LUV) can be prepared by the reverse phase evaporation technique (U.S. Pat. No. 4,234,871, Papahadjopoulos). This technique consists of forming a water-in-oil emulsion of (a) the lipids in an organic solvent and (b) the substances to be encapsulated in an aqueous buffer solution. Removal of the organic solvent under reduced pressure produces a mixture which can then be converted to the lipid vesicles by agitation or by dispersion in an aqueous media.
U.S. Pat. No. 4,016,100, Suzuki, et al., describes still another method of entrapping certain biologically active materials in unilamellar lipid vesicles by freezing an aqueous phospholipid dispersion of the biologically active materials and lipids. All the above liposomes, made prior to 1983, can be classified either as multilamellar or unilamallar lipid vesicles. A newer type of liposomes is referred to as multivesicular liposomes (S. Kim, M. S. Turker, E. Y. Chi, S. Sela and G. M. Martin, Biochim. Biophys. Acta 728; 339-348, 1983). The multivesicular liposomes are spherical in shape and contain internal granular structures. A lipid bilayer forms the outermost membrane and the internal space is divided up into small compartments by bilayer septrum. This type of liposomes required the following composition: an amphiphatic lipid with net neutral charge, one with negative charge, cholesterol and a triacylglycerol. The aqueous phase containing the material to be encapsulated is added to the lipid phase which is dissolved in chloroform and diethyl ether, and a lipid-in-water emulsion is prepared as the first step in preparing multivesicular liposomes. Then a sucrose solution is shaken with the water-in-lipid emulsion; when the organic solvents are evaporated liposomes with multiple compartments are formed.
For a comprehensive review of types of liposome and methods for preparing them refer to a recent publication "Liposome Technology" Ed. by G. Gregoriadis. CRC Press Inc., Boca Raton, Fla., Vol. I, II, & III 1984.
Solutions are one of the oldest type of pharmaceutical dosage forms or drug delivery systems. A true solution is defined as a mixture of two or more components that form a homogeneous molecular dispersion, i.e., a one phase system. According to the United States Pharmacopeia, Twentieth Revision (USP XX, page 1027), solutions are liquid preparations that contain one or more soluble chemical substances usually dissolved in water. Further, solutions are used for the specific therapeutic effect of the solute, either internally or externally. Id.
Suspensions are preparations of finely divided, undissolved drugs dispersed in liquid vehicles (USP XX page 1030). In this sense a suspension is a heterogenous, two-phase system. Suspensions have been used as drug delivery systems for centuries, for providing an insoluble bioactive ingredient for oral, parenteral and for the topical route of administration. In the present multicomponent, multiphase liposomal system the biologically active substance is present in the solid form dispersed in the aqueous medium both inside and outside the lipid vesicles.
Hydrogels can be any one of a wide variety of synthetic and natural hydrophilic polymers. They are used in pharmaceutical dosage formulation for various purposes, i.e., as viscosity inducing agents for suspensions and ophthalmic solutions; as protective colloids to stabilize emulsions and suspensions; as vehicles for topically applied dosage forms; as controlled-release drug delivery systems (J. D. Andrade (ed) "Hydrogels" for Medical and Related Applications: ACS Symposium, Series Nol. 31 ACS Washington, D.C., 1976). A gel is generally a semisolid system of at least two constituents, consisting of a condensed mass enclosing and interpenetrated by a liquid. The gel mass may consist of flocculles of small particles or macromolecules existing as twisted, intermingled, matted strands. The polymer units are often bound together by electrostatic, hydrogen and van der Waal forces. Gels containing water are called hydrogels, those containing organic liquid are called organogels.
The hydrophilic polymers in aqueous media exhibit "pseudoplastic flow" due to the effect of intermolecular entanglements and the binding of water molecules. When the long randomly coiled polymer chain moves, their solvation layer (water of hydration) are dragged along which increases the resistance to flow, or the viscosity of the solution. This property is often utilized in pharmaceutical formulation to increase the viscosity of the preparation. Recently the hydrogels have been disclosed as useful for a controlled drug delivery system (S. W. Kim, Pharmacy International 4: 90-91 (1983)).
PRIOR ART
A large number of liposomal preparations are known, as described above. A method for preparing liposomal preparations using contact masses such as glass beads to increase the surface area for liposome formation is described in U.S. Pat. No. 4,485,054. Several publications disclose the use of glass beads and the like to accelerate dispersion during the addition of the aqueous phase. See, e.g., U.S. Pat. No. 4,342,826; UK patent application No. 2,050,833; A. D. Bangham, et al., Methods in Membrane Biology 6 (London 1974); and A. D. Bangham, et al, Chem. Phys. Lipids 1:266 (1967).
SUMMARY OF THE INVENTION
The present invention particularly provides:
a pharmaceutical composition comprising:
(a) multilamellar lipid vesicles with a slightly water soluble biologically active compound captured therein;
(b) a saturated solution of the biologically active compound; and
(c) the biologically active compound in solid form. The present invention further provides:
(1) the composition described above wherein the vesicles, the solution, and the solid form of the biologically active compound are dispersed in a hydrocolloidal gel; and
(2) a method for preparing this latter composition comprising
(a) providing a vessel partially filled with inert, solid contact masses;
(b) providing a lipid component and the biologically active material dissolved in a suitable organic solvent within the vessel;
(c) removing the organic solvent by evaporation so as to form a thin lipid film on the inner wall of the vessel and on the surfaces of the contact masses;
(d) thereafter adding an aqueous liquid solution containing the biologically active material and possibly electrolytes and hydrocolloids to the vessel, and agitating the vessel to form an aqueous dispersion of lipid, gel and bioactive substances; and
(e) allowing the dispersion to stand essentially undisturbed for a time until the formation and dispersion of the multilamellar lipid vesicles and the hydrogen is completed.
The present invention further provides:
a method for administration of slightly water soluble biologically active compounds comprising topically applying a composition described above.
Alternatively, where the biologically active material has a melting point low enough to be fused together with the lipid components without any chemical decomposition (typically less than 100° C.) and the biologically active ingredient(s) in powder form and placed in the vessel containing the solid contact masses and fused together by rotating or shaking the vessel.
During the above procedures, a person having experience in the art of making liposomes can easily realize, that optimal results can be achieved, if various temperatures are utilized, depending on the transition temperature of the lipid component(s) and depending on the nature of the hydrogels, the efficiency of encapsulation can be favorably affected by selection of the appropriate types of lipids, the shape and size of the vessel in which the procedures are carried out, the amount and size of solid contact masses, the degree of vacuum during evaporation and the agitation and the temperature during hydration of the lipid film. A thin, even film is desired for optimal results.
Generally, dipalmitoyl phosphatidyl choline, pear shaped flasks, mild heating, (up to about 60° C.) and mild vacuum are preferred.
The present invention thus provides a liposomal product which contains a biologically active material in a higher concentration than its water and/or lipid solubility. The active material is dispersed in the product in (a) liposome encapsulated form (b) in super-saturated solution form and (c) in solid form. Further objectives of this invention are: (a) to provide a process that ensures maximum encapsulation of the biologically active material in the lipid vesicles; (b) to efficiently accommodate both lipophilic and hydrophilic substances; and (c) to provide a process of preparation which is applicable for large scale production.
A product composed of the multicomponent system of this invention is suitable for various routes of drug administration, i.e., oral, rectal, parenteral and particularly local administration to the skin, eye and mucous membranes. This multicomponent system, in which the active ingredient is present in two states, i.e., in solution and in solid form within and outside the lipid vesicles provides a unique biopharmaceutical system, where the absorption and disposition of the biologically active material can be optimized. It is especially useful for local activity because of the different rates of absorption, distribution (clearance) and metabolism, due to its various states, (i.e., in the "free" form in solution, as solid particles, in the liposome-encapsulated form, and as dissolved molecules and particles).
These and other objectives are achieved by utilizing the method for preparing multilamellar lipid vesicles described in U.S. Pat. No. 4,485,054, and is expressly incorporated herein by reference, to formulate a biologically active ingredient in a concentration above its water and lipid solubility.
The process is characterized by the following steps:
(a) providing a vessel partially filled with inert, solid contact masses;
(b) providing a lipid component and the biologically active material dissolved in a suitable organic solvent within the vessel;
(c) removing the organic solvent by evaporation so as to form a thin lipid film on the inner wall of the vessel and on the surfaces of the contact masses;
(d) thereafter adding an aqueous liquid containing the biologically active material and/or other substances to the vessel and agitating the vessel to form an aqueous dispersion of lipid and bioactive substance; and
(e) allowing the dispersion to stand essentially undisturbed for a time until the formation and dispersion of the multilamellar lipid vesicles is completed.
As noted above, the lipid film can be formed without using organic solvents if the ingredients (lipids and biologically active materials) have a melting point low enough to be fused together with the lipid components without causing thermodecomposition.
If desired the size of the lipid vesicles and solid particles can be reduced by ultrasonication. Dispersion of the lipid vesicles and the bioactive material (including the gel) can be further improved by putting the product through a homogenizer.
To manufacture the liposomal preprations of the present invention on a larger scale. The procedure described above (and in U.S. Pat. No. 4,485,054) is modified by replacing the writs action shaker with a gyro shaker and using an oven to provide the appropriate temperature environment rather than a water bath. Equipment employing a container and a shaker with gyro action could be used.
In the present invention the biologically active material is dissolved, i.e., present in a molecular state in both the aqueous media and in the lipid media. Its aqueous solution is present both within and outisde the lipid vesicles. Since the present invention contains the biologically active material also in the solid form, the solution phase should be in a saturated state.
As used in the specification and claims, the terms(a) "biologically active material", "biologically active substance" or "bioactive" ingredient mean a compound or composition which, when present in an effective amount, produces an effect in living cells or organisms. Examples of biologically active compounds used in this invention include dermatological agents, (i.e., triamcinolone acetonide, retinoic acid); antibacterial agents (e.g., ampicillin); antifungal agents (e.g., econazole base, econazole nitrate, amphotericine B); anti-convulsants (e.g., diphenylhydantoin); antihypertensive agents (e.g., minoxidil); anticancer agents (e.g., methotrexate); immunomodulators (e.g., lipophilic derivatives of muramyl dipeptide), antiviral agents (acyclovir, interferons); nonsteroidal anti-inflammatory agents (e.g., ibuprofen); and the like. By "slightly water soluble" is a solubility in water which is too low for the biologically active compound to be practically used in conventional aqueous solution formulations, i.e., the water solubility compared to the potency of the compound is too low for an effective dose to be practically administered in aqueous solution form or in other types of liposomal forms. Examples of such slightly soluble biologically active compounds are those described above.
"Hydrogel", "hydrocolloid" or "gel" means any chemical substance which exhibits the ability to swell in water, retaining a significant amount of water within its structure; it could be inorganic, e.g., bentonite or organic, e.g., methylcellulose; single or polymer compound. Any of the known lipids and lipid-like substances can be used in the present invention, both from natural or synthetic sources, such as ceramides, lecithins, phosphatidyl ethanolamines, phosphatidyl serines, cardiolipins, trilinoleins, phophatidic acid, and like compounds.
The present invention may be used as a vehicle for drug delivery for both human and veterinary purposes. By "drug" is meant any biologically active compound which is useful for human or veterinary purposes and is capable of being captured by the vesicles of this invention.
Thus, drugs which are employed in the present invention are any slightly water soluble drug capable of being captured by the lipid vesicles in some way. "Captured" includes entrapment within the enclosed lipid bilayer (either by fusing smaller vesicles around the drug or by transmission through the membrane or forming the lipid vesicles within the solution containing the drug), or (for lipophilic or ampophilic drugs) incorporation into, or binding them to, the lipid membrane itself. These drugs may be of varying degrees of lipophilicity, and their use in the present invention would be obvious to a pharmaceutical formulator skilled in the art of lipid chemistry when the properties of these vesicles are described.
Advantages of this multicomponent liposomal system are:
(a) Biologically active ingredients can be incorporated into this liposomal system in a concentration higher than their water or lipid solubility.
Consequently this system is particularly suitable for compounds with low lipid or water solubility where purely liposomal preparations can contain the ingredient only in low concentration, which may prevent proper dosing for activity of the ingredient in solution or other previously known liposomal forms.
(b) The bioactive ingredients are present in this system (i) in solution form possibly in a supersaturated state, either encapsulated in the lipid vesicle, or outside the lipid vesicle in both the aqueous and in the lipid phase; and (ii) in solid state, crystalline or in amorphous form both within or outside of the lipid vesicles.
Consequently the biopharmaceutical fate of the bioactive material will be different according to its state, i.e., the rate of absorption and in vivo disposition of the liposome-encapsulated, and the "free" solution, and the solid form of the ingredient will be different. It is anticipated that this difference will provide a sustained-prolonged action.
(c) The activity of the bioactive ingredients may be localized at or near the site of application, i.e., skin, eye and mucocutaneous membranes (lung, nose, and gastrointestinal tract, and vagina). The large multilamellar lipid vesicles penetrate these organs, but, because of their size, they are not taken up by the blood circulation. The lipid vesicles may also act within the organ, as a slow-release vehicle. The prolonged release and the reduced clearance rate leads to an accummulation of the bioactive ingredient at or near the site of application, which results in an intensification and also in prolongation of the local action, with a reduction in systemic action. The "free" form also penetrates into these organs at a higher rate, because of the presence of liposomes results in an occlusive effect. The "free" form of the bioactive ingredient can also be bound to the lipid vesicles or "dragged along" with the liposomes into the tissue.
The hydrogels, besides influencing the structure and inter-relation of the lipid vesicles, are particularly useful for topical application because of their effect on the viscosity and adhesive properties of the final product. Certain hydrogels also directly affect the absorbing biological membranes, especially the muco-cutaneous membranes.
The bioactive ingredient is dissolved in the aqueous solution at a saturation level. The bioactive material is also present in the lipid film in a concentration higher than its lipid solubility. The lipsome formation is taking place at higher than room temperature, therefore, at the completion of the product, the bioactive ingredient will be present in solution in both the aqueous and lipid phase in a saturated state and also in crystalline or amorphous solid state. No attempt is made to prepare and separate the liposomal fraction. Instead the system is intentionally made heterogeneous, where the bioactive material is dispersed in solution and in solid form both within and outside the lipid vesicles, and the lipid vesicles are dispersed in an aqueous media.
The present invention differs from previously known liposomal compositions in that the product formed contains the biologically active material in solid and molecular (dissolved) state in both "liposome-encapsulated" and in "free" form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is seen more fully by the Examples given below.
EXAMPLE 1
______________________________________Formula______________________________________(i) DL alpha dipalmitoyl 400 mg phosphatidylcholine (DPPC) Cholesterol 200 mg Minoxidil 100 mg(ii) Minoxidil 20 mg Ethanol (95%) 1 ml Propylene glycol 0.7 ml Calcium chloride (8 mM) 8.3 ml solution______________________________________
(i) Components of (i) DPPC, cholesterol and minoxidil were codissolved in 100 ml of chlorform-methanol solvent (2:1) in a 500 ml pear-shaped flask. The solvent was evaporated under vacuum in a rotary evaporator; the lipid and minoxidil residue formed a thin film on the wall of the pear-shaped flask.
(ii) Separately 20 mg minoxidil was dissolved in 0.7 ml propylene glycol and 1 ml ethanol in a 50 ml Erlenmeyer flask at 40-50° C.; 8.3 ml CaCl 2 solution was added and the temperature of this solution was brought up to 55-60° C.
The pear-shaped flask containing the lipid-monoxidil solid film still under vacuum was also brought up to 55°-60° C. The aqueous solution (ii) was added to the lipid-minoxidil film and shaken with the aid of a wrist shaker for 30 minutes immersed in a water bath set at 60° C. The resultant liposomal suspension was allowed to stand for one hour at room temperature.
One droplet of this preparation was examined microscopically under polarized light with 640×magnification. Spherical shaped liposomes of various sizes (between 1μ to 15μ diameters) were observed along with minoxidil crystals.
EXAMPLE 2
______________________________________Formula______________________________________(i) DL alpha dipalmitoyl 400 mg phosphatidylcholine (DPPC) Cholesterol 200 mg Minoxidil 100 mg(ii) Minoxidil 20 mg Ethanol (95%) 1 ml Propylene glycol 0.7 ml Calcium chloride (8 mM) 8.7 ml solution(iii) Methylcellulose 1500 cps 10 mg______________________________________
(i) Components of (i) DPPC, cholesterol and minoxidil were codissolved in 100 ml of chloroform-methanol solvent (2:1) in a 500 ml pear-shaped flask. The solvent was evaporated under vacuum in a rotary evaporator; the lipid and minoxidil residue formed a thin film on the wall of the pear-shaped flask. (ii) Separately 20 mg of minoxidil in 1 ml of ethanol were placed in an Erlenmeyer flask at 40°-50° C.; 8.3 ml CaCl 2 solution was added and the temperature of this solution was brought up to 55°-60° C.
The pear-shaped flask containing the lipid-minoxidil solid film still under vacuum was also brought up to 55°-60° C. Then the aqueous solution (ii) and the 10 mg Methylcellulose powder (iii) were added to the lipid-minoxidil film and shaken with the aid of a wrist shaker for 30 minutes immersed in a water bath set to 60° C. The flask was then placed in an ice-bath (approx. 4° C.) and shaken there for 10 minutes. The resultant liposomal suspension was allowed to stand for one hour at room temperature.
One droplet of this preparation was examined microscopically under polarized light with 640×magnification. Sperical and tubular shaped liposomes of various sizes (between 1μ to 15μ diameters) were observed along with minoxidil micro crystals. Most of the liposomes were closely associated with each other forming unusual conglomerates of the lipid vesicles interspaced with the hydrocolloid (methylcellulose) bridges.
EXAMPLE 3
______________________________________Formula______________________________________(i) DL alpha dipalmitoyl 400 mg phosphatidylcholine (DPPC) Cholesterol 100 mg Minoxidil 100 mg(ii) Minoxidil 20 mg Sodium Carboxymethylcellulose 10 mg Ethanol (95%) 1 ml Propylene glycol 0.7 ml(iii) Calcium chloride (8 mM) 8.3 ml solution______________________________________
(i) Components of (i) DPPC, cholesterol and minoxidil were codissolved in 100 ml of chloroform-methanol solvent (2:1) in a 500 ml pear-shaped flask. The solvent was evaporated under vacuum in a rotary evaporator; the lipid and minoxidil residue formed a thin film on the wall of the pear-shaped flask. (ii) Separately 20 mg minoxidil was dissolved in 0.7 ml propylene glycol and 1 ml ethanol. This solution is gradually added to 10 mg sodium carboxymethylcellulose to prewet the hydrocolloid. CaCl 2 solution (8.3 ml) is heated up to 55°-60° C. and added to the flask containing the lipid-minoxidil film. Within 1-2 seconds the sodium carboxymethylcellulose suspension was added to the same flask which was immersed in a water bath set to 60° C. Then the flask was shaken with the aid of a wrist shaker for 30 minutes immersed in a water bath set to 60° C. The resultant liposomal suspension was allowed to stand for one hour at room temperature.
One droplet of this preparation was examined microscopically under polarized light with 640×magnification. Spherical and tubular shaped liposomes of various sizes (between 1μ to 15μ diameters) were observed along with a few micro crystals. Most of the liposomes were closely associated with each other forming unusual conglomerates of the lipid vesicles interspaced with the hydrocolloid (sodium carboxy methylcellulose) bridges.
EXAMPLE 4
In a manner similar to the preceding examples several other compositions were prepared and tested, including
(a) varying the concentrations of methylcellulose (0.1%-1%), and minoxidil (3%);
(b) using purified soybean or egg lecithin in place of the DPPC;
(c) using other hydrocolloids (e.g, Veegum, colloidal silica, xanthan, tragacanth);
(d) including preservative or antioxidant agents (e.g., benzoic acid, methyl and propyl paraben, BHA, tocopherol, benzyl alcohol);
(e) varying the proportion of DPPC, or other type of lecithins, and cholesterol; and
(f) using other slightly soluble compounds in place of the minoxidil, e.g., econazole base, econazole nitrate, progesterone, β-estradiol, testosterone and the others described above.
Glass beads (40-60 beads with 5 mm diameter) usually were placed in the pear-shaped flask before the evaporation of the organic solvent. The products prepared in the presence of glass beads always had a better quality in comparison to those prepared without glass beads; i.e., they contained a higher number of liposomes and a smaller number of minoxidil crystals. Another advantage of using the glass beads is that the minoxidil crystal size was greatly reduced and the intermingling of the hydrocolloids and lipid vesicles was more noticeable. The major advantage of using the glass beads or any solid contact masses is of course the possibility of large, industrial scale production.
EXAMPLE 5
In this example minoxidii as a model for a slightly soluble biologically active material is incorporated in the multicomponent (heterogeneous) liposomal system of Examples 1 and 2. This compound was selected, because of its physicochemical properties, because of its solubility properties (very slightly soluble in aqueous or in lipid media), it is not a good candidate for liposomal encapsulation. This compound is an oral antihypertensive agent (the active ingredient of LONITEN Tablets), and is useful topically to grow hair (See U.S. Pat. No. 4,139,619). The known methods to encapsulate minoxidil in uni- and multilamellar liposomes resulted in liposomal preparations containing no more than 0.2-0.4% minoxidil (see Table I). The liposomal encapsulation of the bioactive ingredient is always limited by its solubility, i.e., one cannot make the liposomal preparation more concentrated, than the solubility of the bioactive ingredient in the liposomal media. Minoxidil solubility in deionized water is 2.4 mg/ml (0.24%), and in organic solvents (e.g., chloroform, acetone, ethyl acetate, benzene, diethyl ether, 2-propanol, etc.) minoxidil solubility is less than 1 mg/ml (0.1%).
According to the present invention multicomponent liposomal systems that contain 1.2%, 2%, and 3% minoxidil were prepared. It is possible to increase the minoxidil concentration even higher. The total amount of minoxidil was not present within the lipid vesicles; some portion of the minoxidil was outside the lipid vesicle in solution and in solid form, but as a drug delivery system this is advantageous for topical application, for localizing the bioactive ingredient (i.e., minoxidil) at or within the organ to which the composition is applied. Results of animal experiments for drug disposition studies confirm this. The test preparations contained 1.2%, 2%, and 3% minoxidil in the multicomponent liposomal drug delivery system. Two control preparations were used, containing corresponding concentrations of minoxidil (i.e., 1.2%, 2%, and 3%) in a solution form. A 2% minoxidil suspension, containing the identical lipid components in a nonliposomal form, was also prepared for control purposes.
The hair of the dorsal area of albino guinea pigs (300-500 g) was clipped off and an area of 3×3 cm was marked. Five groups of guinea pigs were used; the first group was treated with multiphase liposomal minoxidil 1.2%, the second group with 1.2% minoxidil solution, the third with 1.2% minoxidil in a multiphase liposome containing 0.1% methyl cellulose, the fourth group with 3% minoxidil solution, and the fifth group with 3% monoxidil in a multiphase liposome containing 0.1% methylcellulose. A 0.1 ml dose was applied in a twice a day dosage schedule. A does of 0.05 ml twice a day was used for the 2% minoxidil preparations.
The guinea pigs were treated at t=0, 8, 24, 32, 48, 56, and 72 hours, for a total of seven doses. The drug disposition was determined four hours after the last dose was applied.
The results are presented in Tables II and III.
The multicomponent liposomal dosage form produced higher concentration of minoxidil in all skin tissues compared to the conventional solution form. There was no significant difference between the drug concentrations measured in the internal organs of guinea pigs treated with minoxidil in liposomal or in solution form.
EXAMPLE 6
______________________________________(i) L α dipalmitoyl phosphatidylcholine 400 mg Cholesterol 100 mg Econazole base 100 mg(ii) Benzoic acid 20 mg Butylated hydroxyanisole 0.5 mg Ethanol 1 ml CaCl.sub.2 solution, 8 mM 9 ml(iii) Methylcellulose 1500 10 mg______________________________________
In this example the fine powder form of the lipid components and of the econazole base was placed in a 500 ml pear-shaped flask along with 50-60 glass beads (5 mm diameter). The flask was then placed in a water bath set at 80° C. and rotated gently, with an approximate 60-80 RPM for 15 minutes. The lipids and drug content of the flask liquefied and fused together decreasing the temperature to 60° C. while maintaining rotation yielded a smooth dry film of the components which was formed on the surface of the glass beads and on the wall of the flask.
In a separate flask (50 ml Erlenmeyer flask) benzoic acid and butylated hydroxyanisole was dissolved in 1 ml ethanol and 9 ml CaCl 2 solution was added gradually at 40°. Then both flasks were placed in a waterbath at 60° and within 2-3 minutes the aqueous solution (ii) and the methylcellulose (iii) was added to the dry lipid and econazole base. The flask was shaken with the aid of wrist shaker for 20 minutes at 55°-60° temperature. The resultant liposomal suspension was shaken in a ice-bath (4°) for 10 minutes, then it was allowed to stand for one hour at room temperature.
This example demonstrates a means for preparing liposomes without using any organic solvent, thereby eliminating the need of the experimental steps of dissolving the lipid components and evaporating the organic solvent. The melting point of econazole base was low enough (80° C.) to fuse together with the lipid component. With aid of the glass beads (any other solid contact masses will also work), a thin film of the solid state of the lipids and biologically active materials was prepared. The lipids were then hydrated with an aqueous solution. One droplet of this preparation was examined microscopically under polarized light with 640×magnification. Spherical and tubular shaped liposomes (of various sizes (between 1-7μ diameter) were observed with econazole crystals. Most of the liposomes were conglomerated, the methylcellulose fibres were intermingled with the individual and aggregated lipid vesicles.
EXAMPLE 7
______________________________________(i) L-α-dipalmitoyl phosphatidylcholine 400 mg Cholesterol 200 mg Econazole nitrate 100 mg(ii) Benzoic acid 20 mg Butylated hydroxyanisole 0.5 mg Ethanol 1 ml CaCl.sub.2 solution, 8 mM 9 ml______________________________________
L-α-Dipalmitoyl phosphatidylcholine, cholesterol, and econazole nitrate were dissolved in chloroform: methanol (2:1) in a 500 ml pear-shaped flask. 50-60 Glass beads with 0.5 mm diameter were placed in the flask. The solvent was evaporated under vacuum in a rotary evaporator until a smooth, dry lipid film was observed on the glass beads and on the sides of the flask (i).
Benzoic acid and the butylated hydroxyanisole were dissolved in ethanol and the CaCl 2 solution was gradually added at 40° (ii). Both flasks (i) and (ii) were placed in a waterbath set to 60° and within 5 minutes the CaCl 2 solution (ii) was added to the dry film of the lipids and econazole nitrate (i). The flask was vigorously shaken for 30 minutes and then allowed to stand at room temperature for one hour.
One droplet of this preparation was examined microscopically under polarized light. Spherical and tubular shaped liposomes of various sizes between 1-9μ diameters) were observed with many econazole nitrate crystals. The size of these crystals were larger (approximately 10-20μ) than in the preparation described under Example 6. The lipid vesicles were not aggregated in this preparation.
EXAMPLE 8
______________________________________(i) Vegetable lecithin (ethanol extract) 800 mg Cholesterol 200 mg Econazole nitrate 100 mg(ii) Benzoic acid 20 mg Butylated hydroxyanisole 0.5 mg Ethanol 1 ml CaCl.sub.2 solution, 8 mM 9 ml______________________________________
The components of (i) were dissolved in 10 ml chloroform: methanol (2:1) in a 500 ml pear-shaped flask. Glass beads (50-60 with 5 mm diameters) were added and the organic solvent was evaporated with the aid of a rotary evaporator. The residue of the lipids and econazole nitrate formed a thin film on the surface of the glass beads and on the wall of the pear shaped flask. The angle of the pear-shaped flask attached to the rotary evaporator was adjusted that the evaporating solvent had a maximum contact with the glass beads and the wall of the flask.
Benzoic acid and the butylated hydroxyanisole were dissolved in ethanol and the CaCl 2 solution was gradually added to this alcoholic solution. The content of both flasks was brought up to 60° in a water-bath. The aqueous solution added to the pear-shaped flask containing the thin film of the lipid and econazole nitrate residues. The flask was vigorously shaken at 60° for 30 minutes. The resultant liposomal suspension was allowed to stand for one hour at room temperature. Microscopic examination indicated that spherical and tubular shaped liposomes were formed (1-12u diameters). Most of the liposomes were connected with each other, 4 to 6 lipid vesicles in one bundle. A large number of econazole nitrate crystals were observed under the polarized light.
EXAMPLE 9
Two preparations described above by Examples 7 and 8 were tested against a control preparation (Pevaryl®) containing the same concentration (1%) econanozole nitrate but in a cream vehicle base. The purpose of these tests were to study the drug disposition in guinea pigs after topical application of these products.
The hair of the dorsal area of albino guinea pigs (300-500 g) was clipped off and an area of 3×3 cm was marked. A 0.1 ml dose was applied in a "twice a day" dosage schedule, i.e.: t=0, 8, 24, 32, 48, 56, and 72 hours. Three groups of guinea pigs were used; one group was treated with the control preparation (Pevaryl®); the second and the third groups with the liposomal products described in Examples 7 and 8 respectively.
Ninety minutes after the last treatment the guinea pigs were killed under CO 2 atmosphere. Blood and other tissue samples were taken immediately. The samples were kept in deep freeze (-16° C.) condition until processed for analysis. The skin samples were sliced horizontally with a Castroviejo Keratotome, set to 0.2 mm slice (the epidermis), then 0.5 mm slice (the dermis) and the remaining portion labelled as the subcutaneous tissue. The results are presented in Table IV.
From these results it could be concluded that the multicomponent liposomal dosage form produced higher concentration of econazole nitrate in all skin tissue than the cream form. The drug concentration measured in the internal organs of guinea pigs treated with econazole nitrate in the newly developed liposomal forms were usually lower than of those treated with the control, cream form.
The data also indicates that the multicomponent liposomal drug delivery system of the present invention is particularly useful for topical drug delivery and has a special advantage of accommodating slightly soluble biologically active substances in a concentration above than their lipid or water solubility.
EXAMPLE 10
Method for Large Scale Production of Liposomal Minoxidil
Preparation
______________________________________Formula: Each 100 ml contains______________________________________ 4.0 g Lecithin (Soy Phosphatide NC 95-H) 2.0 g Cholesterol USP 2.0 g Minoxidil Milled 5.0 mg Butylated Hydroxyanisole USP *0.9 ml Benzyl Alcohol NF 10.0 ml Ethanol (95%), USP 7.0 ml Propylene Glycol USP(82.1)* (82.0)** 83.0 ml 8 mM CaCl.sub.2 solution** 1.0 ml Tween 80______________________________________ *Alternate Formula with preservative, benzyl alcohol **Alternate Formula with surfactant, Tween 80 * & **If Tween 80 and/or benzoyl alcohol are used they displace an equivalent volume of CaCl.sub.2 solution
Stock Solution
1. CaCl 2 (8mM)
For each 1 liter volume prepared in a suitable volumetric flask, 1.176 g of Calcium Chloride dihydrate USP is first dissolved in purified water USP and then diluted to volume with purified water USP. This material may be used for up to one month after the date of preparation.
A. Step 1: Lipid-Minoxidil Film Coating (Batch size 500 ml)
To a 2 liter pear shaped flask attached to a rotary evaporator is added the following:
______________________________________Material______________________________________Lecithin 20 gCholesterol USP 10 gMinoxidil Milled 8 gChloroform 113 mlMethyl Alcohol 67 ml6 mm glass beads 450 g______________________________________
The mixture is agitated at room temperature until fully dissolved.
Placing the evaporating flask on a Rotovapor at an angle so that none of the solution spills out of the neck, and so that rotation (approximately 80 rpm) provides gently continuous motion of the glass beads, the solvent is removed by heating the flask to 34°±2° C. and reducing the pressure to 100±50 toor. The solvent is continued to be evaporated until visually the glass beads appear to be uniformly coated with an opaque layer of solids. If no uniform, thin film is formed, the procedure is repeated, i.e., the residue is dissolved in 200 ml CHCl 3 : CH 3 OH (2:1) and the solvent is evaporated as above.
The solvent collection flask is emptied and the flask and contents are allowed to remain under vacuum for an additional 15 min for complete removal of any residual solvent. Note: beads may begin to stick to the sides of the flask. If during continued rotation the beads do not come off, the rotation is stopped and the sides of the flask are gently tapped until the beads are all dislodged. Rotation is then resumed. The beads should be freely rolling due to rotation.
Once the lipid minoxidil residue is dry of sovlents, it may be stored at refrigerator temperature in a tightly closed container under a nitrogen atmosphere for up to 10 days.
B. Step 2 Hydration of Lipids (Lipsome Formation)
For each 2 liter capacity flask plus glass beads coated in Step 1, the following solution is added, prepared as follows:
______________________________________Materials______________________________________Minoxidil Milled 2 gButylated Hydroxyanisole USP (BHA) 25 mgEthanol USP (95%) 50 mlPropylene Glycol USP 35 mlBenzyl Alcohol NF* 4.5 mlStock Solution (CaCl.sub.2 8 mM solution) 415 mlTween 80** 5.0 ml______________________________________ *Not to be added to the 2% minoxidil liposome formulation without preservatives. * & **If Tween 80 and/or benzoyl alcohol are used they displace an equivalent volume of CaCl.sub.2 solution.
2 g minoxidil and 25 mg BHA are dissolved in 50 ml ethanol in a 1 liter flask then add 35 ml propylene glycol and 4.5 ml benzoyl alcohol (if preservative is needed for the formulation). With continuous stirring, 415 ml ()r 410.5 ml if preservative is used) CaCl 2 stock solution is gradually added.
The flask plus glass beads and the above solution is prewarmed to 50°-55° C. in an oven or water bath. The solution is quickly added to the flask containing the beads, and all ports are spaled with stoppers and immediately shaken by hand vigorously for one minute. An orbital, gyro shaker is attached and the unit is maintained in a controlled temperature environment (may be an oven) of 50°-55° C. and shaken for 20 min until a uniform "milky white" suspension of liposomes is obtained and all of the thin film of phospholipid has been removed from the inside of the flask and from the surface of the beads. The gyro shaker dial was set to 200 rpm. The 2L pear shaped flask is placed on the shaker at a 75° angle (approximately). This angle provides greater shaking effect as the beads swirling around the flask land covering most of the available space.
After one hour, the liposomes are formed and may be seen by examining a drop microscopically.
EXAMPLE 11
Comparison of Multiphase Liposomal Preparation, Suspension, and Solution Preparations of Minoxidil
The minoxidil disposition of two liposomal formulations, prepared using Soy Phosphatide in place of dipalmitoyl phosphatidyl-choline, were tested against a suspension and a solution form. All preparations contained 2% minoxidil. The chemical composition of the lipsomal and suspension forms were identical, except one liposomal product did not contain a preservative, benzyl alcohol.
______________________________________Formula for Products Tested.______________________________________1. Liposomal Minoxidil without Preservative240 mg Lecithin (Soy Phosphatide NC 95-H)120 mg Cholesterol (USP)120 mg Minoxidil Milled (600 Ci 3H)0.3 mg Butylated Hydroxyanisole (USP)0.054 ml Benzyl Alcohol NF0.6 ml Ethanol 95% (USP)0.42 ml Propylene Glycol (USP)4.926 ml CaCl.sub.2 (8 mM) solution2. Liposomal Minoxidil with Preservative240 mg Lecithin (Soy Phosphatide NC 95-H)120 mg Cholesterol (USP)120 mg Minoxidil Milled (600 Ci 3H)0.3 mg Butylated Hydroxyanisole (USP)0.6 ml Ethanol (95%), (USP)0.42 ml Propylene Glycol (USP)4.98 ml 8 mM CaCl.sub.2 Solution3. Minoxidil Suspension240 mg Lecithin (Soy Phosphatide NC 95-H)120 mg Cholesterol (USP)120 mg Minoxidil Milled (600 Ci 3H)0.3 mg Butylated Hydroxyanisole (USP)0.054 ml Benzyl Alcohol NF0.552 ml Ethanol (95%), (USP)0.384 ml Propylene Glycol (USP)4.56 ml 8 mM CaCl.sub.2 Solution4. Minoxidil Solution120 mg Minoxidil Milled (600 Ci 3H)3.6 ml Ethanol (95%), (USP)1.2 ml Propylene Glycol (USP)1.2 ml Distilled Water4.98 ml 8 mM CaCl.sub.2 Solution______________________________________
The liposomal products were prepared as described in Example 10, "scaled down" to make 6.0 ml batches.
The suspension was prepared by first blending the solids through a conventional sieving process. The solids are stirred into the liquid components, and the mixture is maintained at room temperature. Analysis of the suspension indicates virtually no liposomes are formed. The solution was prepared by conventional means.
Four groups of guinea pigs (control and test groups) were used. Each group contained seven guinea pigs weighing 250-350 g, housed in individual cages. The hair of the dorsal area was clipped off and an area of 3×3 cm was marked. In place of the previous dose of 0.1 ml here the dose was only 0.05 ml. The 0.05 ml dose of the control or test preparation was applied in a "twice a day" dosage schedule, i.e., t=0, 8, 24, 32, 48, 56 and 72 hr.
Four hours after the last treatment the guinea pigs were killed under CO 2 atmosphere; blood and other tissue samples were taken immediately. Before the skin was dissected the treated area was washed with guaze swabs soaked in ethanol to remove product that remained on the surface of the skin. The samples were kept in deep freeze (-16°) condition until processed for radioactivity analysis. Before slicing the skin samples, the hair grown during the four day-treatment was shaved off and added to the swab fraction. The combined hair and swab should contain minoxidil remaining on the surface of the skin. The skin samples were sliced horizontally with a Castroviejo Keratotome, set at 0.2 mm slice which was designated as the epidermis, the 0.5 mm slice which was referred to as dermis and the remaining portion labelled as the subcutaneous tissue. The results are presented in the Tables and Figures attached.
In this study, one of the controls, the suspension preparation, contained the same chemical composition as the liposomal (MCL) products; the only difference in this control and the test preparations was that the minoxidil was present in the control preparation in "free" form, while in the test product the drug was mainly in the liposome-encapsulated form. The other control preparation was the solution form, which is an Upjohn formula.
The results are depicted in Tables V and VI. They clearly demonstrate that the liposomal encapsulation is responsible for the favorable drug disposition; i.e. an increased drug concentration in the skin.
TABLE I______________________________________ Percent of Minoxidil in the Final LiposomalMethod of Preparation Preparation______________________________________Multilamellar lipid vesicles (MLV) 0.15%(Bangham, et al., J. Mol. Biol.13:238-252, 1965)Large Unilamellar vesicles (REV) 0.2%(Szoka, et al., Proc. Natl. Acad.Sci. (USA) 75:4194-4198, 1978)Multilamellar lipid vesicles (MLV) 0.4%(U.S. Pat. No. 4,485,054)______________________________________
TABLE II__________________________________________________________________________The Effect of Liposomal Encapsulation on Drug Disposition*μg Minoxidil/g Tissue Liposome of Liposome of Control Solution Example 1 Example 2 (Gel)Tissue Mean ±SD Mean ±SD Mean ±SD__________________________________________________________________________Skin 3146.9 721.8 2411.2 327.9 3407.9 721.9SurfaceEpidermis 2886.3 219.6 13411.7* 2270.9 11669.7* 2302.2Dermis 194.7 54.7 877.1* 84.9 886.9* 402.7Sub. Cut. 25.8 10.3 267.3 157.8 146.4* 64.8Brain 0.458 0.174 0.281 0.132 1.47 0.59Heart 1.884 0.779 1.608 0.213 3.19 1.01Kidney 0.707 0.167 0.837 0.841 2.63* 0.76Liver 0.988 0.269 0.755 0.363 3.66* 1.68Lung 1.774 0.271 1.757 0.275 3.28** 1.03Spleen 1.425 0.607 1.305 0.198 3.10** 0.87Urine.sup.xx 379.03 315.05 55.53 48.78Blood 0.0239 0.0090 0.0438 0.0360 0.120 0.094__________________________________________________________________________ *Seven doses of 0.1 ml preparation were applied on a 3 × 3 cm area (t = 0, 8, 24, 32, 48, 56, 72 hr). The guinea pigs were sacrificed under CO.sub.2 atmosphere four hours after last treatment. .sup.xx Total urine, collected during the treatment period. SD = Standard Deviation with N = 5 The degree of significance *p < .005 **p < .05
TABLE III______________________________________The Effect of Liposomal Encapsulation on Drug Disposition*μg Minoxidil/g Tissue Liposomal Control 3% Gel 3%Tissue Mean ±SD Mean ±SD______________________________________Skin Surface 7999.3 2181.4 8164.4 2935.9Epidermis 5116.3 1283.6 20758.0 6212.4Dermis 312.1 43.2 1503.0 619.3Sub. Cut. 95.1 31.7 519.1 256.6Brain 2.39 0.81 5.32 2.69Heart 2.51 1.39 8.99 2.69Kidney 5.20 2.29 6.79 1.916Liver 8.00 1.56 10.61 3.88Lung 4.37 1.06 9.67 2.44Spleen 5.11 0.76 9.99 2.55Urine** 8255.3 1084.7Blood 0.0563 0.0389______________________________________ *Seven doses of 0.1 ml preparation were applied on a 3 × 3 cm area (t = 0, 8, 24, 32, 48, 56, 72 hr). The guinea pigs were sacrificed under CO.sub.2 atmosphere four hours after last treatment. **Total urine, collected during the treatment period.
TABLE IV__________________________________________________________________________The Effect of Liposomal Encapsulating on DrugDisposition After 72 Hour-Treatment.sup.aug Econazole-NO.sub.3 /g Tissue Pevaryl Liposomes Liposomes Control Cream Example 7 Example 8Tissue Mean ±SD.sup.b Mean ±SD Mean ±SD__________________________________________________________________________Epidermis 832.5 311.0 7311.9 2644.4 6379.2 3823.8Dermis 138.7 53.1 270.9 105.0 226.9 59.3Sub. Cut. 20.0 15.0 50.7 29.9 24.0 21.0Skin Surface 703.2 151.9 3028.1 2317.9 1111.9 178.9Blood 0.166 0.045 0.213 0.173 0.022 0.004Brain 0.345 0.063 0.445 0.312 0.469 0.138Liver 5.832 1.145 6.63 2.41 0.101 0.003Spleen 1.864 2.255 1.90 1.25 0.167 0.012Kidney 2.158 0.501 5.10 3.98 0.220 0.032Lung 1.465 0.148 3.40 2.71 0.036 0.013Heart 0.522 0.177 1.81 1.41 N.A. N.A.__________________________________________________________________________ .sup.a Seven doses of 0.1 ml preparation were applied on a 3 × 3 cm area (t = 0, 8, 24, 32, 48, 56, 72 hr). The guinea pigs were killed under CO.sub.2 atmosphere 90 minutes after the last treatment. .sup.b Standard Deviation; N = 5
TABLE VA______________________________________The Effect of Dosage Form on DrugDispositionug Minoxidil/g TissueLiposomes Liposomes(with preservative) (without preservative)Tissue Mean ±SD Mean ±SD______________________________________Epider- 4350.3 2903.9 4186.8 2824.7misDermis *524.8 298.6 **343.3 108.2Sub. Cut. **80.1 34.6 **90.2 26.8Skin 292921.4 79447.8 165071.4 54371.5SurfaceBlood 0.017 0.013 0.021 0.006Brain 0.444 0.133 0.510 0.172Liver 0.976 0.436 *1.234 0.392Spleen *0.701 0.143 0.612 0.129Kidney 0.676 0.235 *0.849 0.152Lung *0.668 0.086 *0.624 0.091Heart *0.673 0.120 0.568 0.138Urine *626.5 223.4______________________________________ Seven doses of 0.05 ml preparation were applied on a 3 × 3 cm area (t = 0, 8, 24, 32, 48, 56, 72 hr). The guinea pigs were sacrificed under CO.sub.2 atmosphere four hours after the last treatment. Total urine, collected during the treatment period. SD = Standard Deviation with N = 7. The degree of significance *p < 0.01 **p < 0.001
TABLE VB______________________________________The Effect of Dosage Form on DrugDispositionug Minoxidil/g Tissue Solution Suspension ControlTissue Mean ±SD Mean ±SD______________________________________Epidermis 1958.7 879.4 1291.4 304.3Dermis 139.8 82.1 108.9 52.3Sub. Cut. 29.9 17.5 16.2 4.1Skin 78300.7 56009.0 84804.7 33091.1SurfaceBlood 0.031 0.027 0.008 0.005Brain 0.618 0.236 0.301 0.125Liver *1.275 0.260 0.695 0.137Spleen *0.804 0.216 0.417 0.072Kidney 0.927 0.244 0.515 0.159Lung *0.872 0.285 0.404 0.089Heart *0.749 0.198 0.394 0.077Urine *954.1 264.7 1554.4 278.9______________________________________ Seven doses of 0.05 ml preparation were applied on a 3 × 3 cm area (t = 0, 8, 24, 32, 48, 56, 72 hr). The guinea pigs were sacrificed under CO.sub.2 atmosphere four hours after the last treatment. Total urine, collected during the treatment period. SD = Standard Deviation with N = 7. The degree of significance *p < 0.01 **p < 0.001
TABLE VI______________________________________Changes in Minoxidil Concentration due toLiposome-Encapsulation Expressed as Percent of Control% of Control % of Control(suspension) (solution) Liposomes Liposomes Liposomes Liposomes (with pre- (without pre- (with pre- (without pre-Tissue servative) servative) servative) servative)______________________________________Epider- 222.1 213.7 345.4 194.6misDermis 375.4 245.5 481.9 315.2Sub. Cut. 267.9 3-1.7 494.4 556.8Skin 374.1 210.8 345.4 194.6SurfaceBlood 54.8 67.7 212.5 266.2Brain 71.8 82.5 147.5 169.4Liver 76.5 96.3 140.4 177.5Spleen 87.2 76.1 168.1 146.7Kidney 72.9 91.6 131.3 164.8Lung 76.6 71.5 165.3 154.4Heart 89.8 75.8 170.8 144.2Urine 65.7 40.3______________________________________
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The present invention provides a novel multiphase drug delivery system which comprises:
(a) lipid vesicles with a biologically active compound captured therein;
(b) a saturated solution of the biologically active compound; and
(c) the biologically active compound in solid form.
Optionally this composition is dispersed in a hydrocolloid gel.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This present application is a Continuation-in-Part of application Ser. No. 09/990,504, filed on Nov. 21, 2001, which claims priority to Provisional Application Ser. No. 60/1252,230.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to the pneumatic launching devices typically used in the sport of paintball and related applications. More specifically, the present invention relates to a trigger frame housing which can be utilized b:y a wide variety of different launching devices, and to the incorporation of an active return trigger mechanism built into the frame.
[0003] As the game and sport of paintball has grown and become more popular, a variety of manufacturers, each producing its own models of paintball marker have entered the industry. Additionally, those same manufacturers, as well as others, provide numerous aftermarket accessories for use with their products; there are in fact, numerous manufacturers who's sole business is the design and manufacture of aftermarket components for different paintball marker lines, the components adding features and capabilities desired by consumers.
[0004] Typically, most paintball markers are built and sold as ‘standard’ models, such models incorporating basic features. A good example of this are the original manufacturers' barrels supplied with the markers. These are usually simple tubes of a diameter capable of handling a wide range of paintball sizes and are generally built as inexpensively as possible. Most consumers will typically purchase an aftermarket barrel shortly after the purchase of the marker and will select from among as many as a hundred different designs of barrel in choosing the features they most desire.
[0005] As the sport has evolved, aftermarket features other than barrels have also become desired by consumers, including the ‘grip frame’—the portion of the marker which is held by the user's hand and which incorporates the trigger. Numerous styles have evolved and different features, such as finger grooves for comfort, built-in game timers, multiple finger triggers and approximately sized trigger guards, as well as others, have been developed for the market.
[0006] Finally, an increasing reliance on volume fire has evolved This reliance on an increase in volume fire Is evidenced by the introduction of electronically enhanced guns, improved paintball magazines and paintball feeding mechanisms, improved high speed valves and regulators and a host of other technologies all having a common goal of increasing the rate of fire from the paintball gun.
[0007] The goal of increasing the rate at which paintballs can be fired is complicated by an industry prohibition on “fully automatic” firing mechanisms, multiple shot weapons or other enhancements which allow the user to fire more than one paintball per trigger cycle of the weapon. Therefore, an objective throughout the paintball industry is to enhance the rate of fire through various means which maintain the operation of the paintball gun in a true “semi-automatic” firing mode in which one projectile is expelled per complete cycle of the trigger/gun mechanism. Further, a desire exists to eliminate, assist or equalize the force exerted by the use throughout the trigger cycle and to provide a powered or assisted method of returning the trigger to the ready position at the end of the firing sequence.
[0008] Despite previously mentioned solutions and enhancements, there are currently no methods available for an “assisted” trigger mechanism in a paintball: gun. In principle, an assisted trigger mechanism utilizes the user's own mechanical action of pulling or releasing a trigger mechanism as the initiating force, after which mechanical, pneumatic, electronic, magnetic or a combination of these means is introduced and automatically perform some or all of the trigger cycle.
[0009] Because of the numerous styles and designs of paintball marker on the market today, it would be desirable to be able to provide a single grip frame assembly which would incorporate features desired by consumers and which could be utilized by numerous marker designs; distributors and retailers would be able to reduce their inventory requirements and consumers would be able to migrate such a frame—with advanced features—from one market to another, rather than having to purchase an entirely new grip frame with every marker.
[0010] In order to understand the scope of the present invention, it is necessary to understand that there are currently four “classes” of paintball gun design, each of which has a different configuration but all of which operate on the same principles of design.
[0011] The first of the four mechanisms of paintball gun operation is classified as a blowback configuration. This type of gun utilizes a mechanically operated sear connected to the trigger, a spring operated hammer connected mechanically to a bolt, and a spring operated valve mechanism. The bolt is located above the hammer in a separate body channel which is in communication with the gun barrel. In operation, the user first “cocks” the system by pulling a cocking knob connected to the bolt. This causes the hammer to be moved behind the sear and compresses the hammer spring.
[0012] When the trigger is pulled, the trigger actuates a sear, releasing the hammer. Under spring tension, the hammer moves forward. Since the bolt is connected to the hammer, when the hammer moves forward, the bolt moves forward as well to push a paintball into the barrel. When the bolt is at its furthest point of forward travel, a gas passage in the bolt is In communication with a vent hole from the valve. Simultaneously, the hammer impacts a valve stem in the face of the valve, opening the valve and releasing a preset amount of pressurized gas. This gas vents through the bolt, thus firing a paintball, and against the hammer, pushing the hammer and the bolt back into the cocked position. At its rearmost point of travel, the sear once again captures the hammer completing the cycle.
[0013] The next type of paintball gun uses a “blow forward” type of mechanism in which the bolt is retained by the sear, which is mechanically linked to the trigger. The bolt rides on a tube that communicates with the valve and is retained by the sear under pressure, effectively acting as a seal on the valve system. When the trigger is actuated, the bolt is released. Gas pressure from the valve pushes the bolt forward, which in turn pushes a paintball into the barrel. Once the bolt has reached its furthest point of travel, the gas passage is opened, allowing the gas to flow through the face of the bolt, thus firing the paintball A spring located forward of the bolt returns the bolt where it Is again captured by the sear, thus completing the cycle.
[0014] An “autococking” style of semi-automatic paintball guns operate in the same basic manner as the blowback semi-automatic. However, the design is based on what was originally a pump operated paintball gun where the pumping action: has been pneumatically automated. This style of design therefore has several additional mechanisms.
[0015] In the autococking style mechanism, when the trigger is pulled, the hammer is released, striking the valve and sending gas through the bolt and down the barrel, thus firing a paintball. Gas is also vented to a low pressure regulator, which in turn supplies a three-way valve. The three-way valve is connected to a pneumatic ram, which in turn is mechanically linked to a cocking mechanism and to the bolt.
[0016] Gas from the regulator is introduced into the three-way valve which first operates the ram to push the cocking mechanism rearward, pulling the bolt back, allowing a new projectile to enter the barrel and resetting the hammer on the sear. Gas is then vented from the three-way valve, which operates to reverse the flow of gas to the ram, which in turn pulls the bolt and cocking mechanism forward, completing the cycle.
[0017] The final type of paintball gun is classified as an electric paintball gun. In some cases, electric paintball guns replaced some or all of the mechanical systems mentioned above with electronic or electromechanical systems. For example, one widely distributed model substitutes an electronic switch connected to a solenoid for the mechanical sear.
[0018] In each of the types of paintball guns discussed above, the firing rate of paintballs is limited by the rate at which a human finger can depress and release the trigger of the paintball gun. Since the rate at which a human finger can pull a trigger is somewhat limited by the mechanical action of the trigger mechanism, it is an object of the present invention to provide assistance to the user when pulling the trigger and actively assist in returning the trigger to its initial position.
SUMMARY OF THE INVENTION
[0019] The present invention relates to a grip frame and trigger housing for use with paintball markers which is configured for attachment to a wide range of paintball marker bodies and which incorporates an active return mechanism. The grip frame Is manufactured so that different trigger and sear mechanisms can be fitted and will work operationally with different marker bodies. Additionally, the grip frame incorporates one of several different mechanisms which actively return the trigger/sear assembly to the ‘ready-to-fire’ position without being activated by the user.
[0020] In the first embodiment of the invention, the grip frame upper body is sized to mate with the largest (in all dimensions) marker body and contains a number of passages cut through the grip frame body which align with the mounting passages of the different marker bodies.
[0021] Because all paintball marker bodies are made to accommodate the same sized projectile, the differences in length and width of the different model bodies do not prohibit the use of a single sized grip frame body for attachment to all of them.
[0022] Sear pin mounting holes and trigger pin mounting holes are cut through the body at a height and location which matches the requisite positioning for each of the markers the grip frame will be attached to and perpendicular to the main axis of the grip frame. A slot is cut into the interior of the grip frame body, the slot sized to accommodate the largest trigger and sear assembly required to operate one of the markers the grip frame will be attached to.
[0023] In one embodiment of the invention, a secondary magnet or electromagnet is positioned behind the trigger in the trigger housing. The secondary magnet in the trigger housing is used to attract the trigger during initial movement of the trigger rearward, while the polarity of the secondary magnet can be reversed to repel the trigger once the paintball has been fired.
[0024] In another embodiment of the invention, the trigger itself is configured as part of an electromagnet. User actuation of the trigger causes the circuit between the trigger/electromagnet and a power supply to be closed. The magnetic field thus created causes the trigger to be attracted to a secondary magnet behind the trigger while being simultaneously repelled by a secondary magnet positioned in front of the trigger. Once the trigger has traveled past the point where it actuates the sear mechanism Of the paintball gun, the circuit to the trigger electromagnetic is opened, causing a cessation of the magnetic field. Once the trigger has traveled a minute but discernable distance beyond that required to cause a firing event, the circuit is again closed such that the polarity of the trigger electromagnet is reversed. At this point in the trigger cycle, the magnetic field repels the trigger from the secondary magnet positioned behind the trigger, while the secondary magnet in front of the trigger acts to attract the trigger.
[0025] In another alternate embodiment, an adjustment mechanism consisting of a non-ferrous “field strength reducer” is positioned between the secondary magnet in the trigger housing and the trigger. The field strength reducer, when placed between the secondary magnet and the trigger, reduces the strength of the magnetic field emanating from the secondary magnet. The type and size of the field strength reducer can be selected to vary the amount of assistance provided by the secondary magnet.
[0026] In a further embodiment of the invention, the magnets can be replace by a single or a pair of solenoids that are mechanically linked to the trigger. Movement of the trigger during the firing sequence causes activation of the solenoids which extend their solenoid rods to aid in movement of the trigger during the firing sequence.
[0027] In another embodiment of the invention, Hall effect sensors are attached to the electromagnets positioned In the trigger housing. As the trigger is depressed, the change in the field strength monitored by the sensors will alternately cause either power to be transmitted to the electromagnet, the polarity of the magnet change, or power will be cut off to the electromagnet. In this way, the user's actuation of the trigger, and the positioning of the trigger, can be monitored and adjusted.
[0028] In addition to aiding in the actuation of the trigger itself, an alternate embodiment of the invention contemplates replacing the mechanical linkage between the trigger and the cocking/firing mechanism with a pneumatic operating system. In this embodiment of the invention, rearward movement of the trigger opens a pneumatic air valve. As the pneumatic air valve is opened, air pressure is supplied to an actuating ram coupled to the cocking ram of the paintball gun. When the actuating ram is pressurized, the air pressure of the actuating ram operates the cocking/firing mechanism to cause a paintball to be fired. In this manner, the air pressure of the actuating ram causes the mechanical movement of the cocking/firing mechanism, rather than a mechanical linkage between the trigger and the cocking/firing mechanism. The use of air pressure rather than the mechanical linkage allows for a faster and less physically demanding movement by the user on the trigger. After the firing sequence has been initiated, the residual pressure within the pneumatic valve aids in returning the trigger to its prefiring position.
[0029] In another embodiment of the device, an adapter plate or plates is used, the adapter plate having channels which mate with the mounting channels of a marker body and which has additional mounting channels for mating with the grip frame body. In yet another embodiment of the device, the adapter plate incorporates sear pin and trigger pin mounting holes cut through the body perpendicular to the long axis of the mounting plate. In another embodiment of the device, the adapter plate incorporates magnets, which are operable on the trigger, such that the trigger is repelled by the magnets when pulled and attracted by the magnets when released.
[0030] In another embodiment of the device, a pneumatic ram is activated by operation of the trigger and, upon completion of the firing sequence, the ram operates against the trigger to return it to its initiating position.
[0031] Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] In the drawings:
[0033] FIG. 1 illustrates a side view of a current art trigger frame
[0034] FIG. 2 is a side view of one embodiment of the universal grip frame illustrating multiple mounting channels
[0035] FIG. 3 is a side view of an embodiment of the universal grip frame illustrating the adapter plate
[0036] FIG. 4 is a side view illustrating the location of a pivoting trigger mounted in the grip frame
[0037] FIG. 5 is a side view illustrating the locating of a sliding trigger and sear assembly mounted in the grip frame
[0038] FIG. 6 is a side view illustrating the various non-contiguous locations of trigger mounting pins and sear mounting pins for different styles of trigger assemblies
[0039] FIG. 7 is a top view illustrating two different styles of current art sear and trigger slots milled into a grip frame and the slot in the universal grip frame capable of accommodating both
[0040] FIG. 8 is a side view illustrating the location of active return mechanism magnets mounted in the grip frame
[0041] FIG. 9 is a side view illustrating the first embodiment of the assisted trigger mechanism of the present invention;
[0042] FIG. 10 is a second embodiment of the assisted trigger mechanism of the present invention, illustrating a force limiting element between the actuator and triggers
[0043] FIG. 11 is side view of the third embodiment of the assisted trigger mechanism of the present invention;
[0044] FIG. 12 is a fourth embodiment of the assisted trigger mechanism of the present invention;
[0045] FIG. 13 is a side view of the fifth embodiment of the assisted trigger mechanism of the present invention;
[0046] FIG. 14 is a side view of the sixth embodiment of the assisted trigger mechanism of the present invention;
[0047] FIG. 15 is a side view illustrating an autococking mechanism constructed in accordance with the present invention; and
[0048] FIG. 16 is a second embodiment of the autococking mechanism incorporating the features of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0049] Referring first to FIG. 1 , thereshown is a generally schematic illustration of the trigger portion of a paintball gun. The paintball gun includes a handle portion 10 that is grasped by a user during use of the paintball gun. The handle 10 is connected to a trigger mechanism 12 that includes a trigger guard 14 and the actual trigger 16 . The trigger 16 is coupled to the cocking and firing components of the paintball gun such that depression of the trigger 16 will cause a paintball to be discharged from the paintball gun. The trigger mechanism 12 of the present invention is a conventional mechanism used in currently available paintball guns.
[0050] The present invention may provide a secondary magnet 18 is positioned within the trigger housing behind the actual trigger 16 . In the preferred embodiment of the Invention, the secondary magnet 18 could be either a natural magnet or an electromagnet that can be energized by an external circuit (not shown). As illustrated in FIG. 1 , the trigger 16 also Includes a trigger-mounted primary magnet having a known polarity.
[0051] In the embodiment in which the magnet 18 is a natural magnet, the magnet is oriented such that its polarity is aligned in the direction of trigger travel. The polarity of the secondary magnet 18 Is arranged such that the polarity of the secondary magnet 18 and the polarity of the trigger mounted magnet are opposite such that as the trigger 16 moves toward the magnet 18 , the magnet 18 repels the trigger to provide an assisted return for the trigger 16 . The strength and position of the secondary magnet 18 are selected such that the secondary magnet 18 repels the trigger 16 only after the trigger 16 has been depressed far enough to actuate the sear. After the sear has been actuated, the secondary magnet aids in returning the trigger to the resting position.
[0052] In an alternate embodiment in which the secondary magnet 18 is an electromagnet, the polarity of the secondary magnet 18 and the polarity of the trigger mounted magnet are opposite such that the trigger is initially attracted toward the secondary magnet 18 . Once the trigger 16 activates the sear for the paintball gun, a sensor detects such movement and the polarity of the secondary magnet 18 is reversed, such that the secondary magnet 18 repels the trigger 16 to aid in returning the trigger 16 to Its resting position prior to actuation of the next firing sequence.
[0053] Referring now to FIG. 2 , thereshown Is an alternate configuration of the embodiment shown in FIG. 1 . As illustrated in FIG. 2 , the trigger 16 includes a trigger magnet 20 and a secondary magnet 22 is positioned within the trigger housing. In the embodiment of the illustrated in FIG. 2 , a shim 24 is positioned between the secondary magnet 22 and the trigger magnet 20 . The shim 24 is formed from a material that, when placed in front of the secondary magnet 22 , reduces the strength of the magnetic field emanating from the secondary magnet 22 . Thus, each individual shim 24 reduces the magnetic field by a predetermined amount. In this manner, the attraction force between the secondary magnet 22 and the trigger magnet 20 can be adjusted such that the secondary magnet 22 repels the trigger only after the sear of the paintball gun has been activated. Thus, the shim 24 helps control the amount of assistance provided by the trigger mechanism of the present invention.
[0054] Referring now to FIG. 3 , thereshown is another alternate embodiment of the assisted trigger mechanism. In the embodiment illustrated in FIG. 3 , the trigger 16 is configured as part of either an electromagnet or a natural magnet. The mechanism includes a secondary magnet 26 positioned in front of the trigger 16 and a secondary magnet 28 positioned behind the trigger 16 . As the trigger 16 is activated, the trigger 16 causes a circuit between the trigger 16 and a power supply to be closed. The power supply causes the magnetic field created by the secondary magnet 26 to repel the trigger 16 , while the magnetic field created by the secondary magnet 28 ; positioned behind the trigger 16 attracts the trigger. Once the trigger 16 has traveled past the point where it actuates the sear mechanism, the circuit to the electromagnets is open, causing a cessation of the magnetic field. Once the trigger 16 has traveled a minute but discernable distance beyond that required to cause the firing event, the circuit is again closed, such that the polarity of the magnetic fields of the secondary magnet 26 and the secondary magnet 28 are reversed. At this point In the trigger cycle, the magnetic fields repel the trigger from the secondary magnet 28 behind the trigger, while the secondary magnet 26 in front of the trigger attracts the trigger 16 .
[0055] As shown in FIGS. 1-3 , an adjustment mechanism can be utilized for each of the secondary magnets that allows the magnet to be moved closer or farther away from the trigger and the trigger-mounted primary magnet In one embodiment, the secondary magnet can be mounted on a screw that can be threaded into the body of the mechanism housing the trigger, such that the depth or height of the screw can be adjusted externally. In another embodiment, the adjustment mechanism consists of a holder, into which secondary magnets of differing strengths can be placed.
[0056] In yet another embodiment, the adjustment mechanism consists of a secondary magnet that has been machined to include external threads on the outer circumference of the magnet and a tool socket is formed on the outward face of the magnet, such as a slot or hex-head. In this embodiment, the magnet is placed into a threaded channel machined into the trigger mechanism which houses the return mechanism. In another alternate embodiment, the threaded channel can be cut into the center of the magnet, allowing it to be placed on the adjustment screw. By providing such adjustment mechanisms, the strength of each secondary magnet can be adjusted to vary the amount of attraction and repulsion forces created during the trigger cycle.
[0057] Referring now to FIG. 4 , thereshown is yet another alternate embodiment of the assisted trigger mechanism. In the embodiment illustrated in FIG. 4 , a pair of solenoids 30 and 32 are connected to the trigger 16 . The solenoid 30 includes a solenoid rod 34 while the solenoid 32 includes its own solenoid rod 36 . As the trigger 16 is depressed, the trigger 16 trips a sensor which supplies power to the solenoid 30 . When actuated, the solenoid 30 extends the solenoid rod 34 to aid In movement of the trigger 16 to the firing position,
[0058] As the trigger 16 continues its rearward movement, the trigger further trips a sensor indicating that the trigger 16 has activated the sear mechanism. After actuating the sear mechanism, power is supplied to the solenoid 32 , which extends the solenoid rod 36 . Extension of the solenoid rod 36 aids in returning the trigger 16 to its resting position prior to initiation of the firing sequence.
[0059] Referring now to FIG. 6 , thereshown is another embodiment in which a pair of sensors 38 and 40 are positioned on opposite sides of the trigger 16 . The sensors 38 and 40 detect the movement of the trigger between its operating positions. The sensors 38 and 40 are coupled to a circuit-board 42 mounted in the handle of the paintball gun. The circuit board 42 includes various logic elements, electronic connections between the circuit and sensors and switches, electronic connections to pneumatic, electronic, magnetic or other types of actuating devices, and interconnected power supplies. The electronic circuit contained on the circuit board 42 , through communications with the sensors 38 and 40 , can track, analyze and respond to the operation of the trigger by the user and will assist both the actuation and return of the trigger as desired.
[0060] Referring now to FIG. 5 , Hall effect sensors 44 and 46 are positioned relative to the trigger 16 such that as the trigger 16 moves toward one of the sensors 44 and 46 , the change in field strength monitored by the sensors will alternately cause power to be transmitted to the electromagnets, such as shown in FIG. 3 . Movement of the trigger 16 will thus cause the polarity of the electromagnets to change or will cut off the flow of power to the electromagnets 26 and 28 . In this way, the user's actuation of the trigger 16 , and the positioning of the trigger can be monitored and adjusted.
[0061] Although not shown in the drawings, in another alternate embodiment could provide a pneumatic on/off valve positioned behind the trigger such that when the trigger is depressed far enough to actuate the sear of the paintball gun, the pneumatic on/off valve is opened. When the pneumatic on/off valve is opened, a ram is pressurized. As the ram is pressurized, an actuation rod extends to aid in moving the trigger back to its resting position.
[0062] In the embodiment described in FIGS. 1-6 , the active trigger mechanism is used to aid in the depression and return of the trigger between its two operating positions. The mechanisms allow for the trigger to be depressed and released at a higher rate of speed to aid in increasing the number of paintballs that can be fired by the operator. However, in each embodiment, the active trigger mechanism is used to move the trigger itself, while the trigger is part of a cocking/firing mechanism used to operate the sear of the paintball gun.
[0063] Referring now to FIGS. 7 and 8 , thereshown is an alternate configuration that is utilized as an autococking mechanism, rather than simply a trigger return. In the embodiments Illustrated in FIGS. 1-6 , the trigger is mechanically coupled to the sear of the paintball gun such that the mechanical linkage between the trigger and the sear is used to both cock and fire the paintball gun. In the embodiment of the invention illustrated in FIGS. 7 and 8 , the mechanical linkage between the trigger 16 and the sear Is removed and a cocking ram 48 having an actuating rod 50 is coupled to the sear to effectuate the cocking and firing of the paintball gun. Thus, since the trigger 16 is no longer mechanically coupled to the sear, the trigger 16 can be depressed and released with less effort by the user.
[0064] As illustrated in FIG. 7 , a rod 52 is coupled to the back side of the trigger 16 and extends through the trigger housing 54 . The far end of the rod 56 is In contact with a movable plunger 58 of a pneumatic on/off valve 60 . The pneumatic on/off valve 60 is contained in the handle 10 of the paintball gun. The on/off valve 60 includes an air inlet 62 that receives a supply of regulated air pressure from an external source 64 , such as the air supply used to operate and fire paintballs from the paintball gun. An outlet 66 from the on/off valve 60 supplies air pressure to an actuating ram 68 as illustrated. The actuating ram 68 receives the opposite end of the actuating rod 50 .
[0065] During operation of the paintball gun, the user depresses the trigger 16 to move the trigger 16 rearward to fire a paintball. As the trigger 16 moves rearward, the rod 52 depresses plunger 58 which opens the on/off valve 60 . When the on/off valve 60 is opened, the actuating ram 68 is pressurized through the air inlet 67 . After being pressurized, the actuating ram 68 moves the actuating rod 50 , which initiates the firing/cocking sequence for the paintball gun. As can be understood by the above description, the movement of the trigger pressurizes the actuating ram such that the actuating ram cocks and fires the paintball gun Instead of a mechanical linkage between the trigger and the cocking/firing mechanism of the paintball gun.
[0066] Once the paintball has been fired, the trigger 16 is released, which closes the on/off valve 60 . As the trigger is released, the residual pressure within the on/off valve 60 aids in pushing the plunger 58 and thus the rod 52 forward, acting as an active return for the trigger 16 . Once the firing sequence is complete, the on/off valve 60 is vented and the system awaits the next firing sequence.
[0067] Turning now to FIG. 8 , thereshown Is an alternate embodiment, with like parts having corresponding reference numerals. As illustrated in FIG. 8 , the actuating ram 68 and the cocking ram 48 are connected in parallel with each other, unlike the opposed configuration illustrated in FIG. 7 . The actuating ram 50 is received in both the cocking ram 48 and the actuating ram 68 and is coupled to the sear (not shown) of the paintball gun. As illustrated, the air outlet 66 from the on/off valve 60 Is again received at an air inlet 67 for the actuating ram 68 .
[0068] During operation of the invention illustrated in FIG. 8 , the user Initially pulls back the trigger 16 , which again opens the on/off valve 60 by depressing the plunger 58 . When opened, the on/off valve 60 supplies a source of pressurized air to the actuating ram 68 through the air inlet 67 . Once pressurized, the actuating ram 68 moves the actuating rod 50 of the cocking ram 48 to begin the cocking sequence. Once the paintball has been fired, the trigger 16 is released and the residual pressure within the on/off valve 60 causes the plunger 58 to aid in the return of the trigger 16 to its previous position. Once again, the actuating ram 68 is vented to atmosphere such that the system is ready for the next firing sequence.
[0069] The present invention provides for a universal trigger frame including an active trigger return mechanism for use with a pellet and paintball applications. In short, the present Invention, the first set of embodiments of FIGS. 9 through 16 illustrate a method and configuration to aid in moving the trigger between its two positions during the firing cycle. In these embodiments, the trigger is mechanically linked to the cocking and firing mechanism of the paintball gun such that the mechanism aids in reducing the amount of force required by the user to complete the firing sequence. By reducing the amount of force required, the speed of the firing sequence can be increased such that the number of paintballs fired by the user during a given time period can be increased.
[0070] In the second type of system, as illustrated in FIGS. 7 and 8 , a mechanical linkage between the trigger and the cocking/firing mechanism for the paintball gun is eliminated and a pressurized actuating ram is used. In this system, the trigger closes an air valve, which begins the firing sequence. Once again, since the user does not need to actuate the mechanical linkage between the trigger and the cocking/firing mechanism, the rate at which the trigger can be pulled and released is increased, thus increasing the number of paintballs that can be fired during a given time period. In each of the two embodiments illustrated, assistance is given to the user during the trigger cycle such that the speed of the trigger cycle can be increased, effectively increasing the number of paintballs fired by a semi-automatic paintball gun.
[0071] Referring now to FIGS. 9 through 16 , FIG. 9 displays a typical paintball marker grip frame such as may be used with any of the above-mentioned embodiments incorporating the mounting surface 111 for attachment to a marker body, the trigger housing 112 and the grip 110 . FIG. 10 shows the location of mounting channels for one typical model of marker body 120 , and mounting channels for another typical marker body 121 .
[0072] FIG. 11 shows the universal grip frame 110 , standard mounting channels through the mounting surface of the grip frame 125 , and adapter plate 130 sized to fit between the grip frame 110 and the marker body 128 , attachment points 126 for attaching the grip frame 110 to the adapter plate 130 and mounting channels 127 in the adapter plate 130 , aligning with mounting channels 129 in the marker body 128 , with the mounting channels 127 in the adapter plate 130 . In use, screws would first be used to attach the adapter plate 130 to the marker body 128 mounting channels 129 and then the grip frame 110 would be attached to the adapter plate 130 , using the mounting channels 126 .
[0073] FIG. 12 shows a grip frame 110 , incorporating a pivoting trigger 131 , mounted on the grip frame using a pivot pin 132 mounted through the grip frame body. FIG. 13 , shows a grip frame 110 , a sliding trigger 133 , a guide pin 137 mounted perpendicularly to the main axis of the grip frame, a sear pin 136 , mounted perpendicularly to the main axis of the grip frame, a sear 135 mounted on the sear pin 136 and a trigger access hole 134 , cut into the body of the grip frame. Referring now to FIG. 14 , thereshown a grip frame 110 , a pivoting trigger 138 , a pivoting trigger mounting pin 139 , a sliding trigger 140 , a trigger access hole 141 , a sear pin 142 and a sear 143 .
[0074] These three figures serve to illustrate that a single grip frame 10 , can accommodate the mounting holes required for incorporating a variety of different trigger and sear mechanisms within a single grip frame. Referring now to FIG. 15 thereshown the mounting channels 152 & 153 in the upper surface of the grip frame for one style of marker 150 A and the interior cavity 151 in the grip frame required to house the trigger, in 150 B the Interior channel 154 in the grip frame required to house the trigger of a different style marker and in 150 C the interior channel 155 that can accommodate both styles of trigger and sear assembly in both style markers.
[0075] Referring now to FIG. 16 which shows a grip frame 110 , a pivoting trigger 162 , a magnet mounted on the rear surface of the trigger 163 , an adjustable magnet housing mounted on the inside of grip frame 164 , a magnet mounted in the housing 165 , a magnet mounting channel through the main body of the grip frame 160 and a return magnet 161 mounted in the channel.
[0076] In operation, the magnet 163 mounted in the trigger 162 is arranged so that its outer surface polarity is the same as the magnet 165 mounted in the magnet housing 164 , such that the two magnets will repel each other. The magnet housing 164 can be adjusted in order to increase or decrease the relative strength of the magnetic field(s) of the trigger magnet 163 and body magnet 165 , allowing the user to adjust the amount of return force on the trigger after it has been pulled.
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The invention discloses two related improvements over existing trigger mechanisms utilized in pneumatic launching devices—such as pellet or paintball guns. The first improvement is a method for allowing a single trigger frame configuration to be utilized by a multiplicity of launching devices despite differences in attachment points and/or mechanical linkages inherent in the same. The second improvement relates to incorporating a trigger return mechanism within the trigger frame which utilizes magnets, pneumatics or mechanical means to actively return the trigger to its initiating or ‘rest’ position after it has been operated.
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BACKGROUND OF THE INVENTION
The invention relates to a stirring apparatus with a stirrer having a hollow shaft and which is surrounded by a fixed casing and a drive means for the stirrer, wall parts of the casing and/or holow shaft being heatable.
As products to be stirred may have a corrosive action, particularly at high temperatures, known stirring apparatuses of the indicated type must be made from highgrade, stainless steel. To protect against corrosion, it is generally known to coat heated containers with an enamel coating, but as is known, such a protective coating can only be applied to wall parts having a limited thickness and it is destroyed due to its limited elasticity or percussion/impact sensitivity, when the wall part provided with the protective coating is exposed to loads or stresses, which lead to an elastic deformation thereof. It is therefore not possible to use impact-sensitive protective coatings for stirring apparatuses in which considerable stirring forces, due to high viscosity, are to be expected.
BRIEF SUMMARY OF THE INVENTION
The problem of the present invention is to find a stirring apparatus of the aforementioned type for high torques, which is provided with wall parts having an impact-sensitive protective coating, while, in order to reduce the manufacturing costs for the apparatus, these wall parts can be made from non-stainless steel. This problem is sloved by providing the wall parts of the casing and the stirrer coming into contact with the product to be stirred with an impact-sensitive protective coating and by accomplishing the force transfer between such wall parts and adjacent apparatus parts by means of at least one elastic intermediate member or interconnection.
As a result of the features according to the invention, forces acting locally on a wall part do not lead to a corresponding local material stress, and therefore to the destruction of the protective coating. Because of the use of elastic intermediate members or interconnections, the forces are uniformly distributed over the adjacent apparatus parts.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein:
FIG. 1 is a partly axial-sectional side view of a stirring apparatus, according to the invention;
FIG. 2 is a larger scale axial partial section through the stirrer shafts of the apparatus with an embodiment of an elastic intermediate member between a shaft casing and an inner support shaft;
FIG. 3 is a cross-section taken along line III--III of FIG. 1;
FIG. 4 is a larger scale 90° partial section with a stirring arm;
FIG. 5 is a stirring apparatus with a double-mounted stirrer shaft.
DETAILED DESCRIPTION OF THE INVENTION
The stirring apparatus according to FIGS. 1 to 3 has a stirrer vessel 1 which has its longitudinal axis arranged horizontally and which surrounds a coaxially arranged stirrer shaft 2. Unlike in the embodiment according to FIG. 5, the stirrer shaft 2 is only mounted on one side and is consequently only passed through a stuffing box 3 on one side of vessel 1. The stirrer vessel 1 is fixed and has on its top surface a filling connection 4, which enables vapors to be removed. An emptying connection 5 at the bottom of vessel 1 surrounds a conically inserted gas-tight cover or lid 6 (FIG. 3), which can be swung downwards by means of an actuating device 7, as indicated by the curved dot-dash line 8.
The right-hand part of the stirring apparatus in FIG. 1, as well as a stirrer vessel cover 10 and a drive casing 11 connected thereto, can be moved away from the stirrer vessel 1 together with stirrer shaft 2, after releasing screw clamps 12 of a flanged connection 13. For this purpose, the apparatus apart can be movably positioned on rails in a manner not shown. Flanged connection 13 encloses a semi-elastic and relatively thick packing 14, which forms an elastic intermediate member or interconnection between drive casing 11 and a fixed vessel part 15. Packing 14 prevents that, in the case of a suddenly occurring force-closure, a corresponding sudden load peak has to be absorbed in an undamped manner in the stirrer shaft 2 or its stirring arm 16, 17, 18 and stirrer vessel 1, because the forces emanating from the shaft 2 must be transferred from the vessel 1 to the drive casing 11, which carries the drive of stirrer shaft 2.
As in the case of load peaks during the stirring of lumpy and/or oily viscous products, sudden stresses also occur on the stirrer shaft 2 and emanate from the stirring blades 22, 23, 24, elastic intermediate members or interconnections are also provided on the force path from the stirring blades to the moved part of drive 20, in accordance with an elastic insert 26 on the stirring blade, shown in FIG. 4, and metallic spring bellows 27, 28 between a relatively rigid, hollow support shaft 29 and a shaft casing 31 carrying an enamel coating 30.
The subdivision of the stirrer shaft 2 into a relatively rigid, inner hollow shaft 29, which absorbs the bending forces, and a shaft casing 31 spaced therefrom, makes it possible to provide that part of shaft 2 arranged in stirrer vessel 1 with the enamel coating 30, because in this way the shaft casing can be correspondingly constructed in a relatively thin-walled manner. Without the aformentioned elastic intermediate members 27, 29, deformations could be caused by the stirring forces in shaft casing 31 and this would lead to the fracture of the enamel coating. A pipe 33 carrying a heating medium is passed through the hollow support shaft 29 and is passed into a heating medium in an area 34 between support shaft 29 and the enamelled shaft casing 31. The return flow of the heating medium takes place through a cross-sectionally annular area 35 between the heating medium pipe 33 and support shaft 29. In order to permit this flow guidance, openings 37 and 38 are provided respectively in elastic intermediate member 27 and in support shaft 29 in front of intermediate member 28.
To permit the heating of the stirrer vessel 1, outside the region of flanged connection 13, the vessel is provided with heating jackets 40, 41, to which are connected supply and discharge lines 42, 43 or 44, 45.
FIG. 2 shows an embodiment for the support between support shaft 29 and shaft casing 31 by means of an elastic intermediate member constructed as a spring bellows. This metallic spring bellows permits, as a result of its cross-sectionally corrugated shape, a relatively large elastic deformation, both in axial and in radial direction of the shaft. The two axial ends 47, 48 of spring bellows 28 are in each case fixed to a thrust ring 50 or 51 respectively, which in turn is welded to the shaft casing 31 or the support shaft 29, respectively.
FIG. 4 shows in a relatively large scale cross-sectional view, the arrangement of a stirring blade 23 on a stirring arm 17 of stirrer shaft 2. Stirring arm 17 is coated with an enamel coating 30, whereas stirring blade 23 is itself formed from a corrosion-resistant and wear-resistant material. Stirring blade 23 is screwed to stirring arm 17 by means of one or more screws 53, while the screw head 54 of each screw 53 is located in a countersunk hole, which is filled with a corrosion-proof sealing compound 55. Stirring blade 23 surrounds the tapering outer end 56 of stirring arm 17, and the elastic insert 26 between said stirring arm end and the stirring balde 23 prevents damage to the enamel coating 30 and simultaneously seals the gap between stirring arm 56 and stirring blade 23. In addition, casing 58 of stuffing box 3 is connected by means of an elastic intermediate member 59 to the stirrer vessel 1, so that stresses enamating from the shaft 2 and acting in a shock-like manner on stuffing box 3 are damped or compensated and cannot lead to an overloading of enamelled areas of the stirring apparatus. A corrosion-proof sleeve 61 is mounted and fixed on the tapered end 60 of shaft casing 51 and it is also possible to insert an elastic packing (not shown) in the area of the leading edge of said sleeve between the two parts. The stuffing box packing 62 engages on the outside of sleeve 61. A flange 63 presses the stuffing box casing 58 against the elastic intermediate member 59, which is constructed as a sealing washer, and therefore against an opening edge 64 of stirrer vessel 1.
Stirrer shaft 2 is driven by drive 20 fitted laterally to the stirring apparatus, from an electric motor 66 via a gear 67 and a drive transmission enclosed in a casing 68 and which e.g. comprises V-belts.
The embodiment of FIG. 5 differs from the aforementioned embodiment essentially only through the two-sided mounting of stirrer shaft 2', so that the latter is exposed to smaller bending forces. However, the aforementioned embodiment has shown that, as a result of the present invention, the stirrer shaft can also be mounted on one side only. The stuffing box construction 3', 3" are constructed in accordance with the aforementioned stuffing box construction 3. Heating medium is supplied by stirrer shaft 2', from heating medium jacket 33'. As the annular gap between the heating medium duct 33' and shaft 29' is blocked by a ring 70, the heating medium passes through bores 71 into the heating medium area 34' between support shaft 29' and stirrer shaft 2'. The return flow of the heating medium from area 34' is by means of radial bores 72 in support shaft 29'. Other parts of the stirring apparatus according to FIG. 5, which correspond to parts of the previously described stirring apparatus, are indicated by reference numerals followed by apostrophes.
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The stirrer vessel and stirrer shaft of a stirring apparatus are heated and carry an enamel coating on the surfaces coming into contact with the product. In order to prevent destruction of this enamel coating when the stirrer shaft is severely stressed, elastic intermediate members are arranged between a rigid support shaft and a shaft casing. The stuffing box is also held on the stirrer vessel by a further elastic intermediate member. An elastic packing between the fixed part of the stirrer vessel and the vessel cover fixed to the drive casing balances forces which are transferred from the vessel wall to the drive casing.
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[0001] This application claims priority to Brazilian Application No. PI0404603-0, filed Oct. 22, 2004, entitled “SISTEMA DE INJECÃO DE ÁGUA CAPTADA EM AQUIFERO SUBTERRÂNEO E POCOS INJETORES EM RESERVATÓRIO DE ÓLEO”, and incorporates the same herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a system for collecting and injecting water from a subterranean aquifer into hydrocarbon reservoirs, more specifically, the invention is directed to a system of water collection wells in subterranean aquifers and of injector wells in hydrocarbon (oil and gas) reservoirs, wherein one or more pumps may be utilized to improve injection rate. The invention finds application in hydrocarbon production systems, where water injection is utilized to maintain hydrocarbon (oil and gas) reservoir pressure, thereby enhancing oil recovery.
BACKGROUND OF THE INVENTION
[0003] One of the principal methods of secondary recovery, known and employed in the art, especially in subsea petroleum systems, utilizes water injection to maintain the pressure in hydrocarbon producing reservoirs.
[0004] Typically this water is collected and treated directly from the sea and/or from water produced jointly with the hydrocarbons.
[0005] U.S. Pat. No. 4,234,047 (hereinafter “the '047 Patent”) teaches the installation of a Submersible Centrifugal Pump (SCP) within a dummy well for injecting water into injector wells. The system described in the '047 Patent has the following deficiencies. It requires the construction of a shallow well for installation of the pump. Furthermore, a water treatment plant is required to treat the water to be injected, which has been collected from the sea and/or produced jointly with the hydrocarbons.
[0006] In Petrobras' Brazilian Patent application PI 0400926-6 a method of installing a pump in a dummy well, in this case an oil production well, is also disclosed.
[0007] The principal deficiencies in the current state of the art include the high cost of treating the collected water, as well as the reliability of the quality of the water being treated and injected into the well. Furthermore, the method presently utilized for collecting and injecting water results in the injected water having a temperature which approximates that of the low temperature water found at the ocean floor.
[0008] For hydrocarbons, in general, and especially for heavy oils, it is highly desirable and advantageous that the water be injected at a temperature which is higher than that found at the ocean floor. Water, injected under these conditions, facilitates the dislodgement and scouring of the reservoir. Another difficulty in the current state of the art is the installation of a water injection pump.
[0009] There exist some models of compact pumps that may be installed on the ocean floor in metal structure bases (skids) or may be integrated into the wellhead itself. However, utilizing submersible centrifugal pumps has certain advantages notably that this type of equipment is produced on a large scale and at a low cost. Furthermore, this type of equipment possesses a slender geometry which requires the drilling and construction of dummy wells for accommodating the equipment, as described in the patents above.
[0010] The disadvantages in the state of art discussed above are remedied in the instant invention by an injection system which utilizes water collected from subterranean aquifers.
[0011] More specifically, the present invention discloses a system of water collecting wells in aquifers and injector wells in oil (petroleum) reservoirs which provides a means of maintaining pressure in hydrocarbon reservoirs by injecting water, of higher quality (lower sulfite concentration) and at a higher temperature, into the reservoirs, thereby dispensing with the necessity of a water treatment plant and reducing the costs of installation and operation of stationary units in subterranean petroleum production fields.
[0012] In this way, it is possible to maintain reservoir pressure using water having a higher quality and temperature than that presently achieved in the art, thereby increasing productivity and the oil recovery factor of the reservoir.
[0013] Another application of the instant invention is in mature fields where there is no physical space available for the construction or enlargement of the existing water injection unit.
SUMMARY OF THE INVENTION
[0014] The instant invention has the main objective of creating a system possessing an innovative concept and arrangement of wells to enable water collection from subterranean aquifers and the injection of that water into hydrocarbon producing wells for the purpose of maintaining pressure in those wells.
[0015] The collection of water in subterranean aquifers is accomplished by using a system of water collecting wells. This collected water may be pressurized by means of a submarine pump and thereafter injected through injector wells, whose points of destination (targets) are located at the base of the oil (petroleum) reservoirs or in an active aquifer in the oil reservoir.
[0016] The hydraulic connection for pumping between the collection well and the injector well may be accomplished in accordance with the following embodiments:
(1) at the seabed with underwater pipes linking at least one collection well with at least one injector well. In this case the pump may be installed at the seabed (the most basic embodiment), in a dummy well or on a metal structure. The pump may also be installed at the collection well itself, thereby reducing the necessary interfaces and underwater connectors, (2) in the interior of a simple or multilateral well, with access to the collection zone and to the injection zone; and, (3) at the exterior of a simple or multilateral well, with access to the collection zone and to the injection zone.
[0020] In the first embodiment described above, the hydraulic interface occurs at the ocean floor through underwater pipes which link at least one collection well with at least one injector well and requires the construction of at least two independent wells: a first well (collection well) and a second well (injector well). This increases production costs and reduces the temperature of the water being injected, due to the substantial thermal exchange which occurs between the water and the sea water over the length of the submarine line which connects the wellheads of the wells (i.e., of the collection well and the injector well).
[0021] The pumping unit maybe installed externally of the wells, thereby permitting it to be retracted and reinstalled by means of a cable from a low daily cost vessel.
[0022] The solution herein described presents greater flexibility in the spacing between the point of collection and the point of injection. In this embodiment of the invention the design of the wellhead, collection column and injection column are conventional. Alternatively, the pumping unit may be installed at the collection well, utilizing a simplified and innovative design, thereby eliminating the need for a wet Christmas tree (WCT) installed at the collection well.
[0023] In the second embodiment described above both the pump and the hydraulic connection between the collection and injector wells are located in the interior of a conventional or multilateral well which has access to the collection and injection zones. This arrangement eliminates the need for constructing two wells (for collecting and injecting) and maintains the injection water at a higher temperature by avoiding thermal exchange with sea water on the ocean floor, which is generally colder. In this case, with the pumping assembly being positioned in the interior of the well, maintenance will require the use of a rig, with its associated higher costs.
[0024] In the third embodiment, the pump and the hydraulic connection, between the flows from the collection well and the injector well, are located externally to a conventional or multilateral well, thereby facilitating their being retrieved and re-installed via cable by a low daily cost vessel. There is a substantial reduction in costs with the construction of only one well with dual functions, i.e., collection and water injection, as opposed to constructing two wells. Furthermore, the temperature of the water being injected is higher because there will be no substantial thermal exchange with the water on the ocean floor, which is generally much colder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a basic embodiment of the invention wherein a conventional collection well is linked through submersible pipes to one or more injector wells, and a pump is installed externally between the collection well and the injector well on a metallic structure, a dummy well or other adequate means.
[0026] FIG. 2 illustrates another embodiment of the invention wherein at least two wells (a collection well and an injector well) are externally linked. The pump is installed within the collection well, thereby avoiding the need for installing a wet Christmas tree (WCT)
[0027] FIG. 3 illustrates another embodiment of the invention wherein the pump is installed within a multilateral well linking (communicating) the collection zone to the water injection zone.
[0028] FIG. 4 illustrates another embodiment of the invention wherein a pump is installed externally from a multilateral well linking the collection zone to the water injection zone.
[0029] FIG. 5 illustrates another embodiment of the invention wherein a pump is installed externally from a conventional well, linking the collection zone to the water injection zone.
[0030] FIG. 6 illustrates another embodiment of the invention wherein a pump is installed within the interior of a conventional well, linking the collection zone to the water zone.
[0031] FIG. 7 illustrates another embodiment of the invention wherein a pump is installed internally or externally of a multilateral well, permitting injection of the collected water at different locations within the injection zone.
[0032] Summarizing:
Number FIG. of wells Type of well Pump location 1 >=2 Directional or Horizontal External to the collection well 2 >=2 Directional or Horizontal Internal to the collection well 3 1 Multilateral Internal to the well 4 1 Multilateral External to the well 5 1 Directional or Horizontal External to the well 6 1 Directional or Horizontal Internal to the well 7 1 Multilateral Internal or External
DETAILED DESCRIPTION OF THE INVENTION
[0033] In accordance with the invention, the specification and the claims of the instant application, the following terms are defined as follows:
[0034] 1 . Collection well
[0035] 2 . Injector well
[0036] 3 . Injection Pump
[0037] 4 . Directional or Horizontal (Conventional) well
[0038] 5 . Annular space
[0039] 6 . Multilateral well
[0040] 7 . Collection column
[0041] 8 . Injection column
[0042] 9 . Telescopic assembly (Tubing Seal receptacle (TSR))
[0043] 10 . Obturator (Tubing Packer Hanger)
[0044] 11 . Injection control element
[0045] 12 . Wellhead
[0046] 13 . Injection zone
[0047] 14 . Collection zone
[0048] 15 . Water collection line
[0049] FIG. 1 is a general schematic view of an embodiment of the invention with a hydraulic connection positioned externally between the collection well 1 and one or more injector wells 2 . An injection pump 3 is installed externally to the two wells, either on a metallic structure or on a dummy well, coupled to the wellhead or alternatively secured by any other means. In this way the water collected from the collection well 1 is pressurized by the injection pump 3 and is injected into one or more of the injector wells 2 .
[0050] FIG. 2 is a general schematic view of another embodiment of the invention wherein an injection pump 3 is installed internally in the collection well 1 and the hydraulic connection between the collection well 1 and the injector well 2 (not shown in the drawing) is external to those wells.
[0051] In this simplified arrangement, there is no need to install a wet Christmas tree (WCT) in the collection well 1 . A collection column 7 is seated and positioned several hundred meters below the wellhead 12 by an obturator (tubing packer hanger) 10 .
[0052] An injection pump 3 , encapsulated in a small section of mounting tubing, is installed between the tubing packer hanger 10 and the wellhead 12 . An injection control element 11 , such as a valve, is installed in a portion of the collection column 7 , below the tubing packer hanger 10 . The injection control element 11 may be operated remotely to blockade the collection well 1 in the event of an intervention. The injection control element 11 may be hydraulic or electric.
[0053] In the event of a failure in the injection pump 3 , the pump may be retrieved without the necessity of retrieving the collection column 7 , since a telescopic assembly 9 , installed between the tubing packer hanger 10 and the injection pump 3 , facilitates the assembly and disassembly operation.
[0054] Since safety concerns are less critical in the operation of a collection well 1 , the control of such a well may be accomplished by an injection control element 11 . This eliminates the need for installing a wet Christmas Tree (WCT) for this purpose, thereby reducing installation and maintenance costs. In this way, it is possible to connect the water collection line 15 directly to the wellhead 12 .
[0055] FIG. 3 is a general schematic view of an embodiment of the invention wherein not only the injection pump 3 but also the hydraulic connection between the collection zone 14 and the injection zone 13 , are positioned within the interior of a multilateral well 6 . The collection column 7 is hydraulically linked to a suction orifice of the injection pump 3 . The discharge flow of the injection pump 3 is injected into the injection zone 13 through the injection column 8 .
[0056] FIG. 4 is a schematic view of another embodiment of the invention wherein the hydraulic connection between the collection zone 14 and the injection zone 13 is located in the interior of a multilateral well 6 by means of an injection pump positioned externally of the multilateral well 6 .
[0057] The existing water in the injection zone flows through the annular space 5 to the suction orifice of the injection pump 3 where it is pressurized and returns through the injection column 8 to the injection zone 13 .
[0058] FIG. 5 illustrates an embodiment of the invention wherein an injection pump 3 is installed externally to a conventional well 4 , which interconnects (communicates) the collection zone 14 to the water injection zone 13 . The collected water flows through the annular space 5 to the suction orifice, where it is pressurized, thereafter returning through the injection column 8 to the injection zone 13 .
[0059] FIG. 6 illustrates an embodiment of the invention wherein an injection pump 3 is installed in the injection column 8 , which itself is positioned in the interior of a conventional well 4 . The water collected in the collection zone 14 is pressurized by the injection pump 3 and flows through the injection column 8 until reaching the injection zone 13 .
[0060] FIG. 7 illustrates an embodiment of the invention wherein a multilateral well 6 possesses an injection pump 3 . The injection pump 3 may be installed internally or externally (not shown in the drawing) to the multilateral well. In this embodiment of the invention, it is possible, with a single multilateral well 6 , to inject water into more than one injection zone 13 . In this arrangement, each injection zone 13 includes an injection control element, e.g., a type of valve. The collection of water may be done from one internal collection zone 14 to a multilateral well 6 or from another collection well (not shown in FIG. 7 ) specified for this purpose.
[0061] Although the present invention has been described herein according to its preferred embodiments, it should be obvious to one skilled in the art that various alterations and modifications are possible without departing from the scope of the instant invention, as defined by the claims appended hereto.
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The instant invention relates to a system for collecting and injecting water from a subterranean aquifer into hydrocarbon reservoirs, more specifically, the invention is directed to a system of water collection wells in aquifers and injector wells in oil reservoirs (petroleum) and one or more pumps. The invention finds application in production systems for hydrocarbons, where it is utilized for injecting water to maintain the pressure in a hydrocarbon reservoir (oil and gas), thereby enhancing oil recovery.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a motor-powered wheeled vehicle in which an upright orientation is maintained by a gyroscopic stabilizer member. The invention also relates to various braking, steering, aerodynamic control, and power transmission systems for use in a motor-powered wheeled vehicle of the type in which an upright orientation is maintained by a gyroscopic stabilizer member.
[0003] 2. Description of Related Art
[0004] The use of wheeled vehicles for recreational purposes dates back at least to the days of ancient Roman chariot races. By harnessing a chariot to a team of horses, the chariot racer was able to experience a combination of speed and power that offered thrills unlike any other activity of the time. With the advent of gasoline powered engines, the amount of power available to recreational users increased significantly relative to cost, allowing a far greater number of persons to experience the adrenaline rush resulting from traveling overland at high speeds.
[0005] For many persons, a major part of the thrill of operating high speed motor powered wheeled vehicles results from the sense of danger involved in having the ground pass by at speeds which would cause serious injury if one were to fall from the vehicle. For such persons, motorcycles are superior to other types of recreational vehicles, such as sports or racing cars. Motorcycles offer an intimacy between rider and vehicle that is lacking in three or four wheeled vehicles such as sports cars. In a four wheeled vehicle, control of the vehicle requires sitting back while pushing pedals and turning a steering wheel. In contrast, the motorcycle rider embraces his or her vehicle, letting the vehicle respond to the most subtle movements, with the whole body being involved in its control.
[0006] The present invention seeks to provide a vehicle that offers pleasures similar to those provided by motorcycles, with an even greater degree of involvement by the rider in controlling the vehicle, and an even greater sense of danger provided by an apparent additional degree of freedom to crash, without making the vehicle unreasonably difficult to control or unduly increasing the actual risk of injury. To do this, the invention makes use of a gyroscopic stabilizer member, and in particular a rotating funnel-shaped member extending upwardly from a pair of closely spaced substantially parallel wheels.
[0007] According to the gyroscopic principle, when a symmetrical object is free to rotate about the axis of symmetry, any torques applied to a point on the object in a direction perpendicular to the axis of rotation will be added to the angular momentum of the point at which the torque is applied, diminishing the apparent effect of the torque and causing the axis of rotation to precess only slightly in response to the torque. This effect is readily seen in a child's top, and is also used as the basis for control systems in ships and aircraft, as well as in compasses and other orientation sensitive devices.
[0008] The type of gyroscopic stabilizer member utilized by the present invention is to be distinguished from flywheel-based arrangements, in which the stabilizer has a relatively high mass. The purpose of a flywheel is to store energy, and while the gyroscopic effect of a flywheel can be used to maintain stability, the mass of the flywheel increases the mass of the vehicle and makes acceleration, steering, and braking difficult. In contrast, the rate of rotation of the gyroscopic stabilizer member utilized by the vehicle of the present invention may be controlled in order to improve vehicle performance and handling.
[0009] A number of gyroscopically stabilized vehicles have previously been proposed, but each involves use of inertial flywheels having a large mass, the rate of rotation of which cannot be readily controlled, or unduly complex control and stability mechanisms. Examples of previously proposed vehicles of this type include those disclosed in U.S. Pat. Nos. 5,314,034 (Chittal), 5,181,740 (Horn), 3,876,025 (Green), 3,399,742 (Malick), 3,724,577 (Ferino), and 2,415,056 (Wheeler).
[0010] Unlike previous gyroscopically stabilized vehicles, the present invention does not rely solely on inertia, but rather drives the stabilizer only as necessary to maintain stability, with maximum power from the engine being available on demand to drive the wheels. The effect of the rotating cone is essentially transparent to the rider, with the stabilizer having little effect on performance and steering.
[0011] Even with the gyroscopic stabilization feature, a motor-powered vehicle with a wheel-base of zero would present stability problems due to the tendency of gyroscopic elements to precess when a force is applied. Pressing on the top of a spinning top will eventually cause the axis of the top to approach horizontal, and the same would be true of acceleration, deceleration, and steering forces. To counter these tendencies, the present invention adds aerodynamic stabilizers and scaled steering and braking controls which enable control of the vehicle to be maintained during high speed maneuvers. Despite these additional complications, however, the controls for the vehicle are simple hydraulic or mechanically actuated controls which should prevent the cost of the vehicle from exceeding the resources of the average thrill-seeking recreational user.
[0012] While the invention is particularly suited to manned operation, it will of course be appreciated that, as with other types of relatively stabile motor vehicles, such as automobiles and three wheeled recreational vehicles, remote control operation as a toy will also offer opportunities for fun and excitement. This aspect of the invention has no analogue in motorcycles, since balancing of a motorcycle can only be achieved by a rider.
SUMMARY OF THE INVENTION
[0013] It is a first objective of the invention to provide a gyroscopically stabilized motor-powered vehicle which provides optimal performance and handling using relatively simple controls that can be manipulated by the average person.
[0014] It is a second objective of the invention to provide a gyroscopically stabilized motor-powered vehicle in which the wheels and stabilizer are driven by a common motor capable of delivering maximal on-demand power to the wheels for high acceleration, and in which the angular velocity of the stabilizer can be controlled in order to permit rapid acceleration and high speed maneuverability, with compensation for the reduced gyroscopic effect being provided by aerodynamic auxiliary stabilizers.
[0015] These objectives are achieved, in accordance with the broad principles of the invention, by providing a gyroscopically stabilized vehicle in which the gyroscopic stabilization member is a funnel-shaped member rotatable in a frame having a neck that supports at least one wheel and a relatively wide upper portion within or on which are located a motor for causing the stabilizer to rotate and for propelling the at least one wheel, a support for a rider, and subsystems for controlling the rate of rotation of the stabilizer, steering the vehicle, braking the vehicle, and providing auxiliary stabilization when the rate of rotation of the stabilizer is decreased to permit rapid acceleration and high speed maneuverability.
[0016] In a preferred embodiment of the invention, the vehicle includes a motor and two closely spaced generally parallel wheels, with power from the motor being transmitted directly to the funnel-shaped stabilizer member and to the wheels via a differential that distributes power between the stabilizer member and the wheels so that at low speeds, the stabilizer member is driven at a relatively high speed for maximum stability, and during acceleration, the rotation speed of the stabilizer is decreased in order to transmit maximum power to the wheels, with front-to-back stability being maintained during acceleration by independently controlled forward and rear auxiliary spoilers or stabilizers.
[0017] In an especially preferred embodiment of the invention, steering is facilitated by selective braking of the stabilizer member and the two wheels and, during high speed maneuvering, by the auxiliary stabilizers and by control of wheel position.
[0018] Preferably, the braking system including two types of brakes, one of which provides a fine braking control primarily for steering purposes and the other of which provides a higher degree of positive braking in order to decelerate the vehicle. The fine braking control is provided by a regenerative electromagnetic brake and the higher degree of positive braking is provided by a mechanical cam driven brake with anti-lock capabilities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a perspective view of a gyroscopically stabilized vehicle constructed in accordance with the principles of a preferred embodiment of the invention.
[0020] [0020]FIG. 2 is a perspective view of the gyroscopic stabilizing member used in the gyroscopically stabilized vehicle of FIG. 1.
[0021] [0021]FIG. 3 is a perspective view showing details of a frame for the gyroscopically stabilized vehicle of FIG. 1.
[0022] [0022]FIG. 4 is a perspective view of a drive train used in the gyroscopically stabilized vehicle of FIG. 1.
[0023] FIGS. 5 A- 5 C are perspective views showing the construction of a differential mechanism used in the gyroscopically stabilized vehicle of the preferred embodiment of the invention.
[0024] FIGS. 5 D- 5 H are perspective views showing the construction of a second differential mechanism used in the gyroscopically stabilized vehicle of the preferred embodiment of the invention.
[0025] [0025]FIG. 6 is a perspective view of the overall steering and braking systems used by the gyroscopically stabilized vehicle of the preferred embodiment of the invention.
[0026] [0026]FIG. 7 is a perspective view of the principal braking mechanisms of the gyroscopically stabilized vehicle of the preferred embodiment of the invention.
[0027] [0027]FIG. 8 is a perspective view showing the two main braking subsystems used by the gyroscopic vehicle of the preferred embodiment of the invention.
[0028] [0028]FIG. 9 is a perspective view showing an electromagnetic braking subsystem used in the gyroscopic vehicle of the preferred embodiment of the invention.
[0029] FIGS. 10 A- 10 D are perspective views of a mechanical braking subsystem for use in connection with gyroscopic vehicle of the preferred embodiment of the invention.
[0030] [0030]FIG. 11 is a perspective view of a controller that identifies the type of vehicle movement and direction of rotation for use in controlling the differential mechanism illustrated in FIGS. 5 D- 5 H.
[0031] [0031]FIG. 12 is a perspective view of a steering control subsystem for use in connection with the vehicle of the preferred embodiment of the invention.
[0032] [0032]FIG. 13A is a perspective view of the operator steering controls used in the vehicle of the preferred embodiment of the invention.
[0033] [0033]FIG. 13B is a perspective view showing a portion of the power steering mechanism used in the vehicle of the preferred embodiment of the invention.
[0034] [0034]FIG. 14 is a perspective view of a braking mechanism for the gyroscopic stabilizer for the vehicle of the preferred embodiment of the invention.
[0035] [0035]FIG. 15 is a perspective view of an auxiliary stabilizer control system for use in connection with the vehicle of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] [0036]FIG. 1 is a perspective view of a gyroscopically stabilized motor-powered vehicle constructed in accordance with the principles of a preferred embodiment of the invention. The vehicle includes a generally funnel or inverted cone-shaped frame 1 in which is rotatably mounted a generally funnel or inverted cone-shaped gyroscopic stabilizer member 2 , shown in detail in FIG. 2, and a motor 3 . At the apex of the frame are mounted a pair of wheels 4 and tires 5 . Extending laterally from the front and rear of frame 1 are auxiliary stabilizers 6 - 9 , each of which is independently movable relative to one of respective supports 10 and 11 , while a control pod 12 extends forwardly of the cone-shaped frame 1 . Also shown in FIG. 1 are braking control lines 13 for controlling a magnetic and mechanical braking system used for both deceleration and steering purposes, and additional steering control lines 14 used to control wheel positions during high speed maneuvering.
[0037] As is apparent from FIG. 2, the stabilizer member is generally in the form of a funnel 16 ′ having a relatively long cylindrical base portion 15 and a wide upper portion 15 ′ which can be fitted into a correspondingly-shaped base and upper portions of the frame on appropriate bearings. If the facing surfaces of stabilizer and frame are sufficiently smooth, for example, a Bernoulli effect can be utilized to permit the stabilizer to “float” relative to the frame, i.e., to be pneumatically supported, eliminating the need for mechanical bearings, although mechanical bearings may also be used. The width of the upper portion of the frame must be sufficient to permit a seat 17 to be mounted in the frame, and to leave room for the rider's legs to extend downwardly. In addition to the seat, the frame contains the motor 3 , and a foot-actuator for the main braking mechanism. There is also a gear 16 ″ (not shown in FIG. 2, but shown in FIG. 4) mounted in the inner surface of the portion 15 . This gear touches the four gears 44 which are connected to the propulsion system that provides power for rotation of the cone. The remaining controls can be placed on the outside of the frame or in control pod 12 .
[0038] Control pod 12 can be designed to have an aerodynamic shape, or simply to serve as a windbreak for the rider, and includes as best shown in FIG. 3 a handlebar support 19 and torso support 20 against which the rider can lean while controlling the vehicle. Preferably, the frame includes interior surfaces 21 that cover at least portions of the rotating gyroscopic stabilizer member 2 to protect the rider from contact with the stabilizer. In addition, as also shown in FIG. 3, frame 1 supports a set of struts 22 and cylinders 23 connected to control lines 14 for changing the position of the wheels, i.e., banking the vehicle, in response to a steering command, and support rings 24 and 25 which support drive gears 26 and 26 ′ for the wheels. The wheels are supported on axles (see FIG. 4) by hubs 77 ′ and spokes 77 .
[0039] It will be appreciated by those skilled in the art that while the vehicle of the preferred embodiment includes wheels 4 having tires 5 , the principles of the invention are not limited to two-wheeled vehicles, but rather may be extended to cover vehicles having multiple wheels and tracks designed to travel in snow or mud, as well as, in its broadest form, to vehicles with only one wheel, and to vehicles having auxiliary wheels in varying numbers, skis, or other stabilizing or traction elements. In addition, while FIG. 1 shows a person 30 having a body 31 , head 32 , and arms 33 seated in the vehicle on seat 17 , the vehicle could also be designed to be operated by remote control in an unmanned condition, for example for use as a toy or novelty item, with the rider replaced by an infrared or radio frequency receiver and electromagnetic actuators for the various subsystems.
[0040] Because of the high center of balance of the vehicle relative to its wheelbase, it may be necessary to provide some sort of supporting mechanism (not shown) in order to hold the vehicle in an upright position before starting the motor. However, once stabilizer 2 has reached a sufficient rotational speed, the vehicle will maintain an upright position without added support even while the rider is climbing into the vehicle. Access to the vehicle can be facilitated by including doors in the portion of the frame which extends above the top of the rotating stabilizer, although the height of the vehicle may be low enough so that the rider could simply step over the top of the frame in order to enter the vehicle.
[0041] As shown in FIG. 4, motor 3 , illustrated as an internal combustion powered engine with exhaust pipes 40 , but which could also be an electrically-powered or hybrid internal combustion/electric motor, outputs power to a gear 41 which transmits power to a gear 42 coupled by a shaft (not shown) to a differential mechanism 43 through a transmission system. Differential mechanism 43 transfers power to output gears 44 , which are connected to cone gear 16 ″ and shaft 45 , respectively, in order to drive gyroscopic stabilizing member 2 and wheels 4 . Shaft 45 serves as an input to a second differential mechanism 46 , which transfers power to two output gears 47 arranged to drive gears 26 shown in FIG. 4.
[0042] A lever 48 mounted on right stationary handlebar 51 is connected by wires to the clutch mechanism, with the wires being carried in conduit 49 , while a second conduit 50 extending around the periphery of frame 1 from handlebar control 51 carries engine speed signals in a manner similar to corresponding motorcycle speed controls.
[0043] The operation of differential 43 is illustrated in FIGS. 5 A- 5 C. Input power to the differential is provided by shaft 54 and bevel gear 55 , which engages bevel gears 56 . Each of bevel gears 56 is connected to a shaft 57 situated inside a cylindrical member 58 . There is a gear 59 ′ fixed in the member 58 , which drives a number of other gears 59 . Gears 59 are connected to shafts 60 which extend outwardly through openings in the differential housing 61 and which are attached to gyroscopic stabilizer 2 through the gears 44 , gears 44 being connected to gears 59 through output shaft 60 . In addition, bevel gears 56 also engage a second bevel gear 62 connected to output shaft 45 through the gears 44 .
[0044] In operation, rotation of shaft 54 and bevel gear 55 causes rotation of bevel gears 56 . If second bevel gear 62 is prevented from rotating because the wheels are braked, then gears 56 will orbit around the input axis, causing the member 58 to rotate and eventually the gear 59 ′ to rotate, thereby transmitting power to gears 59 and shafts 60 connected to gears 44 , causing the gyroscopic stabilizer member to rotate. On the other hand, if the gyroscopic stabilizer member is braked or prevented from rotating, then rotation of gears 56 causes gear 62 and shaft 45 to rotate, transmitting power to the wheels, with the amount of power distributed between the stabilizing member and the wheels proportionally to the relative braking forces applied to the stabilizing member and wheels. As a result, differential mechanism 43 automatically distributes power between the stabilizing member 2 and the wheels 4 .
[0045] The second differential mechanism 46 is a regular differential that has some modifications, as illustrated in detail in FIGS. 5D to 5 G. FIG. 5H shows the relationships between the various elements illustrated in FIGS. 5 D- 5 G. A driver for the second differential is illustrated in FIG. 11, described below.
[0046] The primary components of the second differential mechanism are illustrated in FIG. 5D, and include a primary gear D 2 attached to the propulsion source through a rod D 1 (D 1 here is shaft 45 ), and gear teeth D 4 . Rods D 7 are fixed to one of the sides of driving ring D 6 , and driving gears D 9 are situated inside the ring. In addition, the second differential mechanism includes a ring D 3 connected to ring D 6 and having teeth D 4 on an inner side and teeth D 5 on an outer side. Inside ring D 3 are smaller rings D 8 that touch rods D 7 .
[0047] [0047]FIG. 5E shows the terminal gears in the differential mechanism of FIG. 5D. These include a right gear that consists of a rod D 11 , teeth D 13 , and base D 12 , and a left gear that consists of a rod D 21 having a square shape, teeth D 23 and base D 22 . The terminal gears engage the driving gears D 9 from one side and the gears 47 from the other side, in the manner of a conventional differential. Unlike the conventional differential, however, the differential of the preferred embodiment further includes a freely rotatable member D 31 attached to the ring D 3 , and H-shaped members D 105 and D 106 that engage member D 31 . These H-shaped members are also connected to actuators D 101 , D 102 , D 103 , and D 104 which are connected through a wire with the controlling pedals. A fixing member D 41 is fixed to the differential mechanism from one of its sides, and has teeth D 42 at the other side, as shown in FIG. 5F.
[0048] Finally, as illustrated in FIG. 5G, the left terminal gears are driven by ring D 51 having teeth D 52 on a first side, and connections to L-shaped rods D 53 on a second side. The four L-shaped rods are fixed to a square sleeve D 54 that slidably holds a rod D 21 . Like the ring D 3 , ring D 51 is attached to a freely rotatable member D 55 , which is further attached to the H-shaped members D 105 and D 106 .
[0049] Operation of the differential illustrated in FIGS. 5 D- 5 H is similar to that of an ordinary differential. Rotation of gear D 2 causes ring D 3 , which drives rods D 7 and small rings D 8 , causing rotation of ring D 6 . Rotation of ring D 6 in turn causes rotation of driving gears D 9 , which drives the wheels of the vehicle through the left and right terminal gears.
[0050] The differential is engaged by pulling the pedals 110 in order to pull a wire 113 , as illustrated in FIG. 11, described below. Wire 113 activates the actuators D 101 , D 102 , D 103 , and D 104 . These actuators move the H-shaped members D 105 and D 106 , which move the freely rotatable member D 31 , ring D 3 , and teeth D 4 away from the primary gear D 2 . Movement of ring D 3 also engages teeth D 5 with teeth D 42 to lock the ring D 3 and driving gear D 6 . The movement of the H-shaped members also moves the freely rotatable member D 55 closer to the primary gear, which consequently moves the ring D 51 and teeth D 52 in order to touch the primary gear D 2 . Rotation of the primary gear D 2 that engages teeth D 52 rotates ring D 51 , which rotates rods D 53 and D 21 . Rod D 21 is connected to the left wheel and therefor will rotate the wheel. Moreover, rod D 21 is connected to the base D 22 and teeth D 23 , which are connected to the driving gears D 9 . Therefore, rotation of rod D 21 causes rotation of the driving gears D 9 because the driving ring D 6 is locked. Rotation of the driving gears then causes rotation of the teeth D 13 , the base D 12 , and consequently rod D 11 which is connected to the right wheel in a direction opposite to the direction of the left wheel.
[0051] The gyroscopically stabilized vehicle of the preferred embodiment of the invention utilizes two principal braking systems. The first is a magnetic braking mechanism that provides fine control for purposes of steering the vehicle, and the second is a mechanical brake that provides a greater braking force and is used to decelerate the vehicle. In addition, a parking brake for the cone is provided to lock the wheels during initial start-up so that full power can be transmitted by differential mechanism 43 to the cone-shaped gyroscopic stabilizer 2 . The magnetic braking system is illustrated in FIGS. 7 - 9 , while the principal mechanical brake is illustrated in FIGS. 7, 8, and 10 A- 10 D. Both braking systems are connected together, i.e., pressing the brake pedal activates both of them. However, the magnetic braking mechanism is softer than the mechanical braking mechanism and therefore will be activated first, the mechanical braking system being activated upon further pressing of the braking pedal.
[0052] The magnetic braking mechanism utilizes the drag exerted by pairs of coils 70 wrapped around a magnetizable element 70 ′″. The composite member, i.e., coils 70 and 70 ′″ are situated in a magnetic field generated by pairs of magnets 71 mounted in or on each of the wheels 4 to rotate with the wheels around the coils 70 . The transfer of energy from the moving wheels, and therefore from the rotating magnets 71 , to the coils is accomplished by the induction effect, in which the relative movement of the coils and the magnetic field surrounding the magnets causes a current to be induced in the coils. The number of turns of the coils that are within the magnetic field of the magnets determines the amount of rotational energy transferred to the coils according to well-known principles of electromagnetic energy transfer, with the transfer of rotational energy resulting in a rotation retarding force being exerted by the coils on the wheels. By moving the coils into and out of a position between the magnets for each of the wheels, the amount of energy transferred can be precisely controlled.
[0053] Movement of the coils with respect to each of the wheels 4 is accomplished by four hydraulic actuators 72 having pistons 73 arranged to move the coils into and out of a space present between the inside surface of wheels 4 and a non-rotating disc 74 . Disc 74 supports the non-rotating portions of the braking mechanism and is connected to frame 1 by struts 22 , while power to the wheels is supplied by gear 75 . Gear 75 is driven by gear 26 and is pivotally connected to axle 76 , and axle 76 is connected to the magnet 71 by spokes 77 ″ and to the corresponding wheel 4 by cover 77 ″″ and spokes 77 located on the outside of the wheel assembly so as not to interfere with movement of coils parallel to the axle. Each of the actuators 72 is connected to branches 78 ′ of a common hydraulic fluid line 78 , which in turn is connected at ends 79 to steering control lines 140 and magnetic brake master cylinder 134 , shown in FIG. 12. One fluid line 78 controls the left side pair of coils and the other controls the right side pair.
[0054] Those skilled in the art will appreciate that in order to complete the transfer of energy from the wheels to the magnetic braking system, the current induced in the coils must dissipated, which can be accomplished by supplying the current to a battery or to other electrical subsystems via wires 82 . In addition, those skilled in the art will appreciate that while the actuators for moving the coils in appreciate that while the actuators for moving the coils in and out are hydraulic, as will be explained below, the invention could also be implemented using mechanical or electro-mechanical actuators.
[0055] The mechanical braking mechanism utilized in the preferred embodiment may be similar to the one disclosed in allowed U.S. patent application Ser. No. 08/407,079, filed May 20, 1995, and incorporated herein by reference, which discloses a braking mechanism in which a rotating cam is slidable along a rotating axis, the axial position of the cam determining the pressure applied to cam followers, and therefore to the brake shoes. In the preferred embodiment, illustrated in FIGS. 10 A- 10 D, the cam 90 is moved axially by an axially slidable plate 91 , with the cam being caused to rotate relative to the plate by axle 76 . Cam followers 92 extend through openings in a housing 93 mounted on disc 74 and are biased against cam 90 by springs 94 attached to brake shoes 95 .
[0056] In order to brake the vehicle using the brakes illustrated in FIGS. 10 A- 10 D, cam 90 is moved axially relative to axle 76 in response to hydraulic actuators 96 connected to hydraulic control lines 97 . The surface of cam 90 which is engaged by cam followers 92 has a cross-section that decreases in diameter from the side of the cam on the outside of the wheel to the side of the cam on the inside of the wheel. As a result, as the cam is moved axially toward the outside of the wheel by hydraulic actuators 96 , the cam followers 92 are pushed outwardly, causing brake shoes 95 to engage an appropriate lining (i.e., drum 99 ) on the inside of wheel 4 and thereby brake the vehicle. If desired, the shaped of cam 90 can be varied according to the principles described in allowed U.S. patent application Ser. No. 08/407,079, so that the larger diameter portions of the cam are elliptical in cross-section, which will cause the cam followers move in and out for a given brake pressure as the cam rotates, and thereby provide an anti-lock braking effect.
[0057] In the preferred embodiment, the mechanical brakes are actuated by a foot pedal arrangement using pedals 100 positioned under the heel of the rider. Movement of pedals 100 is transmitted by wires 101 or other mechanical linkages to brake cylinders 102 , the outputs of which are carried by conduit 103 to an intermediate cylinder 104 . Intermediate cylinder 104 includes a branched piston 105 arranged to supply equal amounts of pressure to respective cylinders in housing 106 , the output of which is carried by hydraulic lines 97 and 79 to actuators 96 . The connection between lines 97 and 79 is shown in FIG. 12 as the terminal for conduits 140 . Actuators 96 move the cam 90 and actuators 72 , which respectively move the ring 70 . Not shown are bias springs to cause return of the brake pedals and cams when the rider releases the brake pressure.
[0058] [0058]FIG. 11 shows the driver for the second differential illustrated in FIGS. 5D to 5 H. The driver uses a simple wire control actuated by pedals 110 located in the vicinity of the main brake pedals 100 . Pedals 110 move wires 111 which are combined in mechanism 112 to move a single output wire 113 , which passes through a cable to control the second differential described above via actuators 114 .
[0059] Turning to FIGS. 12, 13A and 13 B, steering is accomplished by turning the motorcycle-like handlebar 120 , shown in FIG. 13A, which causes a vertical rod 121 and horizontal rod 122 to rotate correspondingly. Rod 122 extends through cam slots 123 in cam plates 124 , as illustrated in FIG. 13B, such that rotation of rod 122 causes the rods 120 - 122 to bend or swing relative to support 126 . Frame 127 tilts in response to the relative tilting of rods 121 , and causes rotation of a pinion 128 . Pinion 128 engages a rack 129 and causes the rack to move linearly in response to tilting of frame 127 . Connected to rack 129 is piston shaft 130 , which is connected to pistons in each of hydraulic cylinders 131 , cylinders 131 in turn being connected to a master cylinder 132 in such a manner that tilting of the frame 127 in one direction causes shaft 133 to extend out of cylinder 132 , and tilting of the frame 127 in the other direction causes the shaft to withdraw into the cylinder. Shaft 133 simultaneously moves pistons (not shown) in three different master cylinders 134 - 136 . Cylinder 134 serves as a master cylinder for the electro-magnetic and mechanical braking subsystem, while cylinder 135 serves as a master cylinder for a banking or wheel positioning subsystem, and cylinder 136 serves as a master cylinder for the auxiliary stabilizer subsystem.
[0060] Locking and unlocking of the control pod 12 for movement in forward and backward directions is accomplished ugh the use of a mechanism consisting of a lever 137 connected by a wire 138 which controls the pads 126 ′. Pads 126 ′ allow movement of the pod along bars 126 .
[0061] At low speeds, steering may be accomplished solely by braking of the wheels using the electro-magnetic braking mechanism combined with the mechanical anti-lock braking mechanism described in connection with FIGS. 7 - 10 . The connection between the steering and braking mechanisms, and in particular connection points 79 shown in FIG. 12, is provided by lines 140 , which are connected to master brake cylinder 134 so that movement of the piston 133 causes a corresponding movement of the left or right coils 70 with respect to magnets 71 in wheels 4 , and the corresponding movement of the left or right member 90 with respect to followers 92 .
[0062] At higher speeds, however, it becomes desirable to bank or tilt the vehicle during a turn, which requires braking of the rotating stabilizing member, and therefore use of the auxiliary stabilizing members to stabilize the vehicle during high speed turns. These functions are accomplished by master cylinder 135 , which is connected by lines 14 , as described above, to cylinders 23 and struts 22 , and by master cylinder 136 , which is connected to auxiliary stabilizer control system shown in FIG. 15.
[0063] When the handlebars are turned, frame 127 will tilt by an amount sufficient to actuate both the banking and stabilizer control cylinders 135 and 136 in addition to the electromagnetic and mechanical brakes master cylinder and therefore automatic activate the wheel position control and auxiliary stabilization subsystems as described below. It will be appreciated, however, that rotation of the gyroscopic stabilizer 2 will serve to prevent the vertical axis of the vehicle from tilting. As a result, the preferred embodiment includes a subsystem, shown in FIG. 14, for reducing the rotational speed of the stabilizer member 2 when rapid acceleration and high speed maneuvering is desired. The subsystem for braking the gyroscopic stabilizer includes a control lever 142 mounted on handlebar 120 , a wire 143 , and a brake shoe 144 arranged to press against the rotating stabilizer in order to reduce its rotation and angular momentum.
[0064] The auxiliary stabilizers 6 - 9 are in the form of airfoils, with the front stabilizers 8 and 9 being inverted to pull the front of the vehicle downwards as the rear of the vehicle is lifted by the rear stabilizers 6 and 7 . The effect of the stabilizers to counter the tendency of the vehicle to tilt backwards during acceleration, and to facilitate banking during a high speed turn by increasing the lift on the right or left side. Each of the auxiliary stabilizers 6 - 9 includes, as is best illustrated in FIG. 15, a respective hydraulically operated pivot mechanism 150 - 153 actuated by pairs of cylinders 154 / 155 - 160 / 161 to pivot about a principal axis of the stabilizers and thereby control the amount of lift generated by the stabilizers. If the stabilizers are pivoted sufficiently, it will be appreciated that the stabilizers can also be used to provide an air braking effect to facilitate rapid deceleration.
[0065] Actuation of the respective cylinders 154 - 161 is accomplished by cylinder assembly 162 , shown in FIG. 12,15 and cylinder assembly 163 , shown in FIG. 15. Cylinder assembly 162 is part of the steering mechanism and includes master cylinder 136 , which is connected to cylinder 164 by hydraulic lines 165 . Cylinder 164 includes a piston shaft 168 having four branches to actuating hydraulic fluid in each of four cylinders 169 - 172 , which are connected to cylinder 164 so that stabilizers 6 and 8 may rotate in opposite directions to stabilizers 7 and 9 and thereby provide different amounts of lift on each side of the vehicle in order to facilitate high speed turning of the vehicle in cooperation with the banking effect provided by actuation of struts 22 .
[0066] The second cylinder assembly 163 , on the other hand, simultaneously move stabilizers 6 - 9 in a direction which increases lift at the rear of the vehicle and a downward force at the front of the vehicle so as to maintain stability during acceleration or deceleration. This is accomplished by connecting master cylinder 181 via a branched piston to cylinders 182 , 183 and 188 , 189 and hydraulic lines 173 - 180 in such a manner that cylinders 182 and 188 commonly actuate the two rear stabilizers, and cylinders 183 and 189 commonly actuates the two front stabilizers. Master cylinder 181 is actuated by a rotatable sleeve 184 on handlebar 120 , wires 185 attached to a disc attached to the sleeve, cylinders 186 , and hydraulic lines 187 which serve to actuate the piston in master cylinder 181 .
[0067] Having thus described a preferred embodiment of the invention in sufficient detail to enable those skilled in the art to make and use the invention, it will nevertheless be appreciated that numerous variations and modifications of the illustrated embodiment may be made without departing from the spirit of the invention. For example, while the illustrated embodiment utilizes a single rotating stabilizer member, a second stabilizer could be added to a counter-torque and therefore provide additional stabilization. In addition, the gyroscopic stabilizer could be driven by a motor separate from the main propulsion motor, and each of the hydraulic control lines could be replaced by electrical controls, with such features as microprocessor control in order to fine tune the response of the various subsystems to operator control. As indicated above, the vehicle may also be remotely controlled to serve as a toy. Because of the possibility of such variations and modifications of the preferred embodiment of the invention, as well as numerous others which may occur to those skilled in the art, it is intended that the invention not be limited by the above description or accompanying drawings, but that it be defined solely in accordance with the appended claims.
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A gyroscopically stabilized vehicle includes a funnel-shaped member rotatable in a frame having a neck that supports two closely spaced generally parallel wheels and a relatively wide upper portion within or on which are located a motor for causing the stabilizer to rotate and for propelling the wheels, a support for a rider, and subsystems for controlling the rate of rotation of the stabilizer, steering the vehicle, braking the vehicle, and providing auxiliary stabilization when the rate of rotation of the stabilizer is decreased to permit rapid acceleration and high speed maneuverability. Power from the motor is transmitted directly to the funnel-shaped stabilizer member and to the wheels via a differential that distributes power between the stabilizer member and the wheels so that at low speeds, the stabilizer member is driven at a relatively high speed for maximum stability, and during acceleration, the rotation speed of the stabilizer is decreased in order to transmit maximum power to the wheels, with front-to-back stability being maintained during acceleration by independently controlled forward and rear auxiliary spoilers or stabilizers. Steering is facilitated by selective braking of the two wheels and, during high speed maneuvering, by selective braking of the stabilizer member and independent control of the auxiliary stabilizers and the position of the wheels relative to the frame.
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BACKGROUND OF THE INVENTION
An OSB panel in the sense of the present invention consists of at least one layer constituted by flat wood chips, so-called strands. The strands of this layer are oriented in a preferred direction (here in production direction=longitudinal panel direction. Even in the case of a single-layer panel, a lower and a mirror-equal upper face sheet are normally combined into an internally homogenous layer in course of manufacture of this panel.
In case of a multi-layered construction, the previously described layer constitutes the lower and upper face sheet, and the medial layer (in case of a 3-layer model) with no preferred orientation of the strands is located between them. This dispersion is also designated as “random” in language of the specialized field. The innermost layer of the panel is designated as the medial layer. Thus a 3-layer panel consists of an upper and a lower face sheet and a medial layer, a 5-layer panel or one with more layers consists of an upper and lower face sheet of a medial layer and of layers between the upper or the lower face sheet and the medial layer. A preferred embodiment of the invention is in form of a 3-layer panel, a 5-layer panel or one with even more layers (whereby an odd number of layers is rational). Even numbers of layers are however just as possible.
SUMMARY OF THE INVENTION
It is the technical aim of the invention to indicate an OSB panel suitable for utilization on large surfaces, e.g. one that can also be used to erect buildings.
The above technical aim is attained through the invention by an OSB panel having the characteristics of claim 1 . Additional embodiments are indicated in the sub-claims and are described in detail further on.
The present invention describes a large-size panel of wooden material, a building component produced from it as well as a process for the production of a large-size panel with high mechanical properties such as e.g. the parameters for flexion, traction and pressure without increasing the specific weight of the panel beyond the normal extent for that purpose. In addition, technological properties of an OSB panel are described through which these improved mechanical properties can be obtained, as well as possible utilizations of this OSB plate.
The strand geometry (length, width, thickness), the orientation of the strands within a layer in a desired direction, the amount and type of the bonding material or of the mixture of several bonding materials, the amount of additives such as hardeners and paraffin, the thickness relationship between the outermost layer and the medial layers or layer, the density profile that is influenced by targeted control of the process parameters and finally the overall panel thickness and the panel size, adapted to the intended application, are all influence parameters for the preferred embodiments of the present invention.
The present invention as well as its preferred embodiments makes it possible to achieve the following mechanical and technological properties. These should be understood to be minimum values and are indicated as mean values. The dispersion of the parameters is low because of manufacturing conditions. The properties are determined in accordance with EN 789:1995 “Testing Methods for Wooden Structures—Determination of the mechanical Properties of Wood Materials”. This standard regulates the determination of characteristic properties of wood materials used in construction of bearing purposes. The designation “longitudinal” means that the orientation of the strands in the upper face sheet is parallel to the sample length in the sense of EN 789, and “transversal” indicates a strand orientation perpendicular to the sample length. The following indications relate as an example to panels with a minimum thickness of 25 mm. Even higher parameters are to be expected as a rule for thinner panels.
Flectional strength perpendicular to the plane of the panel: Longitudinal ∃ 30.0 N/mm 2 Transversal: ∃ 15.0 N/mm 2 Flectional elasticity modulus, perpendicular to the plane of the panel: Longitudinal: ∃ 7000 N/mm 2 transversal: ∃ 3000 N/mm 2 Transversal strength in the plane of the panel Longitudinal: ∃ 1.2 N/mm 2 transversal: ∃ 1.40 N/mm 2 Rigidity modulus in the plane of the panel: Longitudinal: ∃ 200 N/mm 2 transversal: ∃ 190 N/mm 2 “Moist” resistance to pressure in the plane of the panel Longitudinal: ∃ 24.0 N/mm 2 transversal: ∃ 16.5 N/mm 2 “Moist” elasticity of compression modulus in the plane of the panel Longitudinal: ∃ 5000 N/mm 2 transversal: ∃ 3200 N/mm 2
For the moisture tests (designation “moist) the sample was stored for a period of 15 hours in water at room temperature before the test. The test was conducted with drained-off samples.
Flexural strength in the plane of the panel: Longitudinal: ∃ 20 N/mm 2 Elasticity of tension modulus in the plane of the panel: Longitudinal: ∃ 6000 N/mm 2 Resistance to pressure in the plane of the panel: Longitudinal: ∃20.0 N/mm 2 Elasticity of compression modulus in plane of the panel: Longitudinal: ∃ 6000 N/mm 2
In an additional embodiment of the invention the following properties apply:
Flectional strength, perpendicular to the plane of the panel: Longitudinal: ∃ 35.0 N/mm 2 transversal: ∃ 10.0 N/mm 2 Flectional elasticity modulus, perpendicular to the plane of the panel: Longitudinal: ∃ 8000 N/mm 2 transversal: ∃ 2000 N/mm 2
The properties of the wood material panels are influenced by the geometry of the strands and by the as much as possible uniform configuration of the strands of the face sheet, by the ratio of thickness of the face sheets and the overall thickness or of the weight per surface unit of the face sheet and the overall weight per surface unit of the panel and the median specific gravity (density) of the panel.
It has been shown that the following parameters regarding strand dimensions are advantageous in achieving the desired mechanical and technological properties:
Strands of the outer layers (face sheets): Length: 130-180 mm Width: 10-30 mm Thickness: 0.4-1.0 mm Strands of the medial layer: Length: 90-180 mm Width: 10-30 mm Thickness: 0.4-1.0 mm
Each of the two face sheets (outer layers) should consist in the finished product of at least 30 percent in weight of the overall dispersed chip quantity, so that the sum in the upper and in the lower face sheet represents a proportion of at least 60%. The remaining 40% represent the medial layer in a 3-layer panel. The specific gravity of the panel should amount at most to 700 kg/m 3 , but a value of less than 650 kg/m 3 is to be desired. These data relate to dry panels.
As a rule, the strands are produced from round stock, preferably available in a debarked state. The round stock logs are conveyed to a chipping machine (flaker) that produces strands in the desired dimensions in one single pass through the rotating tools. However a multi-stage production of the strands is also possible, such as e.g. from a peeled veneer that is reduced into strands in another operation.
It is advantageous for the obtention of the desired properties if the part of minute particles is reduced to a minimum in the individual layers. A minute particle is to be understood as a strand with dimensions significantly different from the strand dimensions described earlier. The preponderance of minute particles should be avoided primarily in course of production, e.g. through careful debarking and periodic sharpening of the cutting tools of the flaker. It is however also possible to provide for the separation of minute particles after the production of the strands.
Of course the proportion of minute particles can only be reduced to a tolerable minimum but cannot be completely avoided, even when care is taken in strand production and in separation. The proportion of minute particles may easily represent 10 to 15 percent in weight of the weight of the finished panel.
The type of wood used for the strands is not relevant. In principle all types of wood such as e.g. poplar, birch, beech, oak, pine, fir etc. can be used. Fir wood has proven to be especially suitable because of its good chipping properties and its relatively high content in resin.
In order to reduce the swelling characteristics, paraffin or wax can be added. It can be applied in form of a melted mass at the higher temperature required for this (liquid wax application), or close to room temperature in case of emulsions.
Urea-formaldehyde binders (UF), melamine formaldehyde binders (MF), phenol formaldehyde binders (PF) binders on basis of isocyanate (e.g. PMDI) and also binders based on acrylates have proven to be effective binders. In most cases a mixture of at least two of these types of binders is used, but a mixture of several binder types is also possible. A mixture should not be understood to be only one consisting of different types of binders that are already usable, but also mixtures of different of the listed types resulting in course of production in form of mixture. Thus e.g. melamine-urea-formaldehyde binders (MUF) or melamine-urea-phenol-formaldehyde binders (MUPF) can be produced by boiling the ingredients together in the same reactor. The individual layers of the panel may also contain different types of binders and their mixtures, it being advantageous in case of multi-layer panels for reason of stability under load to provide the same types of binder or the same mixture for those layers that are placed in the same position relative to the panel surfaces. Thus it has been shown, for example, that the requirements of the invention in case of a 3-layer panel can be very well met if the upper and lower face sheets are provided with an MUPF binder, and the medial layer with a binder based on isocyanate (PMDI).
The proportion of binder and the type of binder are determining factors for the desired mechanical and technological properties. The content in binder depends on the type of binder. Binder content for UF, MF, PF and their mixtures are within a range from 10 to 15 percent in weight (in mixtures, the sum of the components used) calculated as solid resin relative to the dry mass of wood strands. When isocyanate is used the proportion of binder can be reduced to 5-10 percent in weight.
The strands are coated with binder before forming the strand mats. Large binder coating drums are normally provided for this purpose, making continuous binder coating possible in course of the pass. The drums rotate around their longitudinal axis and thereby keep the supplied strand material in constant movement. A fine binder mist that is deposited evenly on the strands is produced in the drums by means of nozzles. The drums contain integrated structures, on the one hand in order to be able to constantly grasp the strand material, and on the other hand in order to convey the strand material from the inlet going into the drum to the outlet. An inclination of the drum in longitudinal direction can assist the forward movement of the strand.
The desired mechanical and technological properties are achieved by the targeted orientation of the strands.
Especially in case of a single-layer panel as well as with the cover layers of multi-layer panels the orientation of the strands must preferably be in one direction (e.g. parallel to the longitudinal sense of the panel=production sense), whereby orientation shall be ensured to a great extent. Only a small percentage of chips may deviate by more than ∀ 15° from the selected direction of orientation. Nevertheless sufficient strength and rigidity still exists in “transversal” direction of the panel, since the dispersion process always produces a deviation from the target orientation.
In case of 3-layer or multi-layer panels the target orientation of the strands depends on the position of the strand layer within the panel. The two outermost layers, the face sheets, should be oriented parallel to the panel length as described above in case of a single-layer panel. In viewing a 3-layer OSB panel, the strands of the single medial layer are oriented without any preferred direction (random).
A panel consisting of more than 3 layers is also possible. As a rule the number of layers will be uneven, whereby the strand orientation of the face sheets and of the medial layer is as described above, and the orientation of the other layers may be in any desired direction. Thus it is possible that the preferred strand orientation of these other layers may be perpendicular to the strand orientation of each adjoining outer layer. However a random orientation of individual layers is also possible.
A dispersion machine achieves the forming of the strand mats from the different superimposed layers. As a rule, one dispersion head is provided for each layer. Its task is to arrange the binder-coated strands in the target direction or randomly. After the dispersion of the mats, pressing them into a stable panel-shaped product takes place under the action of pressure and temperature. This can be achieved through cadenced pressing (pressing for one or several days) or in continuously operating presses. The latter make it possible to produce an endless panel ribbon that can be cut down to the desired sizes.
The panels can be ground after being produced. Thereby a homogenous panel thickness with low thickness tolerances and improved conditions for the bonding together of two or more panels into structural components, as described below, can be achieved. However if the panel surface quality is sufficiently good and the thickness tolerance of the panels is sufficient, bonding without previous grinding is also possible.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in further detail through examples of embodiments, whereby reference is made to the enclosed drawings. In the drawings
FIG. 1 shows a first embodiment of an OSB panel according to the invention,
FIG. 2 shows the structure of layers in the OSB panel,
FIG. 3 shows two examples of a structural element produced from OSB panels and
FIG. 4 shows the structure of a structural element with large surface produced from OSB panels.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a wood material panel 1 consisting as described earlier of three layers of strands. The upper strand layer 2 shows a preferred orientation of the strands 5 in the longitudinal direction of the panel. It can be seen that the strands 5 of the strand layer 2 are not strictly parallel to the long side of the panel, but that nevertheless a high degree of orientation is achieved. The medial layer 3 is made up of strands 6 that are somewhat shorter than the strands of the face sheets 2 and 4 . The orientation of the strands 6 of the medial layer 3 is random. The lower face sheet 4 is a mirror image of the upper face sheet 2 . The terms “panel length” and “panel width” for the panel 1 shown in FIG. 1 are selected only as example reference values for a detail of a large panel and need not represent the actual dimensions, panel length and panel width. In addition, FIG. 1 shows that the thickness s 1 of each of the two face sheets (the lower face sheet 4 as well as upper face sheet 2 , structured as a mirror image) is 30% of the overall thickness s of the panel and the thickness s 2 of the medial layer 3 is approximately 40%.
The single plate 1 produced according to the process described above may have a thickness s up to 50 mm and dimensions of 2.8×15 m and may be used for various applications in the building field. The panel length of 15 m should definitely not be regarded as a maximum limit. However it has been shown that in manufacture as well as for the subsequent handling of panels in course of further processing, a useful size is around 10 to 15 meters.
If several panels (e.g. 3×32 mm=96 mm) are combined into a sandwich element of greater thickness, components with large surfaces can be obtained. FIG. 2 schematically shows such a component 10 consisting of 3 single panels 1 . In addition the single panels 1 are glued together by means of a binder such as e.g. isocyanate at least partially over large surfaces. Such a component can be used e.g. in building construction for outer and inner walls, with the advantages that elements can be produced without seams to match the length of the wall over a full story height (up to 2.8 m). Current building construction experience (e.g. one-family home, multi-family home) shows that wall elements with a length between 10 and 15 meters are quite sufficient for the production of entire wall, ceiling and roof elements. Regarding the length of panels or components, it should be considered that during the transportation of these elements from the place of manufacture to the place of further processing or utilization, certain limits do exist. Maximum panel and component lengths should also be considered from this point of view. The needed openings such as windows and doors can be produced by means of the usual tools such as saws and grinders normally used for massive wood.
From the above-mentioned sandwich elements with large surfaces it is also possible to make supports in such manner that the strips can be produced in the desired support width or support height. The strips are cut according to the panel length, so that a support length up to 15 m is possible. These supports can be combined on one or both sides with large-format OSB panels to constitute ceiling, wall or roof elements having sufficient stability to bridge spans of several meters.
FIG. 3 shows two different embodiments and a lower panel 23 . The panel 21 itself consists again of 2 single plates 1 , the support 22 itself consists of single plates 1 . The panels 21 and 22 are combined with the support 22 in a positively locking or non-positively interlocking manner. If component 21 is a ceiling element, the panel 21 assumes the function of floor of the upper story and the panel 23 the function of ceiling of the lower story. This also applies in the same sense to FIG. 3 b . Here the component 20 consists of an upper panel 31 made up of only one single panel 1 , then of the support 32 and of the lower panel 33 . Contrary to the support 22 , the support 32 is placed lying flat.
FIG. 4 shows the structure of a large-surface building element 20 consisting of a plurality of single panels 1 . The length L may be up to 15 m and the width B up to 2.8 m. The supports 23 , 33 are fixedly connected to the panels 21 , 31 and 22 , 32 . As a result the component possesses a great bearing capacity in combination with the good mechanical and technological properties of the single panels 1 themselves.
EXAMPLE 1
The 3-layer OSB panel in the following example was produced in an industrial plant.
The production of the strands of the central and face sheets takes place on separate processing lines until formation of the mats. Strands with a length of approximately 150 mm, a width between 10 and 25 mm and a thickness between 0.5 and 0.8 mm are produced from debarked pine logs. Minute material is already separated as much as possible. The drying which follows reduces the moisture content of the strands of both layers to a value between 3 and 5%. Before adding the binder, the proportion of minute material is minimized by means of a sieving arrangement. The binder is added in binder coating drums, whereby the face sheet is mixed with approximately 13% in weight of a melamine-urea-phenol-formaldehyde binder (solid resin relative to dry wood mass) and the medial layer with 8% in weight of a PMDI binder.
The mats are then formed over a width of approximately 2.80 m, whereby the strands of the lower face sheet with a strand orientation in production direction are laid down first, then the medial layer with random dispersion and without unidirectional orientation of the strands, and finally the upper face sheet with a strand orientation that is also in production direction. The weight per surface unit of the lower face sheet, relative to the overall mat weight, is 36%, that of the medial layer 28% and that of the upper face sheet also 36%. The mat thus obtained is compressed into an OSB panel with a final thickness of 33.5 mm under the action of pressure and temperature, and the endless panel produced in a continuous process is then cut down into panels measuring 12.0×2.80 m. Following a maturation time of 5 days, the panel possesses the following properties (median value over 5 tests):
Flectional strength according to EN 789 perpendicular to the plane of the panel, longitudinal: 36.9 N/mm 2 Flectional elasticity modulus according to EN 789 perpendicular to the plane of the panel, longitudinal: 8322 N/rnm 2 (maximum value 8816 N/mm 2 ) Density at approximately 12% moisture: 645 kg/m 3 Panel density at 0% moisture: 585 kg/m 3
Three panels obtained in this manner were ground down to a thickness of 32 mm and were bonded together under pressure over their entire surface by means of a binder based on isocyanate into a panel element with an overall thickness of 96 mm. The sandwich element that was thus obtained has the same dimensions as the single panels (2.80×12.0 m) and possesses the following properties (median value over 5 tests):
Flectional strength according to EN 408 perpendicular to the plane of the panel, longitudinal: 23.8 N/mm 2 Flectional elasticity modulus according to EN 408 perpendicular to the plane of the panel, longitudinal: 6393 N/mm 2
(The German Industrial Standard (DIN) EN 408, March 2001 edition under the title “Wooden structures—construction wood for bearing purposes and layered panel wood—determination of several physical and mechanical properties” defines testing methods for the determination of the dimensions, wood moisture and density, and describes the conditions of the testing samples of construction wood for bearing purposes and for layered panel wood. This standard was used oto test the sandwich elements described above).
EXAMPLE 2
The 3-layer OSB panel in the following example was produced in an industrial plant.
The production of the strands of the central and face sheets proceeds until mat formation on separate product ion lines. Strands approximately 140 mm long, from 10 to 30 mm wide and approximately 0.6 mm thick are produced from debarked pine logs. Minute particles are already separated as much as possible. The then following drying process reduces the moisture content of the strands of both layers to a value from 3 to 5%. Before the addition of binder, the proportion of minute material is minimized by means of a sieving apparatus. The addition of binder takes place in binder coating drums, whereby the face sheet was mixed with approximately 7.0% in weight of PMDI (solid resin in relation to dry wood mass) and the medial layer was mixed with 5.5% in weight of a PMDI binder.
The mat is then formed over a width of approximately 2.80 m, whereby the strands of the lower face sheet with a strand orientation in production direction are laid down first, and then the randomly dispersed medial layer without unidirectional strand orientation, and finally the upper face sheet having a strand orientation that is also in production direction. The weight per surface unit of the lower face sheet relative to the overall mat weight is 35%, that of the medial layer 30% and that of the upper face sheet also 35%. The mat obtained in this manner is compressed under the action of pressure and temperature into an OSB panel with a final thickness of 24.8 mm, and the endless panel produced in continuous process is then cut into formats of 12.0×2.80 m. Following a maturation time of 5 days the panel which has not been ground just as in example 1, possesses the following properties (mean value over 10 tests):
Flectional strength according to EN 310 perpendicular to the plane of the panel, longitudinally: 51.5 N/mm 2 Flectional elasticity modulus according to EN 310, perpendicular to the plane of the panel, longitudinally: 8351 N/mm 2 (maximum value 9004 N/mm 2 ) Flexural strength according to EN 408 in the plane of the panel, longitudinally: 25.3 N/mm 2 (mean value over 4 tests) Elasticity of tension modulus according to EN 310 in the plane of the panel, longitudinally: 7392 N/mm 2 (mean value over 4 tests) Panel moisture: approximately 8% Panel density at 0% moisture: 629 kg/m 2
EXAMPLE 3
The single-layer OSB panel of the following example was produced in an industrial plant.
Strands approximately 140 mm long, from 10 to 30 mm wide and from 0.5 to 0.6 mm thick are produced from debarked pine logs. Minute particles are already separated as much as possible. The then following drying process reduces the moisture content of the strands to a value from 3 to 5%. Before the addition of binder, the proportion of minute material is minimized by means of a sieving apparatus. The addition of binder takes place in binder coating drums, whereby the mixing was effected with approximately 7.0% in weight of PMDI (solid resin in relation to dry wood mass). (In agreement with Wismar)
The unidirectional mat forming then takes place in production direction by means of two dispersion heads in a row over a width of approximately 2.80 m. No “crosswise” or “randomly” oriented medial layer is dispersed. The mat obtained in this manner is compressed under the action of pressure and temperature into an OSB panel with a final thickness of 24.8 mm, and the endless panel produced in continuous process is then cut into formats of 12.0×2.80 m. Following a maturation time of 5 days the panel which has not been ground possesses the following properties (mean value over 10 tests):
Flectional strength according to EN 310 perpendicular to the plane of the panel, longitudinally: 47.2 N/mm 2 Flectional elasticity modulus according to EN 310, perpendicular to the plane of the panel, longitudinally: 8488 N/mm 2 Flexural strength according to EN 408 in the plane of the panel, longitudinally: 24.2 N/mm 2 (mean value over 4 tests) Elasticity of tension modulus according to EN 310 in the plane of the panel, longitudinally: 7275 N/mm 2 (mean value over 4 tests) Panel moisture: approximately 8% Panel density at 0% moisture: 614 kg/m 2
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The invention relates to a large-size OSB-board having improved technical and mechanical properties. The aim of the invention is to solve the technical problems posed by an OSB-board which is suitable for using on large surfaces and also, for example, for the construction of buildings. To this end, the board has a width of at least 2.60 m and a length of at least 7.0 m, and the flectional elasticity module is it least 700 N/mm 2 in the main loading direction.
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BACKGROUND OF THE INVENTION
The present invention relates to a roll press, preferably for the treatment of a traveling web, for instance a web of paper. The roll press comprises two press units, for example press rolls, the main axes of which lie in a pressing plane and form with each other a press nip through which the web travels. The roll press can also comprise three press units which form two press nips, or four press units which form three press nips.
The invention proceeds from a roll press having the following features. It is a roll press for the treatment of a traveling web of paper having two press units which may be in the form of press rolls. Each press unit, hereafter called a press roll, has a respective axis. The axes together lie in a press plane. The press rolls are so placed as to define a first press nip between them. One of the two press rolls includes a stationary support member that supports a traveling or circulating press element around the support member and that supports an internal pressing device for radially outwardly biasing the traveling or circulating press element toward the web and the other press roll. There are respective bearing brackets at each end of each of the press rolls. The bearing brackets at each end of the rolls are connected to each other by detachable tension bars which transmit the pressing force between the bearing brackets at the respective roll end. One set of the bearing brackets for one of the press rolls are rigidly supported on a machine frame or foundation and bear or support the weight of the other press roll. As prior art, referencee is had to WO 92/17641 published after the priority date claimed.
The "main axis" of a press unit can, for instance, be the axis of rotation of a press-roll jacket or the longitudinal axis of the stationary support member of, for instance, a shoe-press unit (in the latter case, the axis of rotation can be arranged eccentrically relative to the main axis).
The "rotating press element" can be a metallic press-roll jacket which is rotatable around a stationary support member and is displaceable radially relative to it, or a traveling or circulating press belt or tubular traveling or circulating press jacket in the case of a shoe press unit.
The "internal pressing device" can be either a pressure chamber in the shape of a half ring or a row of radially movable support elements, or else an elongated radially movable press shoe.
The "one press unit", the bearing brackets of which are rigidly supported, is arranged on a frame, foundation or the like or is fastened (by means of its brackets) suspended from a (for instance, vertical or horizontal) support. The "other press unit" can be arranged above, to the side of, or below the rigidly supported press unit and its weight is borne by the bearing brackets of the rigidly supported press unit. The expression "rigidly supported" includes the bipartite bearing-bracket construction with axial guide elements in accordance, for instance, with Federal Republic of Germany Utility Model 92 04 405.0.
One essential feature of the roll press from which the present invention proceeds is that the bearing brackets are coupled to each other in pairs by means of detachable tension bars. These tension bars are the sole element for transmitting the pressing force from bearing bracket to bearing bracket. Thus, the machine frames of the roll press need be dimensioned only for the weight of the press units themselves, and not for the transmission of the pressing force. It is also important that the tension bars are easily detachable so that the tension bars, while in an unloaded condition thereby exerting zero pressing force, are preferably pretensioned to at most a fraction of the maximum pressing force.
Furthermore, these tension bars are in a certain sense movable or flexible so that the bearing brackets of the "other press unit" are movable parallel to the pressing plane relative to the bearing brackets of the rigidly supported press unit. This is in contradiction to the manner of construction in accordance with U.S. Pat. No. 3,921,514. In that patent, instead of easily detachable tension bars, bolted connections are provided which clamp the bearing brackets together. Thus, these bolted connections must be strongly prestressed already in the unloaded condition of the roll press. Such bolted connections are extremely bulky and expensive in highly loaded roll presses. Thus mounting and loosening of the bearing brackets can be effected only at enormous expense. In this connection, it must be borne in mind that such roll presses are preferably used in paper manufacturing machines, the width of which may in the extreme case be up to 10 m. In particular, many roll presses are developed as shoe presses in which the linear force prevailing in the press nip may reach an order of magnitude of 1000 kN/m. To complicate matters, in many cases an endless felt belt (serving for the removing of water from the web of paper) must pass through the press nip and such a felt belt must be replaced at certain time intervals by a new felt belt. Similarly, in the case of shoe presses, the rotating flexible (for instance, tubular) press element must be replaced from time to time. Due to the use of the easily detachable tension bars, this work can be carried out within a relatively short time, so that the roll press is quickly ready to operate again.
One disadvantage of this proposed construction is, however, that an exact positioning of the two bearing brackets relative to each other is not possible, even though guide cheeks are provided on the machine frame. In other words, there is the danger that the main axis of the "other" press unit having the movable bearing brackets does not lie (at least at times) precisely in the pressing plane. This has the result that the web is treated in a nonuniform manner over its width, and/or that the roll jackets become unevenly worn.
SUMMARY OF THE INVENTION
The object of the invention is, therefore, to improve the roll press described in WO '641 so that the main axis of the "other", i.e. the movable, press unit, always remains as precisely as possible in the pressing plane during operation.
In accordance with the object of the invention, the tension bars--in the unloaded condition of the roll press, and therefore with a pressing force of zero--are not prestressed at all or are prestressed only to a fraction (for instance, one-fifth) of the maximum pressing force. The bearing brackets of the one press unit are supported rigidly on the machine frame, while the bearing brackets of the other press unit are movable along the pressing plane during operation.
Two cases are to be distinguished. If the press unit having the movable bearing brackets (movable along the pressing plane) is located above the press unit which is rigidly supported on the machine frame, then, in the case of a pressing force of zero, the movable bearing brackets rest on the bearing brackets of the rigidly supported press unit located below them . In the other case, the movable bearing brackets are suspended by the tension bars from the bearing brackets located above the bearing brackets of the rigidly supported press unit which is in the top position. In this case, the tension bars are pretensioned by the weight of the lower press unit itself.
In order to achieve the object, the bearing brackets are "centered" with respect to each other by means of at least one guide surface which is parallel to the pressing plane and independent of the machine frame. In this way, the movability of the bearing brackets of the non-rigidly supported press unit along the pressing plane is retained. At the same time, however, the principal axes of both press units always remain precisely during the pressing plane in operation. Non-uniform treatment of the web or non-uniform wear of a roll jacket is thus avoided.
From GB 845,160, a rolling mill having two rolls having the following features is known. Each of the two rolls is supported via a rotatable journal pin in a bearing bracket. Each of the bearing brackets is provided on its outer sides with two large flat guide surfaces by which it can slide in a vertical direction on corresponding flat guide surfaces of a machine frame. The lower bearing bracket rests on the machine frame, which has, above the upper bearing bracket, a threaded spindle with a vertical axis of rotation. The threaded spindle engages on the upper bearing bracket so as to adjust the height of the roll nip and a spreading device presses the upper bearing bracket against the spindle. Additional tension bars are without load in this condition of operation and, in particular, during the rolling. The rolling pressure is thus not transmitted from bearing bracket to bearing bracket via the tension bars but, rather, via the threaded spindle and via the machine frame. As compared with the object of the present invention therefore, the above-described conventional device is an entirely different type of machine. In that case, provision is made for removing the two rolls together with the bearing brackets as a coherent structural group from the machine frame from time to time and then introducing them again (for instance, after repair). In order to facilitate the reintroduction, the outer guide surfaces of the two bearing brackets are held flush in the manner that the bearing brackets have additional guide surfaces which directly contact each other. The additional guide surfaces center the bearing brackets relative to each other, independently of the machine frame. During the rolling, it is, however, not possible to keep the two rolls parallel to each other solely by means of the additional guide surfaces. In this condition of operation, the outer guide surfaces which cooperate with the machine frame, are indispensable. In contrast the guide surfaces of the present invention are independent of the machine frame and are provided only or at least primarily on the bearing brackets. These guide surfaces are arranged centrally in that region of the roll press which lies close to the press nip (as seen in axial direction). In the normal operating condition, in which the roll press is under load and the tension bars are therefore under tension, the guide surfaces cooperate with the tension bars in such a manner that the bearing brackets are held with a high degree of precision in the correct position. In other words, both the transmission of the pressing force from bearing bracket to bearing bracket and the correct positioning of the "other" press unit (the bearing brackets of which are movable) take place completely independently of the machine frame.
In principle, it is sufficient for each bearing bracket to have only a single guide surface. In the simplest case, therefore, only a single pair of guide surfaces is present on each end of the roll press, the pair of guide surfaces being held in contact with each other by, for instance, spring force (or in the case of an inclined arrangement of the pressing plane) or by gravity. It is essential that each movable bearing bracket be positioned by a guide surface of the adjacent rigidly supported bearing bracket so that its main axis always lies in the pressing plane.
Further, two pairs of guide surfaces disposed parallel to the pressing plane are provided on each end of the roll press. Thus, the one bearing bracket can have a projection which engages into a recess in the other bearing bracket.
In accordance with a further development of the invention, however, a known removable intermediate piece is preferably provided between the two bearing brackets. This intermediate piece is, however, now developed as a so-called guide piece, i.e., the side surfaces of the block-shaped guide piece which are parallel to the pressing plane are now guide surfaces, since the guide piece engages--in a manner similar to a feather key between a shaft and hub--snugly in recesses in the two bearing brackets, to assure the correct position of the movable bearing brackets. The intermediate piece can be removed from the recesses if necessary, for instance, for a change of felt.
A spreading device which is provided, for instance, on the guide piece which can be used to produce a small pretensioning force in the tension bars before the roll press is placed in operation, so as to assure the correct position of the tension bars and of the movable bearing brackets with even greater accuracy.
BRIEF DESCRIPTION OF THE FIGURES
One embodiment of the invention will be described below with reference to the drawings, in which:
FIG. 1 is a view of one end of the roll press;
FIG. 2 is a longitudinal section along the line II of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The roll press shown has a bottom, first press roll 1 and a top, second press roll 3. The axes of these press rolls lie in a pressing plane E. The first press roll 1 has a rotatable roll jacket 1a and a journal pin 2 fastened to it, the pin 2 resting by means of an antifriction bearing 2a in a bearing bracket 5 (having covers 5a and 5b). The bearing bracket 5 is arranged on a frame-shaped machine frame 15, a few portions of which are indicated in FIGS. 1 and 2.
The upper, second press roll 3 is a so-called long-nip press roll. Its roll jacket 3a is a tubular, flexible press jacket which is fastened on two turnable jacket support disks 3b. Each jacket support disk rests on the stationary journal pin 4 of a stationary support member 4a which extends through the inside of the roll jacket 3a. The support member 4a has a recess 4b facing the lower press roll 1 and a piston-like, hydraulically actuatable press shoe 4c therein. The concave slide surface of this shoe presses the press jacket 3a against the lower press roll 1 to form a lengthened press nip (lengthened in the direction of travel). Through this nip, there travels a web of paper from which the water is to be removed, together with at least one endless felt belt F. The upper press roll 3 rests (at each end of the roll) by means of the journal pin 4 also in a bearing bracket 6. Between the two bearing brackets 5 and 6 there is a removable block-shaped guide piece 9 which lies on the bearing bracket 5. The bearing bracket 6 of the upper press roll 3 rests on this guide piece 9 when the roll press is in its unloaded condition (i.e., when the recess 4b is without pressure). However, the loaded condition in which the press shoe 4c exerts a pressing force on the lower press roll 1 is shown in the drawing. The forces of reaction which result therefrom are transmitted from the upper bearing bracket 6 to the lower bearing bracket 5 by means of flexurally soft tension bars 7 and 8. The upper bearing bracket 6 is raised in this state by the distance p from the intermediate piece 9.
As shown in FIG. 1, a flexurally soft tension bar 7, 8 is provided on each side of the pressing plane E. These tension bars, as well as U-shaped intermediate pieces 10, 11, are inserted from the side into recesses in the bearing brackets 5 and 6. (The lower bearing bracket 5 has arms 5c and 5d in which T-grooves are provided.) Each of the flexurally soft tension bars 7, 8 is provided on each of its ends with a hammer head 20 and is developed preferably in the manner of a leaf spring, the "leaf plane" of which is perpendicular to the pressing plane E. In this way, the tension bars 7, 8 can deform if the support member 4, 4a of the second press roll 3 experiences a change in length (for instance, caused by heat) and/or bends under the pressing force. Accordingly, the upper bearing bracket 6 can be rigidly fastened to the journal pin 4. Thus, the axial slide surface necessary in conventional devices and located between these two structural parts, as well as, a spherical socket can be omitted. However, it should be emphasized that the invention can be used even if the the axial slide surface and the spherical socket are present, in which case the tension bars need not be flexurally soft. For the aforementioned guide piece 9, a recess 25 is provided, as shown in FIG. 1, in the lower bearing bracket 5, the recess having side surfaces which are parallel to the pressing plane E. Similarly, facing the recess 25, there is provided in the upper bearing bracket 6, a recess 26 which also has side surfaces which are parallel to the pressing plane E. The distances between the side surfaces in the two recesses 25 and 26 are preferably the same. Therefore, the block-shaped intermediate piece 9 fits with its side surfaces 24, which are also parallel to the pressing plane E, in both recesses 25 and 26. The drawing shows this arrangement only at one of the two ends of the roll press. It is understood, however, that the same arrangement is present at the other end. As a whole, therefore, the result is thus obtained that the principal axes 1A and 3A of the two rolls 1 and 3 always lie precisely in the pressing plane E. This is true even if, with the roll press not under load created by tension bars 7 and 8, there is only a relatively loose connection between the bearing bracket 5 and 6. The "centering" of the bearing brackets 5, 6 in accordance with the invention can also be employed in the event of an oblique arrangement of the roll press, as described in the priority patent application DE P 41 40 879.9.
Differing from the drawing, one can, under certain conditions, also dispense with having the guide piece 9 being removable and instead form the guide piece 9 to be a single structural part with the bearing bracket 5. In other words, the guide piece 9 can form the projection developed on the bearing bracket 5. In accordance with another alternative (not shown in the drawing), the guide piece is divided by a horizontal separating line into an upper section and a lower section. In this embodiment, only the lower section performs the guide function and therefore engages into both recesses 25 and 26. The height of the upper section can be adjusted by a spreading device.
However, the embodiment shown which has the following features is preferred. A swivel shaft 27 which is perpendicular to the pressing plane E is fastened in the upper bearing bracket 6. The head 28 of a threaded spindle 23 is mounted for rotation on the shaft so that the axis of the threaded spindle always lies in the pressing plane E (or at a slight distance from and parallel to it). The threaded spindle 23 extends into a hole 21 provided in the guide piece 9. A spindle nut 22 can come into contact with the guide piece 9 by rotating on the spindle 23. In this way, in the unloaded condition of the roll press, a slight initial tension can be applied to the tension bars 7, 8, which tension is retained if the pressing force is temporarily reduced to zero during operation. In such case, therefore, the bearing bracket does not rest directly on the guide piece 9 but rests on it indirectly via swivel shaft 27, spindle 23 and spindle nut 22.
When a new felt F must be placed in the roll press, the following procedure is performed: First of all, by means of a lug 12 and a hydraulic cylinder 16 which is suspended from the machine frame 15, the upper press roll 3 is lifted somewhat so that the spindle nut 22 can be loosened from the guide piece 9 by rotating on the spindle 23. The press roll is then lowered until the bearing bracket 6 rests directly on the guide piece 9. The tension bars 7, 8 and intermediate pieces 10, 11 can now be removed. For example, the tie bar 8 is pushed onto a bolt 14 which is fastened on the machine frame 15. The upper press roll 3 is now again lifted by means of the hydraulic cylinder 16. The guide piece 9 can now be swung upward to the side together with the spindle 23, as shown in dash-dot line in FIG. 2. In this connection the guide piece 9 remains continuously connected to the spindle 23 by means of a small bolt 29 which extends transversely through the guide piece 9 and the spindle 23.
The spreading device includes the parts 22, 23, 27, 28 and can also be arranged below the guide piece 9 in the bearing bracket 5 so that the swinging out of the guide piece occures in a lateral downward direction.
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A press includes at least two press units supported by respective bearing brackets. The bearing brackets are coupled together by releasable tension rods which transmit a pressing force. When the two press units are not transmitting a pressing force in a pressing plane, the tension rods are prestressed at a maximum of a fraction of the maximum pressing force. One of the bearing brackets is movable relative to the other bearing bracket along the pressing plane. The bearing brackets are guided by a pair of guide surfaces disposed parallel to the press plane.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/299,190, filed Dec. 27, 2000.
FIELD OF THE INVENTION
[0002] The present invention is directed to the field of athletic instruction, and more particularly to a method of producing an instructional tool for teaching athletes how to develop consistent rhythm, timing and tempo.
BACKGROUND OF THE INVENTION
[0003] The importance of athletics in today's society continues to rise as evidenced by the huge amount of money that is being devoted to athletics at all levels (i.e., high school, college and professional). A good portion of the money being devoted to athletics relates to the development and use of teaching tools that are utilized to increase an athlete's skill level.
[0004] There are a variety of different tools available to train athletes. Some of these training tools are based on solid principles and facilitate improving an athlete's performance while other theories may actually harm to an athlete (i.e., by causing injury or teaching improper technique). Dedicated athletes typically rely on numerous types of training activities including specialized coaching and/or equipment.
[0005] One major theory focuses on repeating a specified number of events (i.e., drilling) to teach a particular activity. A typical example is in sprinting where a sprinter will run a particular number of sprints at designated distances. Another such example would relate to baseball where a hitter will repeatedly take swings in a batting cage.
[0006] There are additional teaching theories which relate to body movement or mechanics. These theories focus on one or more aspects of the relative location between an athlete's body parts at various points during the athletic activity. These types of theories are used with athletic activities such as baseball, tennis and high-jumping among others. The teaching tools that utilize theories based on body movement or mechanics typically relate to the mechanical aspects of the movement instead of on the tempo with which the athletic activity is performed.
[0007] There are also continuing attempts to improve athletic performance by improving the equipment associated with training for, or performing, an athletic activity. The emphasis on training equipment has resulted in technology playing a big part in the fitness equipment industry. One prominent example of improvements in equipment relates to advancements in the shoe industry. Other examples include improved tennis rackets, golf equipment and an assortment of weight training machines.
[0008] Coaches are typically able to provide general instruction to an athlete as to whether to “slow down” or “speed up” their tempo as an athlete practices the athletic activity. One drawback associated with this type of instruction is that the instruction is limited to the time a coach can actually spend with an athlete. This type of instruction is also rather imprecise because the coach is not the individual actually performing the athletic activity. The coach does not know how the athletic activity “feels” to the athlete as the athlete practices the athletic activity. In addition, these in-person coaching lessons are often quickly forgotten during the heat of competition because athletes often times unconsciously alter their rhythm and tempo as they perform the athletic activity, especially during the pressure of competition.
[0009] There are some instructional tools that are directed toward teaching an athlete to develop a consistent tempo. These tempo-related tools typically supply either a repeating audio or visual signal to an athlete to provide a sensory input which the athlete tries to match as the athlete performs the athletic activity. The rate of the signals is typically adjustable so that athletes can adjust the tempo with which they perform the athletic activity.
[0010] One such device is disclosed in U.S. Pat. No. 4,776,323 in the form of a biofeedback system which is used to train an exerciser. During operation of the biofeedback system an exerciser performs an exercise in which arms and/or feet members move rhythmically. The system translates the hand/foot movement into an audible musical rhythm.
SUMMARY OF THE INVENTION
[0011] Conventional instructional tools that attempt to teach an athlete how to develop a consistent tempo suffer from several drawbacks. One drawback is that such devices are typically not customized for a particular athlete because even though the signals emitted by the devices are adjustable, an athlete that is practicing with the aid of the device may be using a tempo that is inappropriate for that particular athlete. Another drawback associated with most of the existing devices is that the instruction they provide is limited for all practical purposes to designated practice facilities because it would be unacceptable to bring a signal-emitting instructional aid onto a field of athletic activity during completion. These limitations on existing devices are crucial because establishing tempo during practice is one thing but maintaining the appropriate tempo as the athlete feels the pressure during actual competition is quite a different situation.
[0012] The present invention solves the aforementioned problems by providing a method of producing an instructional tool for an athletic activity that teaches an athlete appropriate rhythm, timing and tempo by using the athlete's own best performances as a template. In addition, the instructional tool produced by the method of the present invention supplies the athlete with a technique that is easily translated onto the field of athletic activity.
[0013] The present invention is directed to a method of producing an instructional tool for teaching an athlete how to develop a consistent (and appropriate) tempo for performing a particular athletic activity. The method includes a step of analyzing the tempo of an athlete as they perform an athletic activity and then composing a song that includes a tempo which matches the tempo of an outstanding performance of the athletic activity. The appropriate tempo of the athletic activity is established by determining the amount of time between certain events in the activity when the particular athletic activity is performed at an optimum level by an athlete. The song is composed such that it includes a beat pattern with a time difference between two of the beats in the beat pattern that matches the time difference between two events in the ideally performed athletic activity.
[0014] The song that is composed preferably includes a musical note on a beat within the beat pattern that corresponds to one event during the athletic activity and a musical note on a beat within the beat pattern in the song that corresponds to a second event during the athletic activity. It should be noted that musical notes within the beat pattern can be replaced with the sounds of impact when a particular athletic activity includes contacting a ball (e.g., a tennis ball) or some other device.
[0015] The current invention also relates to an instructional tool for teaching an athlete how to develop a consistent rhythm, timing and tempo as the athlete performs a particular athletic activity. The instructional tool includes a storage medium (e.g., a compact disc) and a song stored on the storage medium so that the song can be readily played back at any time and location. The song stored on the storage medium includes a beat pattern that has a time difference between two beats in the beat pattern which matches a time difference between two events during an athlete's ideal performance of an athletic activity. In a preferred form, the song includes a first musical note on a beat within the beat pattern that corresponds to a first event in the athletic activity and a second musical note on a beat within the beat pattern that corresponds to a second event in the athletic activity.
[0016] Using a song to teach an appropriate rhythm, timing and tempo of a particular athletic activity is effective because most people are able to carry a song with them in their head even after the music has stopped playing. The teaching tool created by the method of the present invention allows an athlete to listen to their customized song anywhere at any time so that the athlete can embed the song within their head. Once the song is embedded in an athlete's head, the athlete can carry the tune with them anywhere. As athlete's attempt to maintain their timing during competition, especially at crucial junctures in a competition, the athlete simply needs to recall the customized swing song within their head.
[0017] The customized song could be used for any type of athletic activity where rhythm, timing and tempo are important. The timeframe for the value of such a customized song is indefinite because the athlete is continually able to refer back to the song. Athletes involved in all sports periodically suffer slumps, and listening to the song may promote shortening the lives of such slumps.
[0018] Other features and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following detailed description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 illustrates one measure of a customized song in four/four time that matches the tempo of an athlete's performance as the athlete performs a particular athletic activity.
[0020] [0020]FIG. 2 illustrates a series of four measures in four/four time in a song created with the method of the present invention.
[0021] [0021]FIG. 3 illustrates one measure of a song in six/eight time that matches the tempo of an athlete's optimal performance as the athlete performs a particular athletic activity.
[0022] [0022]FIG. 4 illustrates a series of four measures in six/eight time in a song created with the method of the present invention.
[0023] [0023]FIG. 5 illustrates various stages associated with pitching a baseball that could be incorporated into a customized song of the present invention.
[0024] [0024]FIG. 6 illustrates various stages associated with hitting a baseball that could be incorporated into a customized song of the present invention.
[0025] [0025]FIG. 7 illustrates various stages associated with shooting a basketball that could be incorporated into a customized song of the present invention.
[0026] [0026]FIG. 8 illustrates various stages associated with rolling a bowling ball that could be incorporated into a customized song of the present invention.
DETAILED DESCRIPTION
[0027] The present invention is related to a method of producing an athletic training tool for teaching an athlete how to develop consistent rhythm, timing and tempo as they perform a particular athletic activity. The method includes the steps of analyzing an athlete's performance and composing a song that matches the tempo of an athlete's ideal athletic performance. This song can be played over and over again to serve as a teaching tool for helping the athlete overcome an inconsistent tempo.
[0028] In a related aspect, the customized song is stored onto a readily playable medium (e.g., a compact disc) so that an athlete can listen to the song at any time to facilitate training the athlete to develop a consistent tempo. As the athlete performs the athletic activity while listening to the song, the athlete develops a proper and more consistent tempo.
[0029] The song is an especially effective tool because it provides an athlete with the ability to carry the tune (inside their head) onto the field of the athletic activity. As an athlete repeatedly listens to their customized song, the song becomes engrained within the athlete's head. In addition, storing the song onto a medium that can be readily played back at any time and location allows the athlete to facilitate the process of engraining the song within their head. Once the song is engrained within the athlete's head, the athlete is able to replay the tune in their head during competition.
[0030] The method of producing the athletic training tool is illustrated in FIGS. 1 - 4 and begins by filming the athlete with a camera, preferably a digital video camera, recording at least one of the athlete's best athletic performances. The athlete will typically be filmed at a practice facility where the athlete will conduct a number of performances identifying those performances that the athlete feels are their best performances. Only those performances that the athlete identifies as appropriate are used to compose the athlete's customized song.
[0031] Once the video and audio images are recorded, they are downloaded onto a computer. The computer includes a software program that contains editing capabilities which allow an operator to view the captured video and audio footage at many frames per second. The software is preferably Final Cut pro R1.X manufactured by Apple. The software allows the athlete's best performances to be examined frame by frame in order to establish a time frame for certain events within the athletic performances. Once the events are identified by their frame position, the events are marked within the software timeline with special audio sounds imported from the file. These events within the timeline allow a timing template to be created and played back in real time. The real time template is then looped and turned into an audio file using an audio wave-editing program, preferably Sound Forge manufactured by Sonic Foundry, or Peak 2.X manufactured by Avid. A looped audio file has its exact tempo determined by the audio wave editor. Depending on the athlete's preference, different points during the athletic activity are used to establish the timing template.
[0032] A particular athlete's timing template is now ready to be incorporated into a swing groove formula. Swing groove formulas (SGF) are beat patterns the athlete follows as the athlete performs the particular athletic activity. Each SGF is related to a time signature that has its own significant field such that the athlete should select their preferred time signature. The two time signatures that are most frequently used are 4/4 and 6/8 time. Both beat patterns include beats that correspond with events in the athletic activity. The beats within the beat pattern that correspond to specific actions within the athletic activity are not necessarily consecutive beats within the beat pattern.
[0033] The athlete's timing template and SGF are merged with the athlete's choice of song type by turning the timing template and SGF into respective audio files (e.g., WAV files). The audio files are merged with the athlete's song type which is also in the form of an audio file. The software, preferably Acid Pro 2.0 manufactured by Sonic Foundry, adjusts the tempo of the song so that it matches the athlete's ideal determined tempo as established in the timing template and SGF. Initially, the song is placed into either 4/4 or 6/8 time depending on the choice of the athlete and then increased or decreased to fit the athlete's appropriate tempo as defined in the timing template and SGF.
[0034] The song includes a musical note on a beat within a beat pattern for one event during the athletic activity and includes another musical note on a beat within the beat pattern or another event within the athletic activity. It should be noted that the number of events within the athletic activity and the corresponding number of beats within the customized song will vary depending on the athlete's preference and the type of athletic activity.
[0035] FIGS. 5 - 8 illustrate various stages of different athletic activities that may be incorporated into a customized song which corresponds to the respective athletic activity. The illustrated athletic activities include baseball (batting and throwing), bowling and basketball, although it should be understood that other events within these athletic activities could be incorporated without departing from the scope of the present invention. The customized song can be created for any type of athletic activity where rhythm, timing and tempo are important.
[0036] Anacrusis movements associated with a particular athletic activity may also be included or excluded from an athlete's customized song based on the athlete's preference. Anacrusis movements technically take place before an athlete begins the athletic activity. The anacrusis movements often help an athlete to establish a proper rhythm, tempo and timing during performance of the athletic movement.
[0037] Anacrusis movements come in various forms and patterns. Some examples include waggling a club head before initiating a golf swing; lightly swinging or moving a baseball bat prior to initiating a swing; and rocking back and forth prior to initiating a run in a high jump.
[0038] Another common event within many athletic activities is a takeaway. A takeaway is typically a post-anacrusis movement that is used to create stored power which will be utilized during performance of the athletic activity. Examples of a takeaway movement include the back swings in golf, tennis and hockey. Takeaway movements are inserted into an athletes customized song depending on a particular athlete's preference.
[0039] A customized song may also include a musical note on a beat within the beat pattern that corresponds to an impact event within the athletic activity. The impact event is typically related to striking some type of ball (e.g., bat contact with a baseball).
[0040] In another form of the invention, a musical note within the customized song may be replaced with a recorded sound of the impact event. The sound of the impact event may be taken from the recording of the athlete's ideal performance. It should be noted that other pre-recorded impact sounds could be used within the customized song without departing from the scope of the present invention.
[0041] [0041]FIG. 1 illustrates one measure in a form of a song that is 4/4 time. The four beats are numbered 1 , 2 , 3 and 4 in the illustrated measure. In this form, a musical note 50 is on beat 1 indicating a first event, a musical note 51 is on beat 2 indicating a second event, and a musical note 52 is on beat 3 indicating a third event, while beat 4 is silent. FIG. 7 illustrates a series of four measures identified as A, B, C and D where the notes in measure C are the same as those illustrated in FIG. 1. The first measure A includes a musical note 30 on beat 1 and a musical note 31 on beat 2 . There are no musical notes on beats 2 , 4 in measure A. Measure B includes musical notes 40 - 43 on each of the four beats in measure B. Finally, measure D includes musical notes on any of the four beats 1 - 4 that facilitates composition of the song (shown with notes 60 - 63 on beats 1 - 4 in FIG. 2).
[0042] It should be noted that the series of four measures A-D can be repeated multiple times at various intervals throughout the song without departing from the scope of the present invention. In addition, there can be four measures in series depending upon how a particular athlete would like their song composed.
[0043] Referring now to FIG. 3, one measure in a song of the present invention is illustrated in 6/8 time. Each measure within a song in 6/8 time includes beats 1 a- 6 a. When the song is in 6/8 time a first musical note 90 is on the first beat 1 a in the measure and provides a signal to initiate the athletic activity, a second musical note 91 is on beat 3 a in the measure and indicates to the athlete the timing for performing a second event within the athletic activity. A third musical note 92 on beat 4 a then identifies to the athlete the time frame for performing yet a third event within the athletic activity.
[0044] [0044]FIG. 4 illustrates a series of four measures E-G of a song in 6/8 time. The measure E includes musical notes 70 , 71 on beats 1 a and 4 a and measure F includes musical notes 80 - 83 on beats 1 a, 3 a, 4 a and 6 a. Measure C includes a beat pattern similar to the one shown in FIG. 3. Finally, measure D includes musical notes on any of the beats that facilitate composing a song that the athlete enjoys (shown with musical notes 100 - 105 on beats 1 a- 6 a). Similar to a song in 4/4 time, the series of four measures in 6/8 time may be repeated multiple times throughout the song.
[0045] The customized song can be any type of music, including rock-n-roll, country & western, easy listening, Latin, big band/swing, techno, classical, rhythm & blues and hip-hop. An athlete chooses the music type and the tempo of the song is composed to fit a particular athlete's ideal tempo.
[0046] In a related form, the customized song is composed by choosing an existing song and modifying the tempo of beat pattern in the song such that a time difference between two of the beats in the modified beat pattern matches a time difference between the first event and the second event in the athletic activity. This form allows an athlete to select a favorite song and customize it so that it has the appropriate tempo.
[0047] An athlete's customized song can be downloaded onto a compact disc or cassette tape. The song can also be played in the form of a digital audio file for an MP3 player. In order to avoid logistical playback problems, the song can be looped over and over for an extended period of time onto the appropriate format. Looping the song for extended play time reduces the need to rewind the song when the athlete is using the song as a training tool.
[0048] The customized song can be merged with the previously captured video to create a new audio\video file in an appropriate format for play by a computer (e.g., AVI, MPEG, and quick Time) or some other device. The merged audio\video file allows an athlete to visually inspect the best performances while simultaneously listening to their customized song. The song and video combination provides even more feedback to the athlete as the athlete practices towards mastering a consistent rhythm, timing and tempo. It should be noted that any action that is part of an athlete's performance in a particular athletic activity can placed into their timing template. There may be certain actions within the athlete's performance that do not fit exactly within an SGF that has been customized for certain events within an athlete's ideal athletic performance of the athletic activity. If certain actions within the athletic activity do not fall within the athlete's established SGF, then the song could be modified and additional musical elements placed over the SGF so that these additional points are included in the athlete's customized song.
[0049] The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. It should be noted that the same principles that are described herein could apply to other embodiments without departing from the scope of the present invention. Consequently, variations and modifications commensurate with the above teachings, and the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described herein are further intended to explain the best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
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The present invention is directed to a method of producing an instructional tool for teaching an athlete how to develop and maintain a consistent tempo for performing a particular athletic activity. The method includes a step of analyzing the tempo of an athlete as they perform an athletic activity and then composing a song that includes a tempo which matches the tempo of an outstanding performance of the athletic activity. The appropriate tempo of the athletic activity is established by determining the amount of time between certain events in the activity when the particular athletic activity is performed at an optimum level by an athlete. The song is composed such that it includes a beat pattern with a time difference between two of the beats in the beat pattern that matches the time difference between two events in the ideally performed athletic activity.
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BACKGROUND OF THE INVENTION
This invention relates to a frame synchronizing method and an equipment for use in a TDMA (time-division multiple-access) radio communication system which, having plural radio communication channels between plural radio stations, separates the channels from one another on a time-sharing basis and permits acquisition of a channel without using a particular reference station.
In such a TDMA system adopted as one of the multiple-access techniques for communications channels, the same frequency is commonly used, and n channels are formed by dividing the time axis as illustrated in FIG. 1 into time slots No. 0 through No. n-1 (where n is an integer) and by transmitting information with independent access to each of these n time slots constituting a frame. In order that these time slots can be used as independent communication channels, they are set so as not to overlap each other. This setting manipulation can be readily done under the condition that one of the radio stations controls all the communication channels as a reference station by inserting a frame synchronization (sync) signal on the time axis using a sync signal generator provided there.
For details of the TDMA system, reference is made to Sekimoto et al, "A Satellite Time-Division Multiple-Access Experiment", IEEE Transactions on Communication Technology, Vol. Com-16, No. 4, Aug. 1968, pp. 581-588. In this example, a specific one of plural radio stations serving as a reference station emits control signals indicating time positions on the basis of which another station finds the time position of a channel and follows a procedure to acquire the channel. In such a satellite communication system, since it is possible for every earth station to receive the control signal from the common reference station, all the stations can be given the common frame sync signal.
However, in a mobile communication system, a stationary communication system and the like, all the stations cannot necessarily receive the common signal from the reference station because of a propagation obstruction of an electromagnetic wave.
Furthermore, in case where, as shown in FIG. 2, the communication of a radio station P 1 is allowed only to subscribers of the other parties C 11 , C 12 , C 13 and C 22 and the area Q in which channels are commonly used is greater than a communication-service available area S 1 , the station S 1 cannot receive all the signals from all the other radio stations P 2 and P 3 . As a result, no particular radio station can serve as a reference station with the result that the communications among the stations become impossible using the TDMA system.
SUMMARY OF THE INVENTION
An object of the present invention is, therefore, to provide a frame synchronizing method and an equipment for use in a TDMA radio communication system which can efficiently allocate channels within a given communication-service available area without relying on a reference station.
The present frame synchronizing method for a time-division multiple-access radio communication system having plural radio channels between plural radio stations and separating the channels from one another on a time-sharing basis, comprises the steps of: enabling one of those radio stations to monitor all the channels upon initiation of a call for communication; acquiring and exclusively occupying one of the channels with its own frame synchronization signal in the case where every channel is unoccupied; acquiring an unoccupied channel synchronized with a burst signal of an occupied channel immediately preceding said unoccupied channel on the time axis under the condition that the occupied channel is followed by said unoccupied channel; and, in the event that the burst signal on said occupied channel disappears during the process of communication, continuing to occupy the same channel with its own frame synchronization signal so that said same channel is slid up or down the time axis to the preceding or following unoccupied time slot and, under the condition that a burst signal appears on another channel ahead on the same time axis of its own channel occupied by the radio station concerned, further continuing to occupy its channel in synchronism with the burst signal.
Also, the present frame synchronizing equipment for use in a time-division multiple-access radio communication system having plural radio channels between plural radio stations and separating the channels from one another on a time-sharing basis comprises means for monitoring every channel upon initiation of a call for communication and for detecting the presence of an unoccupied channel; means responsive to the detection of an occupied channel followed by the unoccupied channel for extracting a pulse in a frame period synchronized with a burst signal of the occupied channel immediately preceding said unoccupied channel on the time axis; and a phase synchronization oscillating circuit for generating a frame synchronization signal in synchronism with said pulse.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail in conjunction with the accompanying drawings, in which:
FIG. 1 shows a channel composition in the TDMA system;
FIG. 2 shows a state of subscribers to which the invention is applicable;
FIG. 3 illustrates how the invention functions;
FIG. 4 gives one example of a radio communication system embodying the invention;
FIG. 5 shows one embodiment of the invention;
FIG. 6 shows details of signals in each part of FIG. 5;
FIG. 7 indicates the composition of a burst signal;
FIG. 8 shows details of a receiver 402 of FIG. 4;
FIG. 9 shows details of a burst composing circuit 409 of FIG. 4;
FIG. 10 shows details of a transmitter 410 of FIG. 4; and
FIG. 11 shows details of a signal detecting circuit 502 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The principle of operation of the invention will be described with reference to FIGS. 3 (a) to (g) which illustrate various states of the (radio communication) channel use. FIG. 3 (a) shows a state in which no radio station is communicating. If, in this state, a radio station P' 0 initiates a call, the station P' 0 generates a frame sync signal at its own frequency, because it detects no signal at all, and thereby exclusively acquires a channel B 0 as shown in FIG. 3 (b). In this state, when another radio station P' 1 initiates a call, the station P' 1 detects a burst signal on the channel B 0 and an unoccupied time slot following the burst signal. The radio station P' 1 generates a frame sync signal in synchronism with that on the channel B 0 , and acquires another channel B 1 in a time slot following the channel B 0 as shown in FIG. 3 (c).
Upon call initiation of still another station P' 2 , the station P' 2 acquires still another channel B 2 by the same procedure as shown in FIG. 3 (d). This procedure can be repeated until there are no more unoccupied time slots in the frame period.
Next, as soon as the radio station P' 1 has finished its communication and as a result there is no longer any signal on the channel B 1 , the radio station P' 2 generates a frame sync signal at its own frequency. Since this frame period is not in tune with that of the radio station P' 0 , the relative position of the channel B 0 to the channel B 1 is changed as shown in FIG. 3 (e). Under the condition that the frame period of the radio station P' 2 is shorter than that of the radio station P' 0 , the channel B 2 gradually approaches the channel B 0 . As a result, when the time interval between the channels B 2 and B 0 becomes shorter than a predetermined length, the radio station P' 2 generates a frame sync signal synchronized with those on the channel B 0 so as to acquire the channel B 2 in a position immediately following the channel B 0 as indicated in FIG. 3 (f). While, in case where the frame period of the radio station P' 2 is longer than that of the radio station P' 0 , the channel B 2 approaches the channel B' 0 in the frame next to the channel B 0 . As a result, the radio station P' 0 generates a frame sync signal in synchronism with that of the channel B 0 so that it can acquire the channel B' 0 in a position immediately following the channel B 2 as seen in FIG. 3 (g). The above description is made, for explanatory convenience, about the case where the frame sync signal given from a radio station is synchronized with that of the channel just before an unoccupied channel or its own channel depending on the initiation or continuation of a call. However, the sync signal may be synchronized with those of other channels than the channel just before an unoccupied channel or its own channel. Moreover, the radio station can monitor a channel in either one direction or channels in both directions when the TDMA system uses two way channels.
FIG. 4 represents a TDMA-based radio communications system in which the frame sync equipment of this invention is used. Immediately after an FSK (frequency shift keying) signal received by a receiving antenna 401 is fed to a receiver unit 402, it appears as a demodulated PCM signal at a demodulating output terminal 403 and, at the same time, a frame sync pulse train is fed to a signal line 404. The frame sync equipment 405 of this invention detects an unoccupied channel out of the frame sync pulse train given to the signal line 404, and generates frame sync pulses for the acquisition of said channel. An analog signal such as a speech signal given to a transmission input terminal 406 is PCM-coded by a PCM coder 407 and stored in a memory 408. The stored PCM signal, to which a preamble word including sync information and data position information is added by a burst composing circuit 409, is fed to a transmitter unit 410 in synchronism with the frame sync pulses generated by the equipment 405, and transmitted from a transmitting antenna 411.
The receiver unit 402 is composed, for instance, as illustrated in FIG. 8. In FIG. 8, an FSK signal from the receiving antenna 401 is fed to a terminal 801 and amplified by an amplifier 802. The amplified signal is mixed with an output of a local oscillator 805 by a mixer 804 through a band pass filter 803, which thereafter takes out an intermediate frequency signal. This intermediate frequency signal enters into a demodulator 810 via an amplifier 807 and a band pass filter 809. The demodulator 810 is matched to the modulation system used. For instance, in the above cited example where the FSK signal is used, a frequency discriminator is employed. An output of the demodulator 810 is sent to a sampling circuit 812 through the low-pass filter 811, and sampled by a clock recovered by a clock recovery circuit 813. The sampling circuit 812 outputs a sampled signal, that is, a demodulated signal, to terminals 815 and 816. Signals derived from the terminals 815 and 816 are fed to the terminals 403 and 404 of FIG. 4, respectively. The sampling circuit 812 and the clock recovery circuit 813 in FIG. 8 are equivalent to the known sampler and clock pulse generator, respectively, referred to in Franks et al, "Statistical Properties of Timing Jitter in PAM Timing Recovery Scheme", IEEE Transactions on Communications, Vol. Com-22, No. 7, July 1974, pp. 913-920, specifically to FIG. 1 on page 915.
The burst composing circuit 409 of FIG. 4 is constructed as illustrated in FIG. 9, where the frame sync pulses generated by the present frame sync equipment 405 are given to a terminal 900. Each of the sync pulses sets flip-flops 901 and 907, and resets counters 902 and 906. An output of a clock oscillator 903 is supplied to a switch 905 and a counter 912 through an AND gate circuit 904 only when the flip-flop 901 is set. When the flip-flop 907 is reset, its output turns the switch 905 toward the counter 906 and a switch 911 toward an address memory 910 to ready a memory 913 for writing. The memory 913 is divided into two parts constituted by one storing the preamble word (see FIG. 7) and the other storing data, and their storage start addresses are stored in address memories 909 and 910. Each of the above-mentioned frame sync pulses sets the contents of the address memory 910 in a counter 912 through an OR circuit 908. The counter 912 then counts the addresses of the memory 913 in accordance with an output of the AND gate circuit 904, and successively stores in the memory 913 data from the memory 408 of FIG. 4 supplied to a data input terminal 914. The counters 906 and 912, simultaneously, count the output of the AND gate circuit 904, and, when they have counted the number of data to be written into the memory 913, the counter 906 emits a pulse to reset the flip-flop 907. The reset flip-flop 907 throws the switch 905 toward the counter 906 and the switch 911 toward the address memory 909 to set the memory 913 to ready for reading. The output of the counter 906 sets, through the OR circuit 908, the contents of the address memory 909 in the counter 912, which counts the read-out address of the memory 913 by the output of the gate circuit 904. The contents of the memory 913, from the preamble word to the data, is thereby read out successively and fed to a terminal 915. Soon after the whole data (both the preamble word and the data per se) have been read out, the counter 902 emits a pulse, resets the flip-flop 901, closes the gate circuit 904 and disconnects the output of the clock oscillator 903 to return the burst composing circuit 409 of FIG. 4 to its initial state. By this procedure, the circuit 409 adds a preamble word to the beginning position of data every time a frame sync pulse comes out, and thereby forms a burst signal as illustrated in FIG. 7.
In the transmitter unit 410 of FIG. 4 composed as illustrated in FIG. 10, the output of the burst composing circuit 409 of FIG. 4 is fed to a modulating terminal 1001 of a modulator (FSK modulator) 1002 in FIG. 10. The modulator 1002 modulates an output of an oscillator 1003 in accordance with the signal fed to the modulating terminal 1001, and the modulated output is given, through a band pass filter 1004, to an amplifier 1005, which amplifies the output and feeds it to an output terminal 1006 connected to the transmitting antenna 411 of FIG. 4.
Referring to FIG. 5 which shows one embodiment of the invention, the frame sync pulse train on the signal line 404 of FIG. 4 is fed to an input terminal 501. In the pulse train, as indicated in FIG. 6 (a), burst signals, each having a length of T B , are present on channels B 0 , B 1 , B 2 , and B i in use while an unoccupied channel B 3 has no signal on it. Each of said burst signals (as illustrated in FIG. 7) has the aforementioned preamble word before data such as a speech signal, and a signal detector 502 detects this preamble word and generates pulses as shown in FIG. 6 (b). A channel timer circuit 503 is reset (R 1 and R 2 in FIG. 6 (c)) by said pulses (FIG. 6 (b)). The circuit 503 reaches a full count (F 1 or F 2 in FIG. 6 (c)) to generate a pulse S 1 of FIG. 6 (d) on a signal line 504 when a sufficiently long time (for instance, 2 T B or more has more) to permit establishment of a new channel between other channels already in use. An AND circuit 505 left open as shown in a signal (G 1 in FIG. 6 (e)) at the time of initial acquisition of the channel supplies a signal line 506 with the pulse S 1 of the signal line 504 as a pulse Sf 1 . At this moment, a switch 507 is switched to the signal line 506, and supplies a timing circuit 508 with the pulse Sf 1 of the signal line 506. After receiving the pulse Sf 1 , the frame timing circuit 508 produces a signal to keep the gate circuit 505 closed until the time when the same pulse of the next frame is expected. As a result, the gate circuit 505 is opened, as represented by a signal G 2 of FIG. 6 (e), at the time when the same signal of the next frame is expected, and the sync pulse f is extracted from the signal ahead of the unoccupied channel and fed to the signal line 506. A phase lock oscillator 509 is actuated in synchronism with the pulse Sf 1 of the signal line 506, and feeds to an output terminal 510 frame sync pulses, which are supplied to the burst composing circuit 406 of FIG. 4. The switch 507 is kept switched to the signal line 506 only at the time of the initial acquisition, but at all other times is switched to the output terminal 510 to supply the timing circuit 508 with the frame sync pulses of the output terminal 510 and to open or close the gate circuit 505. When the signal of the channel B 2 (FIG. 6 (a)) disappears after the acquisition of the channel, the pulse S 1 of FIG. 6 (d) disappears and so does the pulse Sf 1 (FIG. 6 (f)). At this instant, the phase lock oscillator 509 begins oscillating at a free oscillation frequency, and generates at the output terminal 510 sync pulses with a frame period which is in synchronism with no other radio station. As a result, the channel B 3 of FIG. 6 (a) occupied by this specific radio station shifts in relative position toward the other channels B 0 and B 1 . With the approach of the channel B 3 to the channel B 1 , since a pulse S 3 extracted from the burst signal of the channel B 1 appears as a pulse Sf 2 on the signal line 506 and the phase lock oscillator 509 oscillates in synchronism with the pulse Sf 2 from the channel B 1 to give the frame sync pulses, this radio station occupies the channel B 3 synchronized with the channel B 1 . On the other hand, in the case where the channel B 1 approaches the channel B i , the channel B i occupies its own channel synchronized with the channel B 3 .
By the above described procedure, the frame sync equipment of the present invention makes possible frame synchronization with the signal of a channel ahead of the channel occupied by a given radio station.
The signal detector 502 of FIG. 5 is composed as illustrated in FIG. 11. The frame sync pulse train given to a terminal 1101 is further sent to a shift register 1102, and successively shifted from left to right. A predetermined code in the preamble word is stored in a memory circuit 1103 of which the contents of each stage are fed to AND gate circuits 1104 together with the contents of each stage of a shift register 1102 and supplied to an AND gate circuit 1105. The AND gate circuit 1105 feeds to a terminal 1106 a pulse only when an output of every one of the AND gate circuits 1104 is 1, or when the input code of the terminal 1101 is coincident with the contents of the memory circuit 1103. A terminal 1106 is connected to the timer circuit 503 of FIG. 5.
For details of the phase lock oscillator 509 of FIG. 9, reference is made to Byrne, "Properties and Design of the Phase-Controlled Oscillator with a Sawtooth Comparator", The Bell System Technical Journal, March 1962 issue, pp. 559-602, specifically to FIG. 1 on p. 561.
The signal detector 502 for detecting a burst signal by the preamble in this embodiment can be replaced with a circuit which does the same by the presence or absence of an electromagnetic wave. In this instance, the timer circuit 503 may be so designed as to reach full count only when no electromagentic wave is present for at least the length of the burst signal (T B ).
Whereas the above described implementation is based on an FSK modulation system, the use of any other modulation system such as ASK (amplitude shift keying) or PSK (phase shift keying) will merely result in a different structure of the modulator-demodulator, but not affect what is claimed to be the extent of this invention.
As described above in detail, the present invention enables the TDMA technique to be used in a mobile communication system or a small-scale stationary communication system, requires no reference station, and moreover, facilitates simplification and digitalization of radio communication systems.
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A frame synchronizing equipment is disclosed which enables the TDMA technique to be used in a mobile communication system or a small-scale stationary communication system and requires no reference station. Plural radio channels separated from one another on a time-sharing basis are monitored upon initiation of a call by one of plural radio stations to detect the presence of a unoccupied channel. When an occupied channel followed by an unoccupied channel is detected, a pulse is extracted in a frame period synchronized with a burst signal of the occupied channel immediately preceding the unoccupied channel. A phase synchronization oscillating circuit generates a frame synchronization signal in synchronism with the extracted pulse.
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BACKGROUND OF THE INVENTION
It is conventional practice, within the electric utility industry, to use energy conversion devices of various capital costs, various fuel and operating costs, which devices meet instantaneous demands from the aggregated customers. Such demand varies from hour to hour, day to day and seasonally. One proposal for attempting to solve the variable demand problem involves the employment of a gas turbine which is powered by fuel gas and compressed air from a reservoir. The reservoir is recharged periodically by a compressor driven by the motor or heat engine combination during off-load periods only. Such proposals are described in U.S. Letters Pat. Nos. 3,935,469 and 3,831,373, French Patent 1,209,726 and Canadian Patent 596,277. However, such proposals have not been acceptable to the utility industry, among other reasons, because of the electrical-electrical conversion losses inherent in compressing air from an electric system off-peak generation and the failure to conserve capital equipment. Additionally, efficient use of capital requires that expensive heat conversion apparatus operate above average customer demand and with lower than average operating costs, while inexpensive apparatus, utilizing high cost fuels, must operate below average customer demand.
The utility customer commonly varies his demands so as to average about 50%-60% of the available apparatus capability.
It is to the economic advantage of the individual utility and the nation to reduce capital costs, increase output of individual apparatus and use so far as possible local low cost fuels. Requirements of both operation and apparatus need to be met to satisfy these goals, requirements which have not been provided by conventional practice.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of and means for minimizing capital, fuel and operating costs in the generation of power or electricity.
It is one object of the present invention to provide an electric generating apparatus and method of operating same, having reduced equipment requirements operating continuously at a maximum useful output.
It is an object of the present invention to operate a generating unit continuously at high efficiency and at maximum load under varying demand utilizing low cost fuels, such as sulfur containing coal gasified continuously, thereby avoiding the use of premium fuels such as gas and oil, for costly start-up and shut-down.
It is a further object of the present invention to generate power on demand by operating at full capacity and constant input thereby avoiding thermal fatigue, while providing ease of control and simplicity of operation.
It is another object of the invention to provide a method of operating a generating unit with storage by processing compressed air from internal consumption of heat and continuing the process of generating electricity with the unit's heat conversion apparatus.
It is still a further object of the present invention to minimize losses in the generating unit due to partial load operation by operating continuously at maximum capacity while compressed air is stored and/or electricity is generated.
It is still another object of the present invention to provide greater use of coal through making practical and economic the use of complex, more efficient, electrical generating cycles, which become economic and practical by the use of compressed air inventory midway through the generating cycle and the constant continuous operation of the entire fuel processing train.
It is another object of the present invention to permit a nuclear reactor to supply heat to a generating unit at a continuous rate while generating electricity intermittently to permit the reactor to operate and be utilized in a more favorable mode at a more suitable capacity factor.
It is an object of the present invention to utilize a plurality of forms of fuels and heat supply apparatus such as a fluidized bed combustor, the use of recuperative or regenerative cycles, high sulfur coal, oil or solid wastes to generate power.
It is a further object of the present invention to provide means and method of intermittently or continuously generating current or compressing air into a storage reservoir.
And, it is an object of the present invention to provide process steam or by-product heat continuously while providing electricity at variable output dependant on demand
In accordance with the present invention, present and future designs of energy conversion apparatus requiring the input of heated gases at high pressure, which may achieve this energy through thermal interchange or chemical reaction, may be arranged to maximize the operation of the fuel processing apparatus. The generating unit includes a heat engine and a fuel supply with a storage facility or reservoir positioned intermediate thereof for storing compressed air or other gases to produce mechanical, fluid or electrical power at times coincident with but also other than while storing air. For example: low BTU gasification apparatus and purification facilities may be operated continuously at or near maximum rating; fuel gas turbines which compress air for needed combustion and additional air which is stored; and also at the same or at a later time, fuel the same or other gas turbines, used without air compressors, but supplied with stored air, which thus provides mechanical or electrical power. By suitable design and sizing of the components, capital and fuel are conserved and conversion efficiency is enhanced.
In one embodiment electricity or mechanical output can be accomplished at full load for 50 percent of the time, while the entire fuel processing train is operated at full capacity 24 hours per day, thus reducing the size of the fuel supply components. The entire fuel supply, the generating unit, and the storage facility comprise a self-contained peaking or cycling unit in which major portions of the unit operate at base load, an operating method which increases the efficiency of the conventional components of the plant.
Additionally, the present invention provides a method of integrating the operation and design of an electric generating plant which enables the designer to reduce the size of a maximum number of individual components of the proposed plant and thus increase the use of such components. This improves the use of capital, conserves resources such as materials and fuel, and raises the efficiency of the resultant plant.
The present invention further includes a method of and means for meeting users irregular requirements for power or electricity by partially processing energy and storing this energy as a compressed gas in the reservoir and subsequently completing the production of electricity upon demand, thus making it possible to operate nearly all production items at or near full capacity continuously.
Also, the present invention provides a method of and means for conserving thermal energy, fuel and capital through the design and operation of an energy conversion unit which develops power or work upon demand at intermediate or peaking capacity factors. The conversion unit operates at a heat input of substantially a capacity factor of 100 percent while continuously maintaining all high temperature parts under high temperature condition. By proper use of a gas storage reservoir intermediate the overall process, the entire fuel supply, generating unit, and the storage reservoir comprise a selfcontained peaking or cycling unit in which nearly all components of the plant operate at substantially full load, an operating condition which increases the overall efficiency of the essential components of the plant. Furthermore, in the present method, gas which is compressed and sent to storage must be compressed anyway in order to produce electricity using the heat apparatus of the invention regardless of storage. Therefore, the storage reservoir acts as a warehouse for partially processed energy indigenous to the process and as a time delay mechanism. Thus, the present invention utilizes approximately one-half to two-thirds of the energy required to produce electricity to make and store compressed air then utilizes the remainder of the energy combined with the energy in the stored air to produce electricity. In the practice of the present invention, electricity is not produced twice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of a simple cycle, power generating unit in accordance with the present invention employing separate gas turbines for compressing air to storage and for generating current;
FIG. 2 is a schematic drawing of one embodiment of the simple gas turbine cycle application in accordance with the present invention with a single heat or fuel input and a single gas turbine used for compressing and generating;
FIG. 3 is a schematic drawing of a further embodiment of the present invention including a cross compound combined cycle plant having an indirect air heater exchanger heated by a nuclear reactor;
FIG. 4 is a schematic drawing of a low BTU gas tandem combined cycle plant processing coal to provide fuel gas;
FIG. 5 is a schematic drawing of the apparatus required to illustrate the sharing of compressed air for peaking purposes in accordance with the present invention;
FIGS. 6 and 7 are charts illustrating, respectively, one schedule of operation of a conventional peaking unit in which electricity is generated approximately 16.8 hours during the day portion of five days per week and the rate by which fuel is consumed during this same period coincidentally with said generation;
FIG. 8 is a chart illustrating the operation of the present invention showing the air accumulated in storage during a weekly electrical generation cycle of 16.8 hours, 5 days per week for a pattern identical to FIG. 6;
FIG. 9 is a chart illustrating the corresponding output of generation of the represented cycle in accordance with the present invention for a pattern identical to FIG. 8;
FIG. 10 is a chart illustrating the fuel consumed by the present invention during the weekly cycle as described in FIGS. 8 through 10; and
FIG. 11 is a composite chart illustrating examples of weekly cycles at constant heat input for a conventional electric generating unit and for embodiments of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings wherein like numerals have been used throughout the several views to designate the same or similar parts, FIG. 1 illustrates a simple cycle power generating unit or apparatus in accordance with the present invention.
1. Air Supply
An axial or centrifugal air compressor 10 is rotated by the gas turbine 11 and may be varied in output from full to minimum output of air by suitable controls. The compressor serves to take atmospheric air and compress said air to a suitable pressure for the plant process. A shut off valve or check valve 12 is provided to prevent back flow through the compressor 10. Suitable isolation of the compressor 10 and gas turbine 11 from the storage facility or reservoir 15 is required whenever air is not being supplied to or withdrawn from the reservoir.
The compressor 10 operates to supply that air required to process the fuel and combust the fuel in burner 16 and drive air into the storage reservoir 15. In some configurations, the compressed air may be used as a heat exchange medium transferring heat to a heat engine via a heat exchanger 17, as shown in dotted lines of FIG. 1.
2. Fuel and Heat Utilization
Compression of air and the combustion of fuel produce heat and deliver pressurized gases from the burner 16 which rotates the gas turbine 11 and gases from this combustion are exhausted to the atmosphere through duct or conduit 18. Alternatively, a heat exchanger 17 instead of a burner 16 may be used and a heat engine may be powered by the heated air.
As shown in FIG. 1, two gas turbines 11 and 11' and two burners 16 or heat exchangers 17 are used in this embodiment of the present invention. Later embodiments perform essentially all of the functions of this embodiment using a single heat source and a single heat engine with clutching and/or cooling arrangements, as will hereinafter be described.
3. Generation
A conventional electric generator 21 is driven at constant speed by the rotation of gas turbine 11'. As described under air supply supra, the output of the generator 21 may be varied from full to zero or may be shut down. Again the equipment must be isolated, by valves 22 and 22' from the air reservoir 15 when air is not required.
4. The Combined System
Considering only the simple cycle plant, as shown in FIG. 1; for a given fuel input to the gas turbine 11, the gas turbine 11 connected to the air compressor 10 will drive an air compressor or air compressors of special size, which are approximately 50% larger than provided with conventional units. The second gas turbine 11' will drive an electrical generator 21 approximately 300 percent larger than that of the conventional plant. This configuration, if operated at constant heat input to the combined gas turbines, will theoretically produce electricity at 3 times the rate for one-third of the operating hours, provided air is compressed at a maximum rate and the excess is stored for two-thirds of the operating cycle.
One representative cycle of operation of FIG. 1 may be described as follows: Fuel at a maximum designed rate is burned in burner 16 thereby driving the gas turbine 11 which delivers full power to the air compressor 10 which supplies compressed air to the burner 16 and to the storage reservoir 15 and to process fuel, as will be discussed later in conjunction with FIG. 4. Should a demand for electrical power occur, the second gas turbine 11' connected to the electrical generator 21 is started using compressed air from storage reservoir 15 and fuel supplied to burner 16 or interchangeably with heat exchanger 17. Because one of the major objects of the present invention is the conservation of fuel or heat and capital equipment, it will be necessary to reduce the work done by the air compressor 10 to permit the electrical generator 21 to be loaded. The generator gas turbine 11' may be completely supplied with air from storage reservoir 15 for a portion of the time or the unit can be run indefinitely at a condition representing normal full load of the non-storage unit but now operating at approximately one-third the maximum output of this particular embodiment of the invention.
For maximum savings, it is desirable to operate the entire fuel and heat utilization portions of the plant at undiminished maximum input, the load being divided between compressing air and generating electricity. If the compressor 10 and gas turbine 11 fail to receive power through disconnection, the check valve 12 will close and the compressor and gas turbine will be shut down. As the demand for power decreases, the compressor-gas turbine unit can be started and air may again be supplied by the compressor 10 until, as the electrical load is reduced, air becomes available for storage and the generator 21 and associated gas turbine can be shut down.
Although control valves, not shown, will be supplied with the gas turbines, normal or conventional gas turbine-compressor-electrical generator combinations are not generally exposed to pressure after shut-down, valves 22 are shown merely to indicate the unusual conditions which might demand additional shut-off protection.
Now referring to FIG. 2, a second embodiment of the simple cycle gas turbine application with storage is described as follows.
1. Air Supply
Air compressor 10 is either rotated continuously at constant speed by the gas turbine 11 or varied in output from full to zero output of compressed air or disconnected via coupling or clutch means 23. The compressor 10 serves to take atmospheric air and compress the air to a suitable pressure for the plant process. Again, a check valve 12 is provided to prevent back flow through the compressor 10 when the compressor is not supplying air.
The compressor 10 operates to supply the air required to process the fuel and to combust the fuel in burner 16 and supply compressed air to the storage reservoir 15. Additionally in some configurations, the compressed air may be used as a heat exchange medium transferring energy to a heat engine 11 via a heat exchanger 17, as shown in dotted lines in FIG. 2.
2. Fuel and Heat Utilization
Compressed air and the combustion of fuel produce heat and deliver pressure from burner 16 which rotates gas turbine 11 and gases from this combustion are delivered to the atmosphere through duct or conduit 18.
3. Generation
As shown in FIG. 2, a conventional electric generator 21 is driven at constant speed by the common shaft through compressor 10 and gas turbine 11. The output of the generator may be varied from full to zero output of generation of electricity or disconnected via coupling or clutch means 24.
4. The Combined System
Considering the integration of the three elements, air supply, fuel and heat utilization and electrical generation, as illustrated in FIG. 2, the turbine compressor coupling means 23 and the turbine-generator coupling means 24 have been shown for ease of explanation, although it is a superior and practical option to provide cooling for the no load requirements of both the air compressor 10 and the generator 21 and to operate them continuously. Furthermore, it is not essential to the method of operation that the air compressor 10 and generator 21 be connected to the same heat engine 11 because it is understood that the same functions may be carried out by a heat engine driving a compressor unit and by a different heat engine driving a generator. For a combined cycle plant, each of these heat engines may be one-half the size of a conventional heat engine 11. As will be discussed infra, one object of the present invention is to conserve capital costs and FIG. 2 incorporates one such savings, that is, using one gas turbine alternatively for both functions, compressing and generating. FIG. 2 also illustrates a configuration whereby the gas turbine 11 may be shut down upon each change in demand, and the compressor 10 disconnected if electricity is demanded. The generator 21 may be connected and the unit again started. Also, as is well understood, the present invention reduces losses incurred due to such operation.
One cycle of operation of FIG. 2 may be described as follows: Fuel at a maximum designed rate is burned in burner 16 thereby driving the gas turbine 11 while coupling 23 delivers full power to the air compressor 10 which supplies air to the burner 16 and to storage reservoir 15 and to process fuel, as will be discussed infra in conjunction with FIG. 4. Meanwhile coupling 24 is not allowing any delivery of power to the electrical generator 21. Should a demand for electrical power occur, coupling 24 will transmit and coupling 23 will discontinue to conduct power. Thus, the generator 21 will be loaded and the compressor 10 unloaded. As the compressor 10 fails to receive power, the check valve 12 will close and compressed air from storage reservoir 15 will supply the combustion requirements of the gas turbine 11 with the entire fuel and heat utilization portion of the plant continuing to operate at undiminished capacity. Should the demand for electricity cease, coupling 23 permits power to be transmitted to the air compressor 10 wherein check valve 12 will open and the compressor will again be supplying air for combustion and to storage.
The description of the present invention has not been burdened with the constructional details as to the operative connections between the compressor, the gas and steam turbines, and the generator, because such apparatus are well known to persons skilled in the art and, the word "compressor", is merely representative of one type of work zone where the output thereof may be transmitted, stored and later transformed into useful work. Although the air compressor 10 is shown as directly connected to the system or apparatus, it is within the scope of the present invention that the compressor may be driven at higher or lower speeds, if necessary, through the use of a gear box.
Additionally, sound engineering design and practice require the addition of conventional details which are not included on the drawings, such as, fuel supplies, steam required for gasification reactions, intercooling and aftercooling provisions about the air compressor 10, requirements for maximum safe operating temperature in the storage reservoir, requirements for heating the expanding air, recuperation of heat, water treatment facilities, environmental details, and tar treatment, if required, shall all be included as good engineering practice. Details of magnetic clutches or hydraulic couplings are not included. The style or configuration of the storage reservoir is not considered to be pertinent. Also, there is no known limitation on the type of cycle or equipment, provided combustion or heat addition takes place at substantial pressure. However, the discussion herein centers about the more economical options, for example, low BTU gasification integrated with the combined Gas Turbine-Steam Turbine Cycle using coal, see FIG. 4.
The physical embodiments of the present invention may be varied. Chief among such variations are the sources of heat to operate the main gas turbine. Such direct sources as heated gases or combustion products of gaseous liquid, and solid fuels may serve this requirement. Alternatively, such indirect sources as heat exchangers, introducing heat from sources such as nuclear reactors, fluidized bed combustion, or indirect fired air heaters may be used.
One alternative to the systems or apparatus illustrated is that the indirect heat exchangers are used first to recover heat from the exhaust from the heat engine and then used to supply the air for combustion for further indirect heating of the input air to the heat engine. Another alternative results where the air compressor or compressors means uses one type of heat engine connected to and rotating an air compressor, and the generating means may be entirely different. For example, an MHD generator and engine may be compatible.
Importantly, the system may operate as a conventional unit without storage, the invention can, in the failure of the gas storage reservoir, generate power for an indefinite period of time. Most, if not all, prior air storage plans lack this feature.
Considering the previous embodiments disclosed, useful work can be achieved through the addition of a waste heat cycle, as illustrated and shown in FIGS. 3, 4 and 5. This equipment maintains the flexibility of the simple cycle, because it is able to operate without the waste heat cycle during maintenance or start up or for other reasons. The waste heat boiler evaporates water to drive a steam turbine and the installation may have the additional alternate functions of compressing air and generating electricity.
The steam turbine cycle will incorporate such details of the art as are normally provided, such as means for controlling speed and flow, feed water heating and other features familiar to those skilled in the art.
The addition of the steam cycle in this embodiment of the invention however serves another purpose that is unconventional, as shown under the simple cycle, a multiplying effect of generator capacity can be achieved, allowing a maximum efficiency when generating approximately one third of the operating hours. Thus, when using the combined cycle, the two generators (see FIGS. 3, 4 and 5) have a combined capacity of nearly twice that of the conventional unit and a point of maximum efficiency is reached when generating an integrated output of effectively maximum output for 50% of the operating hours, which approximates the output demanded by the electric customers as a statistical entity.
A still further embodiment of the combined cycle plant is the tandem or one shaft alignment of the compressor, heat engine, steam turbine and generator, a feature illustrated and shown in FIG. 4. This enbodiment achieves practicality due to the long continuous heat input to the heat engines of the operating method.
Now referring to FIG. 3, another embodiment of the present invention is the cross compound combined cycle plant wherein the unit consumes nuclear heat through an indirect heat exchanger. This embodinent is described as follows.
1. Air Supply
Air compressor 10 is either rotated continuously at constant speed by the gas turbine 11 or varied in output from full to zero output of compressed air or disconnected via coupling or clutch means 23. The compressor 10 serves to take atmospheric air and compress the air to a suitable pressure for the plant process. Again, a check valve 12 is provided to prevent back flow through the compressor 10 when the compressor is not supplying air.
2. Utilization
Compressed air from compressor 10 is heated in a heat exchanger 27. The compressed air rotates a gas or air turbine 11 and the discharge gases or air from this turbine are delivered through duct or conduit 18 to a waste heat boiler 28 which supplies steam to a steam turbine 29. Condenser 30, pumps 31 and feed water heaters, not shown, are provided with the steam cycle.
As may be readily understood this embodiment conserves heat in the exhaust gases through the waste heat steam cycle identified as 28, 29, 30, 31, which has its own shaft and drives an independent compressor 34 and generator 35 which may be switched in and out of service in a similar manner but independent of compressor 10 and generator 21.
This embodiment has the added flexibility of permitting easy removal of the waste heat cycle identified as items 28, 29, 30, 31, 35, 34, from operation while continuing to operate the combustion turbine 11, its air compressor 10 and/or generator 21 and heat supply by bypassing gases from duct 18 to a stack (not shown).
The nuclear reactor 36, which may be gas or liquid cooled, provides heat to the reactor cooling conduit which is delivered via pump or blower 37 to the indirect heat exchanger 27. There, compressed air from storage reservoir 15 or compressor 10 is heated and delivered to gas turbine 11. At this point the operation becomes identical to that described above with respect to FIG. 2, with the following exceptions. The compressor 34 and the generator 35 may be operated at different times and schedules than the compressor 10 and the generator 21. Also, this particular configuration possess essentially constant heat inputs to the gas turbine 11 and the steam turbine 29. This cycle operated at an electrical output approaching 50 percent capacity factor requires a nuclear reactor system of approximately one-half that of the conventional nuclear plant, for the same rate of electrical production.
Now referring to FIG. 4, a low BTU gas fired tanden combined cycle plant embodiment is illustrated as follows.
A gasifier 40 and a purification system 41 process coal continuously and remove mineral wastes and sulfur compounds to thereby supply clean fuel gas to burner 16. A gas turbine 11 supplies energy to an air compressor means 10 both for compressing of air to storage and for combustion requirements of the gas turbine.
The booster compressor 42 provides the additional pressure required to overcome the resistance of the gasifier and purification systems and produce the desired flow therethrough. Flue gases from the gas turbine 11 are conducted through duct or conduit 18 to waste heat boiler 28 and to a stack or chimney (not shown), Steam is raised in waste heat boiler 28 which drives a steam turbine cycle identified as items 29, 30 and 31. Gas turbine 11 and steam turbine 29 are connected by a common shaft to an air compressor 10 and generator 21. By rotation of the common shaft, energy is transmitted to either the air compressor or the generator thus producing compressed air for storage or generating electricity. For maximum output, the compressor 10 and the gas-steam turbines 11 and 29 will operate at one period charging air to the storage reservoir 15 and the gas-steam turbines 11 and 29 and generator 21 will operate at other periods withdrawing: air therefrom. The waste heat cycle (28, 29, 30, 31), and the booster compressor 42, gasifier 40, burner 16 and gas turbine 41 will operate continuously. However, the arrangement illustrated, and only one of several possible, allows both air compression and withdrawal simultaneously. If adequate cooling is provided for the air compressor 10 and the generator 21, need for couplings or disconnecting clutches are eliminated. Again, check valve 12 operates at any time that the air compressor 10 fails to overcome the pressure in the reservoir 15 thus sealing the air compressor from reverse flow.
It should be noted that this unique embodiment provides a system wherein the fuel supply system for a non storage unit is expensive but which utilizes low cost fuel. This storage unit will have savings which are quite large because the entire expensive fuel system may be smaller. For a maximum output of 50% capacity factor of the generator 21, the fuel supply system and heat engines, identified as items 42, 40, 41, 16, 11, 17, 28, 29, 30 and 31, are approximately 50% of that provided for the conventional unit. There are also substantial savings, in excess of ten percent possible in coal handling and ash handling facilities.
In FIG. 5 the sharing of compressed air storage for electrical peaking functions may be described as follows.
It has been demonstrated that an economical, efficient, combined cycle plant using low cost fuels or heat input, using this method, may be operated continuously compressing air at maximum rate approximating 50% of the time, thus effecting a generation at twice capacity for approximately 50% of the time.
By the purchase and installation of an additional low cost gas turbine 43 and generator 44, in parallel with the combined cycle plants previously described, a large emergency or peaking unit capability can be developed. A premium fuel other than that of the original low cost fuel is required for the burner 45. No additional compressor is used. For example, if one selects natural gas or oil, the added peaker would consist of a fuel supply 46, a gas turbine 43 and a generator 44. Assuming that each fuel supply and heat engine could normally serve a conventional unit of one hundred megawatts, the combined cycle would supply 200 megawatts for 50% of the time, as previously described, and the simple cycle as previously mentioned will provide 300 megawatts for one third of the time. Under this arrangement with primary heat engines of roughly 100 megawatts each, 500 megawatts of capacity can be provided for approximately one third of the time. However, this is limited by the quantity of air that can be produced by the combined cycle.
This additional capacity is readily shown by the following description. For example, a 12 hours compression cycle and 12 hours of generation cycle by the combined cycle 200 mw. generator is assumed for a daily cycle. This cycle may be replaced by eight hours of joint operation of the combined cycle and the peaking unit for a maximum of 500 mw. for eight hours. Thus 12 times 200 or 2400 mw. hours can be replaced by 8 times 500 or 4000 mw. hours by using premium fuel, economical storage, and generating capacity. The additional air is provided by the low cost operation of the combined cycle plant.
A further example using two simple cycle units, with heat engines nominally 100 megawatts each, sharing air in a similar fashion will produce 600 megawatts for approximately twenty percent of the time.
It is an obvious extension of the present invention to use modular construction presently known in the art in which multiple gas turbine-compressor-generator simple cycle plants may each exhaust into a common duct, thus driving or supplying a larger waste heat steam cycle. This would use a common fuel supply adequate to supply all gas turbines necessary for full load operation of the waste heat cycle. The advantages of this embodiment are the anticipated longer term high availability of the waste heat cycle and the opportunity to use and economically maintain smaller primary heat engines of lower reliability.
FIGS. 8, 9, 10 are presented to illustrate one example of the operation possible with one embodiment of the present invention and a comparison with present technology, as illustrated in FIGS. 6 and 7.
To illustrate the unique capability of the present invention, disregard the loading time of the generator but assume that the goal is to operate a conventional generating unit approximately 16.8 hours per day and the five week days of a week, a condition illustrated in FIG. 6 and FIG. 7. The conventional unit is forced to synchronize the requirements of output with fuel input in time and amount, and will have additional losses of time and energy, as shown in FIG. 7. Importantly, a relative fuel input capacity of 200 units is required to produce 200 mw's of output.
The present invention uses compressed air as an inventory of incomplete production and FIG. 8 illustrates by chart a method of managing this inventory by storing energy and then combining this energy with fuel to produce electrical power. Because the fuel plant and heat engine are essentially doing a first operation of compressing air 50% of the time and a second operation of generating electricity 50% of the time, the horizontally cross hatched areas show compressed air being accumulated in storage. The diagonal cross hatching shows times and relative amounts of withdrawal for further processing. FIG. 9 illustrates the same desired outputs as shown in FIG. 6 but FIG. 10 illustrates the fuel input rate to be reduced by more than half. This relationship holds for a unit operating at approximately 50% capacity factor with respect to generator output and it will be seen that major components of plant will be much reduced in size. In the example charted, the air compressor and the generator are closely matched in that the excess air available for storage is accumulated approximately hour for hour of generation. Thus, there is no compressor operation during the period of generation. The final output of the unit is essentially doubled with respect to a normal plant without storage or the fuel plant is roughly one half size. Also, because there are reduced losses due to start up, shut down and partial loads, there are additional savings which effectively allow further reductions in plant size.
FIG. 11 is a chart depicting fuel input and generator output for weekly periods of time for a conventional unit and for three energy output patterns of the present invention operating under the condition of maximum heat input continuously. It should be noted that the output is exactly equal to the input for the conventional unit shown in Column 1. It is impossible for prior art generation schemes, using compressed air storage, to operate at maximum continuous fuel or heat input with the flexibility and economy of this invention.
For the simple cycle plant previously described with respect to FIG. 1, proceeding vertically down Column 2 of FIG. 11, with constant fuel input one can see a block of output of 3 times the rate of that for the conventional unit but for one third of the time. This represents a capacity factor of one third of the generator rating. The next chart shows one possible output sequence increasing the load constantly from zero to maximum load. And the bottom illustration shows production for a weekly cycle of 5 equal weekday periods at maximum output. These are of course shown at one third capacity factor which amounts to generation at maximum output for approximately eleven hours per week day.
Column 3 of FIG. 11, charts the effect of operating the combined cycle plant, previously described with respect to FIG. 4. For a constant maximum heat input of 100 mw. equivalent, 200 mw. can be achieved for 50% of the time, a 50% capacity factor of the generator, or 5 week day periods of nearly 17 hours per day at a maximum output of 200 mw., a rate twice that of the conventional generating unit.
Column 4 of FIG. 11 charts the effect of sharing air by using the combined cycle plant and a peaker, previously described with respect to FIG. 5. As depicted, both plants generating electricity at the same time will produce 500 mws of capacity for one third of the time or about eleven hours per week day.
FIG. 11 and the graphic charts are stylized to illustrate the operating modes possible, with the actual operation not limited to those shown. Importantly, considerable flexibility is possible when meeting an irregular demand for output.
As set forth above, applications where variable power output and less variable input have been described. This has probable effect only on the integrated costs of power.
Plainly, the present inventive process and apparatus works on the storage of high pressure gas and the compression from a lower pressure. Many processes begin with atmospheric pressure. However, by working between two higher pressures, for example, between the pressures of the natural gas pipeline and the high pressure gas storage reservoir normally used by the gas utility, gas compression into the reservoir can be accomplished by the invention with indirect heating using inexpensive fuels. Thus, scarce natural gas can be saved. In addition, load leveling and increased flexibility of the pipeline pressure can be practiced as well as the production of exonomical electrical generation as a by-product.
What has been described therefore is an invention which can utilize state of the art machinery, conserve scarce fuel resources and capital with capital equipment being reduced by one-third or more. Additionally, the energy conversion cycle is 10-30% more efficient than the same cycle without storage, with efficiency of gas storage approaching 100%.
For example, one operating method for generating electricity where the apparatus or unit includes a heat source, a fuel supply system and a heat engine which compresses gas may be described as follows. When the unit is operated continuously with compressed gas storage, the maximum integrated output of the electrical generators which may be, optionally, at a rate of 2, 3, 5, or 6 times larger than that of the nominal generator normally connected to the heat engine of the nonstorage unit. In such instances, the corresponding generation and full output of the present invention is limited to 50, 331/3, 331/3, or 20 percent of the time and the compressed gas will be accumulated in the storage reservoir for 50, 662/3, 662/3, or 80 percent of the time with maximum diversion to storage.
Furthermore, in the present invention, the use and the cost of using storage is not dependant upon off peak power being available. Also in the present invention thermal stresses are reduced, the use of premium fuel is reduced, and control dynamics are minimized. Moreover, the equipment is versatile and can be used for peaking with the most efficient point of operation of the apparatus designed to approximate the electrical generation system capacity factor while maintaining a spinning reserve without loss over a long period of time thus increasing the availability of emergency power.
Furthermore, it is possible to apply the present invention to the day-to-day operation of gasifiers and gas purification processes, as practiced by gas utilities and petrochemical processing plants which operate at steady loads, to the operation of a variable electric plant. This permits the generation of power having lessened environmental impact.
Also, the present invention requires a reduced need for specialized equipment as is presently required in electric power generation. Such power generation can be facilitated by the use of modules and by sharing the compressed air stored by the basic invention. Peakers using premium fuel may be incorporated at substantial savings of premium fuel, capital and operating cost. And, the cycling units of the power generation apparatus operate at greatest economy at a capacity factor which is matched closely with the utility system, with the cycling units utilizing the storage reservoir independent of the operation and costs of the other units in the electrical system.
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A power generating apparatus and method of operation for meeting a variable demand includes a compressor for supplying gas to a heat engine which generates power, and a reservoir positioned intermediate the compressor and heat engine. A portion of the power produced by the heat engine, which may be operated at an average rate of demand, is utilized to compress gas which is directed to the reservoir. The compressed reservoir of gas is selectively directed to the heat engine to increase the generation of power to satisfy increased rates of demand.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for the preparation of kraft pulp with increased pulping yield from lignin-containing cellulosic material using polysulfide cooking liquor.
BACKGROUND OF THE INVENTION
[0002] In conventional kraft cooking implemented in the 1960 - 1970 -ies in continuous digesters was the total charge of white liquor added to the top of the digester. It soon emerged that the high alkali concentrations established at high cooking temperatures was detrimental for pulp viscosity.
[0003] Cooking methods was therefore developed in order to reduce the detrimental high alkali peak concentrations at start of the cook, and thus was split charges of alkali during the cook implemented in cooking methods such as MCC, EMCC, ITC and Lo-Solids cooking.
[0004] Other cooking methods was implemented using black liquor impregnation ahead of cooking stages where residual alkali in the black liquor was used to neutralize the wood acidity and to impregnate the chips with alkaline sulfide. One such cooking method sold by Valmet is Compact Cooking where black liquor with relatively high residual alkali level is withdrawn from earlier phases of the cook and charged to a preceding impregnation stage.
[0005] One aspect of alkali consumption during the cooking process, i.e. including impregnation, is that a large part of the alkali consumption is due to the initial neutralization of the wood, and as much as 50-75% of the total alkali consumption is occurring during the neutralization and alkali impregnation process. Hence, a lot of alkali is needed to be charged to the initial alkalization. This establish a cumbersome problem as high alkali concentrations had been found to be detrimental for pulp viscosity when charged to top of digesters in conventional cooking. One solution to meet the high alkali consumption and necessity to reduce alkali concentration at start of the cooking process was to charge large volumes of alkali treatment liquors, preferably black liquor having a residual alkali content, but having low alkali concentration, which resulted in presence of relatively large amount of total alkali per kg of wood material but still at low alkali concentration.
[0006] IN U.S. Pat. No. 7,270,725 (=EP1458927) Valmet disclosed a pretreatment stage using polysulfide cooking liquor ahead of black liquor treatment. In this process was the polysulfide treatment liquor drained after the pretreatment stage and before starting the black liquor treatment. The polysulfide treatment stage was also preferably kept short with treatment time in the range 2-10 minutes.
[0007] In a recent granted US patent, U.S. Pat. No. 7,828,930, International Paper, is shown an example of a kraft cooking process where 100% of the cooking liquor, in form of polysulfide liquor also named as orange liquor, is charged to top of digester and start of an impregnation stage. Here is also the temperature raised from 60° C. to 120° C. at start of the polysulfide treatment stage. However, as shown in example 1 is a liquor to wood ratio of about 3.5 established in the top of the digester by adding a proper amount of water. This order of liquor/wood ratio is often perceived as a standard liquor/wood ratio in continuous cooking necessary for a steady process. According to this proposal is a part of the residual polysulfide treatment liquor at relative high alkali concentration withdrawn and replaced with cooking liquor at relative low alkali concentration at start of the cooking stage, and the withdrawn residual polysulfide treatment liquor is added at later stages of the cook.
[0008] In Valmet's recent application WO2013032377 is disclosed a most beneficial method for a polysulfide kraft cooking process. The principles with a low temperature first impregnation stage with polysulfide cooking liquor at low liquor-to-wood ratio in the range 2.0 to 3.2 are disclosed. All the advantages with such conditions are disclosed and are included by reference also to the present invention which fully utilize these conditions. However, the system disclosed in WO2013032377 use a pressurized impregnation vessel preceded by a sluice feeder which may led to higher temperatures in the impregnation vessel for the polysulfide impregnation.
[0009] One model to describe cooking conditions is the H-factor. H-factor is a kinetic model for the rate of delignification in kraft pulping. It is a single variable model combining temperature (T) and time (t) and assuming that the delignification is one single reaction. If the activation energy is assumed to correspond to 134 kJ/mol the H-factor could be determined by;
[0000] H =∫ 0 t exp (43.2−16115 /T ) dT
[0000] This one single reaction model is described in Gullichsen, Johan; Fogelholm, Carl.Johan (2000), “Chemical Pulping”, Papermaking Science and technology 6A, Tappi Publications, pp. 291-292, and is used throughout the pulping community to define cooking references, and will be used in this patent to define conditions of the cook. There is also an online H-factor calculator, using the single reaction model as outlined above, available at internet at http://www.knowpulp.com/english/demo/english/pulping/cooking/1 process/1 principle/h-tekijan laskenta.htm, where one could calculate the H-factor for any given stage of the cook, i.e. during heat up (typically during impregnation) as well as during cooking (at full cooking temperature), and the total H-factor established in those stages.
[0010] This low H-factor is also disclosed in WO2013032377, and with the H-factor model used as disclosed above, following H-factors apply for respective retention time and temperatures (Time*Temp=H);
[0011] 60*90=0; 60*100=1; 60*110=3, 60*120=9
[0012] 90*90=0; 90*100=1; 90*110=5; 90*120=13
[0013] 120 * 90 = 1 ; 120 * 100 = 2 ; 120 * 110 = 6 ; 120 * 120 = 18
[0014] Even though slightly different H-factors, or different activation energy than 134 kJ/mol, may apply during the cook, i.e. during initial-, bulk- and final delignification respectively is the same H-factor used for the entire cook, including impregnation and heat up phases for comparative studies, which also is the case in a number of scientific studies published. There are also different H-factors for different wood species, especially between annual plant, hardwood and softwood, but for this patent application is the above identified H-factor, using an activation energy of 134 kJ/mol, used as the base reference for all kinds of wood and all phases of the cook. The H-factor is the best parameter to define process parameters for delignification activity. Hence, an H-factor of 1 is indicating almost no delignification, in cooking processes most often requiring a total H-factor of about 300-1500, and typically about 700 for fully bleached qualities, indicating that only some single digit of percent of total delignification work has been obtained at a H-factor of 1. If a H-factor of only 300 is necessary for the final pulp, as could be the case in high yield cooks, a H-factor of 1 is only indicating that 1/300 of total delignification work is obtained during impregnation, i.e. less than 0.4%.
[0015] There has thus been an ongoing development of cooking methods where both alkali concentrations at start of cook is reduced, and increased yield from the cooking process is sought for using among others addition of polysulfide cooking liquor that stabilize the carbohydrates.
SUMMARY OF THE INVENTION
[0016] The invention is based upon an improved and simplified impregnation process that guarantees that low temperature conditions are established in the polysulfide impregnation process, while reducing the necessary equipment for the process. There is thus no need to install a high pressure feeding system and a top separator in the impregnation vessel as for example shown in WO2013032377 outlining the principles with low temperature impregnation at low liquid-to-wood ratio. According to the inventive process is also the heat economy of the entire cooking process improved as the polysulfide impregnation process is kept at as high temperature as possible, utilizing the heat value in the polysulfide as well as decreasing the heating needs in subsequent cooking process that needs to raise the temperature to full cooking temperature.
[0017] The invention fully utilize the process conditions as outlined in WO2013032377, but as far lower investment costs, utilizing the ImpBin™ concept from black liquor impregnation systems in Compact Cooking™ systems all systems developed and sold by Valmet AB.
[0018] The Compact Cooking and ImpBin concepts are disclosed in Chemical Pulping Part 1, Fibre Chemistry and Technology, Second edition, 2011, pages 350-356, and use an atmospheric impregnation vessel for combined steaming and impregnation, but with addition of hot black liquor flashing off steam for the necessary steaming of chips. With the inventive process is however the risk for emission of malodorous gases reduced to a minimum as no non condensable sulfur gases such as metyl mercaptans are contained in the impregnation liquid used.
[0019] Thus the ImpBin concept may thus be modified from cold top control of steam heating, to hot top, i.e. steam blow through in top of impregnation vessel such that a cleaner grade of turpentine may be extracted from the vented gases. The cold top control of the impregnation vessel in conventional black liquor impregnation using an ImpBin is disclosed on page 356 in said book Chemical Pulping Part 1, second edition.
[0020] One object of the present invention is to provide for a method for the preparation of kraft pulp with increased pulping yield from lignin-containing cellulosic material using polysulfide cooking liquor, comprising:
feeding not previously steamed lignin containing cellulosic material to the top of a first vertical first vessel operating at an applied pressure in the top of the vessel of at most 0.2 bar, and preferably of at most 0.1 bar, and establishing an upper level of lignin containing cellulosic material in the first vessel; charging at least 80% of the total charge of the alkaline cooking liquor, in form of polysulfide liquor, to the first vessel and establishing a lower level of liquor below said upper level, said polysulfide liquor heated to a temperature above the boiling point before addition of the polysulfide liquor allowing steam to boil off from the polysulfide liquor and thus steam the lignin containing cellulosic material kept in a volume above the lower level of liquor; keeping the suspended lignin containing cellulosic material in the first vessel for a time reaching an H-factor of at least 1, and preferably an H-factor between 1-20; feeding the suspended lignin containing material from the bottom of the first vessel to the top of a vertical second vessel where the lignin containing cellulosic material is cooked at full cooking temperature in the range 130-160° C. to a final kappa number below 40, while adding any of the remaining charge of the alkaline cooking liquor, preferably in form of polysulfide liquor, during feeding to or cooking in the second vessel.
[0025] With this process is the process system simplified considerably, as the first vessel is used both as a steaming vessel for the cellulose material as well as a thorough impregnation of the cellulose material with polysulfide cooking liquor. There is no need to install an expensive high pressure feeding system and associated top separator in top of first vessel, as instead a simple conveyor belt may feed the cellulose material to the top and using a low pressure sluice feeder for feeding the cellulose material into the top of the first vessel. As the vessel is atmospheric is the temperature maintained at about 100° C. in liquor surface and no uncontrolled increase of temperature could be established due to exothermic reactions or excessive charges of hotter liquors in bottom of vessel, as all over temperatures results in water evaporating from the liquor surface, i.e. a self-controlling system. The only temperature increase that is developed is preferably the temperature increase due to exothermic reactions that may increase the temperature in the liquor corresponding to the boiling temperature at the existing static head in the vessel. Thus, 10 meter below the liquid level the liquid may assume a temperature of about 120° C., and 20 meter below the liquid level the temperature may be 133° C. at the most, if the pressure at the liquid level is atmospheric pressure. Hence, in an atmospheric vessel the temperature is not exceeding 100° C. at the liquid surface, and some exothermic heating may be developed during the downward flow of the suspension, and in bottom could hotter liquids be added without causing boiling, up to 133° C. if 20 meter liquid head is established.
[0026] An alternative objective is to enable a process system that could be changed between polysulfide impregnation or black liquor impregnation ahead of kraft cooking, with only changes in liquor routing between the two cooking modes.
[0027] According to one preferred embodiment of the method is additional steam added to the volume of the lignin containing cellulosic material kept above the lower level of liquor. This option may be needed in pulp mills in cold climate, as the cellulose material may have a temperature at existing ambient conditions, i.e. be deep frozen at some −30 to −40° C. But in normal operation is the steam released from the polysulfide liquor addition fully sufficient.
[0028] According to another preferred embodiment of the method is a part of the liquor volume in the first vessel withdrawn from the wall of the first vessel and circulated back to the volume of the lignin containing cellulosic material in a first circulation. In this embodiment is preferably the first circulation heated from a heat source.
[0029] Alternatively or additionally is the polysulfide liquor added to the first vessel heated from a heat source. While the heating is necessary in order to release steam, heating of the polysulfide is particular beneficial as the risk for plugging heat exchangers is low with this liquor free from any cellulose material that could be withdrawn in a liquor circulation.
[0030] The heated polysulfide liquor may be added directly into the vessel without further mixing with other liquors, but in a preferred embodiment of the invention is the polysulfide liquor added to the first circulation.
[0031] According to a preferred embodiment of the invention is the heat source used to heat the circulation and/or the polysulfide liquor the hot spent cooking liquor withdrawn from the second vessel. This spent cooking liquor holds full cooking temperature at withdrawal from the second cooking vessel and contains a considerable amount of heat value to be used when heating the liquors in the first vessel.
[0032] Alternatively the heat source used is steam, preferably steam from the low pressure steam net of the pulp mill. As the heating is done to reach temperatures close to 100° C., is the low pressure steam often enough, and is available most often in a mill in abundance. Medium pressure steam is more expensive and utilized for more demanding process conditions well over 100° C.
[0033] According to a most preferred mode of operation is the inventive method operated in line with conditions as outlined in WO2013032377, where the liquor in the first vessel has an alkali concentration above 60 g/l and a polysulfide concentration above 3 g/l, or above 0.09 mol/l, when adding the polysulfide cooking liquor, establishing a liquor-to-wood ratio in the range 2.0 to 3.2 in said first vessel. This establishment of the low liquor-to-wood ratio is however much easier to establish in the present invention, as the cellulosic material is not suspended in any liquor before feeding to the impregnation vessel. The added polysulfide liquor using the inventive method need therefore not to compete with bulk volumes of liquors brought into the impregnation vessel from the preceding feed system, as the cellulosic material contains no more liquid than the natural moisture content of the cellulosic material
[0034] The lignin-containing cellulosic materials to be used in the present process are suitably softwood, hardwood, or annual plants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a schematic cooking system capable of implementing the inventive method.
DETAILED DESCRIPTION OF THE INVENTION
[0036] In FIG. 1 is shown a 2-vessel kraft cooking system, having a first atmospheric impregnation vessel A and a second steam/liquid phase digester B, wherein the inventive method could be implemented. The function of the system is described in following parts.
[0037] Feeding.
[0038] In this type of system is first the lignin containing cellulosic material, Chips, fed with a conveyor belt CB to the top of the atmospheric impregnation vessel A and sluiced into the top using a conventional sluice feeder SF. A first upper level of chips, LE 1 , is established in the vessel. Simultaneously is impregnation liquid added to the vessel establishing a second lower level of liquid, LE 2 . In this process is the new treatment liquid added as polysulfide liquor, identified as Orange Liquor in drawing, and between 80-100% of the total charge of alkali to the entire cooking process is charged in this position. In the embodiment shown in FIG. 1 is the polysulfide liquor added to a circulation established in the vessel A, comprising a withdrawal screen SC, in the vessel wall, piping and pumps leading the withdrawn treatment liquor back to center of vessel using a central pipe CP. The new polysulfide liquor could thus be distributed to the entire cross section of the vessel while being subjected to the circulation flow.
[0039] The second lower level of liquid LE 2 is established some 5-15 meter below the upper level of chips LE 1 , and thus provides for a volume of cellulose material above the liquid level. This dense packed volume of cellulose material provides for a dead weight that drives a plug of cellulose material down and into the pool of liquor contained in the bottom of the vessel. The dense plug of cellulose material also provides for a condensation volume cooling and finally condensing any steam that may evaporate upwardly against the wood material that have been fed to top of vessel and is kept at lower temperature, preferably at ambient temperature.
[0040] Steaming
[0041] The cellulose material must be steamed in order to drive out bound air and enable a thorough impregnation. The air must be expelled to such an extent that the cellulose material loses its buoyancy, as well as enablement of impregnation to such an extent that the entire cellulose volume may be fully cooked and reduce the amount of rejects after the cook. No steaming process in practice is capable of expelling 100% of all air bound in the cellulose material, but most system drive out air to such an extent that the wood material loses its buoyancy as well as keeping the amount of rejects at acceptable levels. Wth the experience from ImpBin concepts it has been proven that the steaming concept used in ImpBin works to such an extent that even large chunks of cellulose material becomes fully impregnated and that the reject volumes in some cases are close to zero. In some implementations of ImpBin system was installation of huge reject bins recommended to mill operators by 3 rd party consultants, but after some weeks of operations it was discovered that not even a toothpick sized reject volume was sent to the reject bin, which proves the perfect impregnation effect from using ImpBin in that installation. This should be compared with some perceptions in the pulping industry in the late 1980-ies that the cellulose material required extensive steaming effects in dedicated apparatuses, first steaming in a chip bin, and then also steaming in a separate steaming vessel at slightly higher pressure before suspending the steamed chips in liquor, which was the standard set up in conventional cooking until the late 1990-ties.
[0042] In the system disclosed is the major part steaming effect, or in some cases the entire steaming effect, obtained by addition of hot liquors having a temperature above 100° C., in this case hot liquors containing the polysulfide liquor, in center of vessel A, and due to the fact that the vessel is atmospheric is steam flashed off into the volume of cellulose material. The steam is released from the outlet end of the central pipe CP located in the lower end of the volume of cellulose material located above the second liquid level LE 2 . In some cases could several central pipes be used to distribute the steam and the polysulfide liquor more evenly over the cross section, using the multipipe system as disclosed in EP2467533.
[0043] As disclosed is the liquors added to the vessel heated preferably using heat exchangers HE 1 and HE 2 . Direct injection of steam may be used, but has the disadvantage that the polysulfide concentration decreases due to the dilution effect of steam condensate. Also, clean steam condensate is expensive to replace if lost, as even ordinary tap water needs thorough and expensive cleaning before use in the steam cycle, so preferably is the clean steam condensate from indirect heat exchangers sent back to the steam cycle.
[0044] A first heat exchanger HE, may be included in the circulation disclosed, and a second heat exchanger HE 2 may be included in supply pipe of the polysulfide liquor, and at least one of these heat exchanger systems are included if not both depending upon need for heating and the starting temperature of the polysulfide liquor.
[0045] In the most preferred embodiment and as disclosed in FIG. 1 is the first heat exchanger HE, using the heat value of the hot spent cooking liquor withdrawn from digester. The spent cooking liquor typically holds full cooking temperature, i.e. 130-160° C. at withdrawal, said temperatures obtained after using live steam from the medium pressure steam net of the mill. This high heat value is preferably used to heat the polysulfide liquor that conventionally is made on site of the mill and is stored in atmospheric tanks holding a temperature of about 70-80° C. Thus the polysulfide liquor may thus be heated easily to a temperature of about 110-130° C. before addition to the system using heat exchangers.
[0046] In the most preferred embodiment and as disclosed in FIG. 1 is the second heat exchanger HE 2 system using the heat value of low pressure steam using live steam from the low pressure steam net of the mill. The low pressure steam is most often available at abundance at the mill, in contrast to medium pressure steam, but is most suitable for heating purposes in the range 100-130° C. The heating obtained in the circulation by the second heat exchanger, preferably in combination with the heating of the polysulfide liquor, is most often sufficient for effective steaming of the cellulose material in warm climate where chips holds an ambient temperature of about 20-30° C. or even higher.
[0047] In particular demanding applications, for example in cold climate with ambient temperatures well below 0° C. and corresponding temperature of the cellulose material, additional steam may be supplied directly to the vessel A as disclosed, using low pressure steam using live steam from the low pressure steam net of the mill. This steam may be supplied in a distribution chamber in the wall of the digester located above the second liquid level LE 2 , and preferably implemented as disclosed in EP2591165 previously used for black liquor impregnation in ImpBin and first implemented in cold climate mills.
[0048] With these alternatives for steaming no risk for emission of malodorous sulfur compounds may be experienced, as all liquors added contains no black liquor. The steaming concept may thus be optionally changed from the cold top control previously used in black liquor impregnation using ImpBin. If instead hot top control is implemented, allowing steam to blow through the entire cellulose volume located above the second liquid level LE 2 , then the vented gases from the vessel may be sent to turpentine recovery, obtaining turpentine with less sulfur content.
[0049] The spent cooking liquor typically holds full cooking temperature, i.e. 130-160° C. at withdrawal, said temperatures obtained after This high heat value is preferably used to heat the polysulfide liquor that conventionally is made on site of the mill and is stored in atmospheric tanks holding a temperature of about 70-80° C.
[0050] A second heat exchanger system HE 2 may be included in the circulation disclosed, and a second heat exchanger system HE 2 may be included in supply pipe of the polysulfide liquor, and at least one of these heat exchanger systems are included if not both depending upon need for heating and the starting temperature of the polysulfide liquor. In the most preferred embodiment and as disclosed in FIG. 1 is the second heat exchanger system using the heat value of the hot spent cooking liquor withdrawn from digester. The spent cooking liquor typically holds full cooking temperature, i.e. 130-160° C. at withdrawal, said temperatures obtained after using live steam from the medium pressure steam net of the mill. This high heat value is preferably used to heat the polysulfide liquor that conventionally is made on site of the mill and is stored in atmospheric tanks holding a temperature of about 70-80° C.
[0051] Each heat exchanger may comprise a number of heat exchangers arranged in a system, not shown, using the hotter heating media in countercurrent mode such that the residual heat value in the heating media heats the coldest flow in a first heat exchanger, and the original heat value heats a flow that has passed at least on preceding heat exchanger in a second heat exchanger.
[0052] Feed from Impregnation to Cooking Vessel
[0053] Thus, the first impregnation stage in vessel is implemented in the vessel B and preferably only charged with the polysulfide cooking liquor and as small amount as possible of additional liquids such as wood moisture, steam condensates, and especially no black liquor nor additional water or filtrates. The resulting liquor-to-wood ratio established should be in the range 2.0 to 3.2 and the temperature should be in the range 100-120° C.
[0054] After the sufficient retention time in vessel A, which should have a retention time resulting in an H-factor in the range 1-20 of the impregnation stage, the impregnated cellulose material will be fed to the steam/liquid phase digester B together with the residual treatment liquor. In FIG. 1 is disclosed a transfer system with parallel centrifugal pumps, corresponding to what is disclosed in EP2268862 and/or EP2268861, but conventional sluice feeders may also be used. As disclosed could optionally additional air be supplied to top of digester, in form of pressurized air CA that could raise the pressure in digester top without excessive heating if higher pressure in top is sought for and using lower cooking temperatures. However, it should be realized that the invention may equally well be implemented with a hydraulic digester, i.e. a digester without a steam phase in top and completely filled with cooking liquor. Due to the low H-factor in impregnation the residual treatment liquor contains most of the original charge of alkali as virtually nothing has been consumed for delignification. Here is shown a conventional transfer system with dilution in bottom of the vessel B using withdrawn treatment liquor from the top separator TS in the top of vessel B sent via return line TRRET. Also, a part of the hot spent cooking liquor withdrawn from a screen SC 2 is added to the return line in order to raise the temperature ahead of cooking in vessel B. At the top of the digester vessel B is the cellulose material heated to full cooking temperature, in the range 130-160° C. depending upon type of cellulosic material. The heating to full digester temperature is conventionally done by adding medium pressure steam from the MP steam net of the mill. Additional liquid is added in order to reduce the alkali concentration at this point, which in this embodiment is a part of the withdrawn spent cooking liquors, withdrawn from screens SC 2 and SC 3 . Most of the withdrawn spent liquor from screens SC 2 and SC 3 is sent to recovery REC, but the heat value is used first in heat exchanger HE 1 as disclosed, and then preferably is finally flashed in a flash tank FT to ambient pressure. The steam flashed off ST s is preferably sent to LVHC (Low Volume High Concentration) or HVLC (High Volume Low Concentration) systems, the latter after diluting the gases, for disposal and preferably combustion of malodorous gases. As also disclosed is the flashed spent cooking liquor first sent to a knotter, and the knots screened out from the spent cooking liquor is sent to knot handling system and thereafter reintroduced into bottom of vessel A
[0055] In this embodiment is shown a digester B with 2 concurrent cooking zones, one cooking zone above the first screen section SC 2 and a second cooking zone above the final screen section SC 3 in bottom of digester, but any kind of cooking scheme may be implemented in the digester vessel B. In a conventional manner is preferably a final counter current wash zone implemented in bottom of digester by addition of wash water/Wash. The final pulp with a kappa number below 40 is fed out from bottom in flow P OUT .
Alternative Embodiments
[0056] The invention could be implemented in a number of different ways besides what is disclosed in FIG. 1 . The digester vessel B could be operated according to EAPC, MCC, ITC or Lo-Solids Cooking, with or without additional charges of alkali to some digester circulations. If the impregnation vessel is operated with cold top then also black liquor may be added to impregnation vessel in order to reach the desired liquid-to-wood ratios necessary (if the charge of polysulfide liquor is not enough).
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The invention is related to a method for the preparation of kraft pulp with increased pulping yield from lignin-containing cellulosic material using polysulfide cooking liquor. In order to obtain a cost efficient system both in aspects of investment costs but also in aspects of heat economy of operating the process is most of the total charge of alkali charged as heated polysulfide liquor to an first atmospheric vessel, wherein the hot polysulfide liquor flashes off steam providing most if not all of the necessary steaming effect for the cellulose material. The polysulfide liquor is then allowed to impregnate the cellulose material at a temperature closer to cooking temperature but still so low that essentially no delignification occurs in impregnation vessel, as the H-factor in impregnation vessel is kept within 1-20.
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CLASSIFICATION OF THE INVENTION
The present invention relates to a method for monitoring and analysing a paper production process, which paper production process includes, as sub-processes:
a wet end, including
stock preparation
a head box
a wire section, and
a dry end, including
a press section, and
a dryer section,
and in which method
a large number of variables are measured from the process, also including electro-chemical measurements in the wet end, and with the aid of these variables, a fingerprint according to a good process situation, relative to runnability, is defined and then stored in a memory, the stored fingerprints are compared with fingerprints obtained in a normal process situation, on the basis of the comparison, an index of the difference, displayed graphically to the user, between the recorded good situation and the momentary process situation is defined.
BACKGROUND OF THE INVENTION
Learning neural networks can be used to effectively classify large amounts of data and to reveal connections and groupings in measurements and large masses of data, which are very difficult to find using statistical analysis, mathematical models, or logical rules. International patent publication WO 01/75222 discloses a method, exploiting a neural network, for monitoring a paper production process and gives references to the general literature on neural networks. According to experience, the method disclosed by the publication can be used to reveal a process moving away from the optimal zone, well before problems appear in the form of, for example, a web break. The electrochemical measurements are preferably carried out using equipment according to publication WO 01/25774.
However, the use of the known method will not determine the cause of a problem very quickly, even if, when an index deviation occurs, the input variables of the neural network are examined. Often, the cause is not a matter of deviation in a single input variable, but rather of a detrimental combination of several variables. In addition, the known method regards a paper machine as being a totality, even though the production process is divided into clearly discernable sub-processes.
SUMMARY OF THE INVENTION
The present invention is intended to create a new type of method in a production process, by means of which the process can be monitored more easily and accurately than previously. Accordingly, a method for monitoring and analyzing a paper production process, in which the paper production process includes, as sub-processes:
a wet end, including
stock preparation
a head box
a wire section, and
a dry end, including
a press section, and
a dryer section,
and in which method
a large number of variables are measured from the process, also including electro-chemical measurements in wet end, and with the aid of these variables, a fingerprint according to a good process situation, relative to runnability, is defined and then stored in a memory, the stored fingerprints are compared with fingerprints obtained in a normal process situation, on the basis of the comparison, an index of the difference, displayed graphically to the user, between the recorded good situation and the momentary process situation is defined, is characterized in that the definition according to a good process situation is made separately in several sub-processes, thus creating a deviation index for each sub-process, to be displayed to the user. A runnability index, depicting the runnability of the entire paper machine, may be further formed from the indices of the sub-processes and a quality index, depicting the quality of the paper being produced, may also be formed for the user. The method is also characterized in that at least the following deviation indices are formed for the user:
a deviation index depicting the properties of the mass used in the process,
an index depicting the operation of the head box, and
an index depicting the operation of the wire section, and
an index depicting the operation of the press section.
Deviation indices of at least two consecutive sub-processes may be formed for the user. In a paper machine, wet-end electrochemical measurements, for depicting printability and/or the permanence of ink/filler, are taken into account in the quality index. Using a neural network, the system can be used under remote control.
The point of departure of the invention is to seek the causes of problems as quickly as possible. The paper machine is divided into sub-processes, with a method according to the document being applied to each of them.
According to the invention, a runnability index, which is obtained from the indices of the sub-processes, is also defined for the entire machine. At the same time, a quality index is also defined for the paper being produced, which uses the actual quality measurements accompanied by electrochemical measurements from the wet end. This is intended to prevent a hidden electrochemical problem from remaining in the paper when, for example, it is wetted by printing ink.
An essential factor in the invention is that most problems clearly relate to a specific sub-process. Such problems include:
incorrect mass mixing in the short circulation poor condition of felts in the press section detrimental electrochemical state in the wet end incorrect water equilibrium in the felts.
These problems are clearly revealed in the indices monitoring the sub-processes. To a considerable extent, the phenomena are machine-specific.
In one paper machine, it was noticed that the press-section felts could become clogged to a considerable extent, without this immediately interfering with production. There is often time to correct such a problem, as factors disturbing running accumulate only over several hours.
Preferably, the output vectors of each neural networks are processed to create a scalar or other single-valued variable for each index. As such, the said indices can be calculated using methods other than a neural network, but the advantage of a neural network becomes particularly apparent in the learning stage.
In certain cases, poor fingerprints can be detected not only by a neural network, but also using simpler logical circuits, because they often have quite precisely defined criteria and are affected by only a few variable factors. Process phenomena are often non-linear.
A multi-level percepton neural network (MLP), which functions particularly well in online conditions, is preferably used in the method. In the learning stage, it is quite possible to use a Back Propagation neural network, for example.
Other advantages and embodiments of the invention will be described later in connection with the examples of applications.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is examined in greater detail with reference to the accompanying drawings, in which
FIG. 1 shows the general arrangement of the method according to the invention, in connection with a paper machine
FIG. 2 shows the steps in the structure of the measurement data of a paper machine
FIG. 3 shows the information hierarchy of a paper machine
FIG. 4 shows equipment according to the invention, in a paper-machine environment.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , a paper machine is shown schematically, and includes a short circulation 1 , a head box 2 , a wire section 3 , a press section 4 , a dryer section 5 , and reeler section 6 . Naturally, the units at the beginning of a paper machine have a greater effect on its runnability than the units at the end. The runnability index of each component can be formed in the manner disclosed in publication WO 01/75222. In addition, it also uses the indices of two poor fingerprints, which does not relate to the present invention.
In one paper machine, the negative effect of a particular mass mix has been detected. This can be recognized quite easily, even directly from the existing measurements results. This can be linked to an alarm, or the index can be intended to be retrieved, for example, only if the short-circulation index deviates from a good value.
In one paper machine, it has been noticed that blockage of the felt causes at least some of the web breaks. However, it is quite easy to measure the condition of the felt and form an index of it, and even a direct alarm, if the condition index drops below a set limit.
In addition, in the starting stage it is best to use a special start-mix, which will ensure a smooth start-up. After start-up, the mass mix is changed to be in accordance with the product recipe.
Similar poor fingerprints can also be recorded from the electrochemical measurements at the wet end, which depict a particular ‘taste index’. It has also be surprisingly observed that it is worth taking into account the wet-end electrochemical measurements, when evaluating the quality of the paper produced, even though, in this case, the learning must be carried out in a quite labourious manner. Naturally, it is nearly impossible to measure any electrochemical properties in dry paper, nor does electrochemistry greatly affect the properties of dry paper. However, the situation is different in a printing machine, in which the absorption and spread of ink, for example, depend on the electrochemical properties of wet paper. The paper's dusting, its travel through a printing machine, and the adhesion of printing ink/filler also partly depend on the said electrochemical properties.
In paper production, electrochemistry affects, in general:
the surface and colloidal chemistry of the paper the structure of the paper sheet formation the action of chemical additives the dirtying of the paper machine the wear of felts/fabrics the operation of the doctor blades.
As can be seen from the above, the properties of the finished paper depend to some extent on the electrochemical properties of the mass used in its manufacture.
Negative fingerprints are generally based on a rather small group of variables (3–6). A good fingerprint, on the contrary, is based on many variables (10–20), but the group can often be reduced after the research stage. In other words, when fine-tuning the monitoring and analysis equipment, it is possible to see which variables are less important.
Individual indices can be made for process variables that must be kept constant (in a paper machine consistencies, pressures, temperatures, 10–20 items), making it possible to see immediately if even one breaks away from its set value.
In practice, the multi-level percepton (MLP) has proven itself to be the most preferable type of neural network, because it functions excellently in online operation and in a process environment, in which the phenomena are non-linear. In the learning stage, a Back Propagation neural network can preferably be used.
Generally, runnability and quality are kept on target by, monitoring the fingerprints of good situations in each sub-process. If a deviation then appears, the cause of the fault or deviation in general will be found considerably faster, if runnability indices relating to the operational sub-process of the paper machine are available. One improved embodiment additionally uses special detection of specific poor fingerprints. Monitoring is facilitated by a common runnability index for the entire paper machine, any change in which will indicate a need to search for the sub-process causing the problem, and ultimately for its input variables.
FIG. 2 shows a diagram of the principle of how data from thousands of process measurements are reduced initially to 8–16 indices and finally to a single runnability index and a single quality index. The sub-processes short circulation, head box, and wire section form the wet end, in which there are also electrochemical measurements. The press section, dryer section, and reeler (pope) form the dry end of the paper machine. An individual index is formed for each sub-process and a common runnability index for the entire paper machine is formed from them.
FIG. 3 shows a more detailed hierarchy, related to the invention, of the paper machine's measurement information. 100–200 process data are formed from existing measurements of the paper machine (several thousands of I/O inputs) and from the particular electrochemical measurements. For the electrochemical measurements, there is one (head box) or more measurement units 10 . In one embodiment, there is one unit for each raw-material branch (TMP, mechanical pulp, cellulose, de-inked mass, broke, and circulation water).
The desired sub-process indices, which are marked in FIG. 3 : Pulp, Raw material, Additive, Electrochemistry (taste), Head box, Wire section, Press section, Felts, Dryer section, and Pope, are formed from the said process data.
An individual data window is formed from these for each operator and specialist. These are the pulp man, the machine man, the automation specialist, the felt supplier, and the chemicals supplier.
Also marked in FIG. 3 are a runnability index, which depicts the operation of the entire paper machine, and a finished paper quality index, which is calculated from the basic indices and from possible ancillary quality measurements. In practice, any deviation in the quality index derived from electrochemistry will cause at least a warning that the printability of the paper and/or the permanence of the filler may be diminished.
Preferably, the indices are calculated from two or more consecutive sub-processes, allowing the cause-effect relationships to be determined by examining the input variables of the neural network of the sub-processes. This is exploited in the research stage of the start-up of the system, for instance, by forming negative fingerprint-indices of unfavourable combinations. In the research stage, the set of neural-network input variables can also be reduced considerably.
FIG. 4 shows one apparatus according to the invention in a paper machine environment. The system is connected to the existing mill data communications network 20 , the data system 21 , and to the mill workstations 24 . The mill system includes, through a sub-network 20 . 1 , the control systems for the wet end (2, 3, 4) and the dry end (4, 5). The system according to the invention collects not only the mill's process information (from the unit 21 ), but also data from its own electrochemical units 10 . For these, a data-link server 22 and an actual neural-network processing unit 23 are connected to the mill network 20 . These are quite conventional industrial PC units. The data-link server 22 collects electrochemical data, used in the neural-network processing, from the units 10 and from the mill's process-data unit 21 . Thus, the processing unit receives all of its data from the link server 22 .
A particular feature of the system are the remote-control units 25 , by means of which the neural networks can be controlled and taught remotely. In addition, the measurement units can also be remotely controlled. The remote control is connected through a public data network (Internet), with the aid of a VPN (Virtual Private Network) formed using two-sided firewalls. With the aid of remote control, an expert can quickly resolve process problems and also effectively make changes to the system.
Remote control of the measurement units permits the measurement units to be monitored along with the rest of the system. This is particularly advantageous, especially in the start-up stage. Remote control can be used to perform the operations disclosed in the publication WO 01/25774 for calibrating each sensor and setting it correctly. Remote control can be used to set the base level of each electrode, once the polarization curve has been run.
Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to;the described embodiments, but that it have the full scope defined by the language of the following claims.
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The invention relates to a method for monitoring and analyzing a production process. In the method, a large number of variables are measured from the process, with the aid of these variables, fingerprints according to a good process situation, relative to runnability, are defined in several sub-processes and are then stored in a memory, the stored fingerprints are compared with fingerprints obtained in a normal process situation, on the basis of the comparison, an index of the difference, displayed graphically to the user, between the recorded good situation and the momentary process situation is defined, and a runnability index, depicting the runnability of the entire paper machine and a quality index depicting the quality of the paper produced, are formed from these indices.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional application No. 60/167,826 (filed Nov. 29, 1999), the contents of which are incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to a new gene that encodes an enzyme inhibitor. In particular, the present invention relates to a novel serpin, designated “Zserp11,” and to nucleic acid molecules encoding Zserp11.
BACKGROUND OF THE INVENTION
[0003] Endogenous proteolytic enzymes provide a variety of useful functions, including the degradation of invading organisms, antigen-antibody complexes, and certain tissue proteins that are no longer necessary. The serine proteases comprise a large family of enzymes that use an activated serine residue in the substrate-binding site to catalytically hydrolyze peptide bonds. Typically, this serine residue can be identified by the irreversible reaction of its side chain hydroxyl group with diisopropylfluorophosphate. Serine proteases participate in carefully controlled processes, such as blood coagulation, fibrinolysis, complement activation, fertilization, and hormone production.
[0004] Normally, serine proteases catalyze limited proteolysis, in that only one or two specific peptide bonds of the protein substrate are cleaved. Under denaturing conditions, serine proteases can hydrolyze multiple peptide bonds, resulting in the digestion of peptides, proteins, and even autolysis. Several diseases are thought to result from the lack of regulation of serine protease activity, including emphysema, arthritis, cancer metastasis, and thrombosis.
[0005] In vivo, serine protease activity is limited by protein inhibitors. Serine protease inhibitors, or serpins, constitute a family of proteins that bind with target proteases. These inhibitors, like their protease targets, play significant roles in physiology. For example, serpin dysfunction is associated with emphysema, blood clotting disorders, cirrhosis, Alzheimer disease, and Parkinson disease (see, for example, Eriksson et al., New Eng. J. Med. 314:736 (1986); Wiebicke et al., Europ. J. Pediat. 155:603 (1996); Kamboh et al., Nature Genet. 10:486 (1995); Yamamoto et al., Brain Res. 759:153 (1997)).
[0006] The discovery of a new serine protease inhibitor fulfills a need in the art by providing a new composition useful in diagnosis, therapy, or industry.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a novel serpin, designated “Zserp11.” The present invention also provides Zserp11 variant polypeptides and Zserp11 fusion proteins, as well as nucleic acid molecules encoding such polypeptides and proteins, and methods for using these nucleic acid molecules and amino acid sequences.
DETAILED DESCRIPTION OF THE INVENTION
[0000] 1. Overview
[0008] The present invention provides nucleic acid molecules that encode a new human serpin, designated as “Zserp11.” An illustrative nucleotide sequence that encodes Zserp11 is provided by SEQ ID NO:1. The encoded polypeptide has the following amino acid sequence: MEASRWWLLV TVLMAGAHCV ALVDQEASDL IHSGPQDSSP GPALPCHKIS VSNIDFAFKL YRQLALNAPG ENILFSPVSI SLALAMLSWG APVASRTQLL EGLGFTLTVV PEEEIQEGFW DLLIRLRGQG PRLLLTMDQR RFSGLGARAN QSLEEAQKHI DEYTEQQTQG KLGAWEKDLG SETTAVLVNH MLLRAEWMKP FDSRATSPKE FFVDEHSAVW VPMMKEKASH RFLHDRELQC SVLRMDHAGN TTTFFIFPNR GKMRQLEDAL LPETLIKWDS LLRTRDTVTP RDAVTSMVTH KAMLDERG SEAAAATSIQ LTPGPRPDLD FPPTLGTEFS RPFLVMTFHT ETGSMLFLEK IVNPLG (SEQ ID NO:2). Thus, the Zserp11 gene described herein encodes a polypeptide of 366 amino acids, as shown in SEQ ID NO:2. The Zserp11 gene resides in human chromosome 14q32.1.
[0009] The expression of the Zserp11 gene was examined using a reverse transcriptase-polymerase chain reaction with sense (5′ GAAGG ACCTC GGCAG TGAAA CC 3′; SEQ ID NO:5) and antisense oligonucleotides (5′ CCATC CGCAG CACAG AGCAT T 3′; SEQ ID NO:6). The study showed that Zserp11 gene expression is detectable in stomach tumor tissue, but not in normal stomach tissue. These results indicate that the detection of Zserp11 gene expression can be used to differentiate between normal and tumor stomach tumor tissue.
[0010] As detailed below, the present invention provides isolated polypeptides having an amino acid sequence that is at least 70%, at least 80%, or at least 90% identical to the amino acid sequence of SEQ ID NO:2. Certain isolated polypeptides specifically bind with an antibody that specifically binds with a polypeptide having the amino acid sequence of SEQ ID NO:2. Particular polypeptides also can be characterized by serine protease activity.
[0011] An illustrative polypeptide is a polypeptide that comprises the amino acid sequence of SEQ ID NO:2. Additional exemplary polypeptides include polypeptides comprising an amino acid sequence of at least 15 contiguous amino acids of an amino acid sequence selected from the group consisting of: amino acid residues 46 to 137 of SEQ ID NO:2, amino acid residues 154 to 285 of SEQ ID NO:2, amino acid residues 296 to 364 of SEQ ID NO:2, and the amino acid sequence of SEQ ID NO:2. For example, certain polypeptides comprise an amino acid sequence of 30 contiguous amino acids of an amino acid sequence selected from the group consisting of: amino acid residues 46 to 137 of SEQ ID NO:2, amino acid residues 154 to 285 of SEQ ID NO:2, amino acid residues 296 to 364 of SEQ ID NO:2, and the amino acid sequence of SEQ ID NO:2. Other illustrative polypeptides comprise an amino acid sequence selected from the group consisting of: amino acid residues 46 to 137 of SEQ BD NO:2, amino acid residues 154 to 285 of SEQ ID NO:2, amino acid residues 322 to 327 of SEQ ID NO:2, and amino acid residues 296 to 364 of SEQ ID NO:2. Additional examples include polypeptides consisting of an amino acid sequence selected from the group consisting of: amino acid residues 46 to 137 of SEQ ID NO:2, amino acid residues 154 to 285 of SEQ ID NO:2, amino acid residues 322 to 327 of SEQ ID NO:2, and amino acid residues 296 to 364 of SEQ ID NO:2.
[0012] The present invention further provides antibodies and antibody fragments that specifically bind with such polypeptides. Exemplary antibodies include polyclonal antibodies, murine monoclonal antibodies, humanized antibodies derived from murine monoclonal antibodies, and human monoclonal antibodies. Ilustrative antibody fragments include F(ab′) 2 , F(ab) 2 , Fab′, Fab, Fv, scFv, and minimal recognition units. The present invention also includes anti-idiotype antibodies that specifically bind with such antibodies or antibody fragments. The present invention further includes compositions comprising a carrier and a peptide, polypeptide, antibody, or anti-idiotype antibody described herein.
[0013] The present invention also provides isolated nucleic acid molecules that encode a Zserp11 polypeptide, wherein the nucleic acid molecule is selected from the group consisting of: a nucleic acid molecule comprising the nucleotide sequence of SEQ ID NO:3; a nucleic acid molecule encoding the amino acid sequence of SEQ ID NO:2; and a nucleic acid molecule that remains hybridized following stringent wash conditions to a nucleic acid molecule consisting of a nucleotide sequence selected from the group consisting of: (a) the nucleotide sequence of SEQ ID NO:1, (b) nucleotides 36 to 411 of SEQ ID NO:1, (c) nucleotides 460 to 855 of SEQ ID NO:1, (d) nucleotides 886 to 1092 of SEQ ID NO:1, and (e) a nucleotide sequence that is the complement of the nucleotide sequence of (a), (b), (c) or (d).
[0014] Illustrative nucleic acid molecules include those in which any difference between the amino acid sequence encoded by the nucleic acid molecule and the corresponding amino acid sequence of SEQ ID NO:2 is due to a conservative amino acid substitution. The present invention further contemplates isolated nucleic acid molecules that comprise the nucleotide sequence of SEQ ID NO:1, 36 to 411 of SEQ ID NO:1, nucleotides 460 to 855 of SEQ ID NO:1, or nucleotides 886 to 1092 of SEQ ID NO:1.
[0015] The present invention also includes vectors and expression vectors comprising such nucleic acid molecules. Such expression vectors may comprise a transcription promoter, and a transcription terminator, wherein the promoter is operably linked with the nucleic acid molecule, and wherein the nucleic acid molecule is operably linked with the transcription terminator. The present invention further includes recombinant host cells comprising these vectors and expression vectors. Illustrative host cells include bacterial, yeast, fungal, avian, insect, mammalian, and plant cells. Recombinant host cells comprising such expression vectors can be used to produce Zserp11 polypeptides by culturing such recombinant host cells that comprise the expression vector and that produce the Zserp11 protein, and, optionally, isolating the Zserp11 protein from the cultured recombinant host cells. The present invention further includes the products of such processes.
[0016] The present invention also contemplates methods for detecting the presence of Zserp11 RNA in a biological sample, comprising the steps of (a) contacting a Zserp11 nucleic acid probe under hybridizing conditions with either (i) test RNA molecules isolated from the biological sample, or (ii) nucleic acid molecules synthesized from the isolated RNA molecules, wherein the probe has a nucleotide sequence comprising a portion of the nucleotide sequence of SEQ ID NO:1, or its complement, and (b) detecting the formation of hybrids of the nucleic acid probe and either the test RNA molecules or the synthesized nucleic acid molecules, wherein the presence of the hybrids indicates the presence of Zserp11 RNA in the biological sample. An example of a biological sample is a human biological sample, such as a biopsy or autopsy specimen.
[0017] The present invention further provides methods for detecting the presence of Zserp11 polypeptide in a biological sample, comprising the steps of: (a) contacting the biological sample with an antibody or an antibody fragment that specifically binds with a polypeptide having the amino acid sequence of SEQ ID NO:2, wherein the contacting is performed under conditions that allow the binding of the antibody or antibody fragment to the biological sample, and (b) detecting any of the bound antibody or bound antibody fragment. Such an antibody or antibody fragment may further comprise a detectable label selected from the group consisting of radioisotope, fluorescent label, chemiluminescent label, enzyme label, bioluminescent label, and colloidal gold. An exemplary biological sample is a human biological sample, such as a biopsy or autopsy specimen.
[0018] The present invention also provides kits for performing these detection methods. For example, a kit for detection of Zserp11 gene expression may comprise a container that comprises a nucleic acid molecule, wherein the nucleic acid molecule is selected from the group consisting of (a) a nucleic acid molecule comprising the nucleotide sequence of SEQ ID NO:1, (b) a nucleic acid molecule comprising the complement of the nucleotide sequence of SEQ ID NO:1, (c) a nucleic acid molecule that is a fragment of (a) consisting of at least eight nucleotides, and (d) a nucleic acid molecule that is a fragment of (b) consisting of at least eight nucleotides. Illustrative nucleic acid molecules include nucleic acid molecules comprising nucleotides 36 to 411 of SEQ ID NO:1, nucleotides 460 to 855 of SEQ ID NO:1, nucleotides 964 to 981 of SEQ ID NO:1, and nucleotides 886 to 1092 of SEQ ID NO:1, or the complement thereof. Such a kit may also comprise a second container that comprises one or more reagents capable of indicating the presence of the nucleic acid molecule. On the other hand, a kit for detection of Zserp11 protein may comprise a container that comprises an antibody, or an antibody fragment, that specifically binds with a polypeptide having the amino acid sequence of SEQ ID NO:2.
[0019] The present invention further provides variant Zserp11 polypeptides, which comprise an amino acid sequence that shares an identity with the amino acid sequence of SEQ ID NO:2 selected from the group consisting of at least 70% identity, at least 80% identity, at least 90% identity, at least 95% identity, or greater than 95% identity, and wherein any difference between the amino acid sequence of the variant polypeptide and the amino acid sequence of SEQ ID NO:2 is due to one or more conservative amino acid substitutions.
[0020] The present invention also provides fusion proteins comprising a Zserp11 polypeptide moiety. Such fusion proteins can further comprise an immunoglobulin moiety. In such fusion proteins, the immunoglobulin moiety may be an immunoglobulin heavy chain constant region, such as a human Fc fragment. The present invention further includes isolated nucleic acid molecules that encode such fusion proteins.
[0021] These and other aspects of the invention will become evident upon reference to the following detailed description. In addition, various references are identified below and are incorporated by reference in their entirety.
[0000] 2. Definitions
[0022] In the description that follows, a number of terms are used extensively. The following definitions are provided to facilitate understanding of the invention.
[0023] As used herein, “nucleic acid” or “nucleic acid molecule” refers to polynucleotides, such as deoxyribonucleic acid (DNA) or ribonucleic acid (RNA), oligonucleotides, fragments generated by the polymerase chain reaction (PCR), and fragments generated by any of ligation, scission, endonuclease action, and exonuclease action. Nucleic acid molecules can be composed of monomers that are naturally-occurring nucleotides (such as DNA and RNA), or analogs of naturally-occurring nucleotides (e.g., α-enantiomeric forms of naturally-occurring nucleotides), or a combination of both. Modified nucleotides can have alterations in sugar moieties and/or in pyrirnidine or purine base moieties. Sugar modifications include, for example, replacement of one or more hydroxyl groups with halogens, alkyl groups, amines, and azido groups, or sugars can be functionalized as ethers or esters. Moreover, the entire sugar moiety can be replaced with sterically and electronically similar structures, such as aza-sugars and carbocyclic sugar analogs. Examples of modifications in a base moiety include alkylated purines and pyrimidines, acylated purines or pyrimidines, or other well-known heterocyclic substitutes. Nucleic acid monomers can be linked by phosphodiester bonds or analogs of such linkages. Analogs of phosphodiester linkages include phosphorothioate, phosphorodithioate, phosphoroselenoate, phosphorodiselenoate, phosphoroanilothioate, phosphoranilidate, phosphoramidate, and the like. The term “nucleic acid molecule” also includes so-called “peptide nucleic acids,” which comprise naturally-occurring or modified nucleic acid bases attached to a polyamide backbone. Nucleic acids can be either single stranded or double stranded.
[0024] The term “complement of a nucleic acid molecule” refers to a nucleic acid molecule having a complementary nucleotide sequence and reverse orientation as compared to a reference nucleotide sequence. For example, the sequence 5′ ATGCACGGG 3′ is complementary to 5′ CCCGTGCAT 3′.
[0025] The term “contig” denotes a nucleic acid molecule that has a contiguous stretch of identical or complementary sequence to another nucleic acid molecule. Contiguous sequences are said to “overlap” a given stretch of a nucleic acid molecule either in their entirety or along a partial stretch of the nucleic acid molecule.
[0026] The term “degenerate nucleotide sequence” denotes a sequence of nucleotides that includes one or more degenerate codons as compared to a reference nucleic acid molecule that encodes a polypeptide. Degenerate codons contain different triplets of nucleotides, but encode the same amino acid residue (i.e., GAU and GAC triplets each encode Asp).
[0027] The term “structural gene” refers to a nucleic acid molecule that is transcribed into messenger RNA (mRNA), which is then translated into a sequence of amino acids characteristic of a specific polypeptide.
[0028] An “isolated nucleic acid molecule” is a nucleic acid molecule that is not integrated in the genomic DNA of an organism. For example, a DNA molecule that encodes a growth factor that has been separated from the genomic DNA of a cell is an isolated DNA molecule. Another example of an isolated nucleic acid molecule is a chemically-synthesized nucleic acid molecule that is not integrated in the genome of an organism. A nucleic acid molecule that has been isolated from a particular species is smaller than the complete DNA molecule of a chromosome from that species.
[0029] A “nucleic acid molecule construct” is a nucleic acid molecule, either single- or double-stranded, that has been modified through human intervention to contain segments of nucleic acid combined and juxtaposed in an arrangement not existing in nature.
[0030] “Linear DNA” denotes non-circular DNA molecules having free 5′ and 3′ ends. Linear DNA can be prepared from closed circular DNA molecules, such as plasmids, by enzymatic digestion or physical disruption.
[0031] “Complementary DNA (cDNA)” is a single-stranded DNA molecule that is formed from an mRNA template by the enzyme reverse transcriptase. Typically, a primer complementary to portions of mRNA is employed for the initiation of reverse transcription. Those skilled in the art also use the term “cDNA” to refer to a double-stranded DNA molecule consisting of such a single-stranded DNA molecule and its complementary DNA strand. The term “cDNA” also refers to a clone of a cDNA molecule synthesized from an RNA template.
[0032] A “promoter” is a nucleotide sequence that directs the transcription of a structural gene. Typically, a promoter is located in the 5′ non-coding region of a gene, proximal to the transcriptional start site of a structural gene. Sequence elements within promoters that function in the initiation of transcription are often characterized by consensus nucleotide sequences. These promoter elements include RNA polymerase binding sites, TATA sequences, CAAT sequences, differentiation-specific elements (DSEs; McGehee et al., Mol. Endocrinol. 7:551 (1993)), cyclic AMP response elements (CREs), serum response elements (SREs; Treisman, Seminars in Cancer Biol. 1:47 (1990)), glucocorticoid response elements (GREs), and binding sites for other transcription factors, such as CRE/ATF (O'Reilly et al., J. Biol. Chem. 267:19938 (1992)), AP2 (Ye et al., J. Biol. Chem. 269:25728 (1994)), SP1, cAMP response element binding protein (CREB; Loeken, Gene Expr. 3:253 (1993)) and octamer factors (see, in general, Watson et al., eds., Molecular Biology of the Gene, 4th ed. (The Benjamin/Cummings Publishing Company, Inc. 1987), and Lemaigre and Rousseau, Biochem. J. 303:1 (1994)). If a promoter is an inducible promoter, then the rate of transcription increases in response to an inducing agent. In contrast, the rate of transcription is not regulated by an inducing agent if the promoter is a constitutive promoter. Repressible promoters are also known.
[0033] A “core promoter” contains essential nucleotide sequences for promoter function, including the TATA box and start of transcription. By this definition, a core promoter may or may not have detectable activity in the absence of specific sequences that may enhance the activity or confer tissue specific activity.
[0034] A “regulatory element” is a nucleotide sequence that modulates the activity of a core promoter. For example, a regulatory element may contain a nucleotide sequence that binds with cellular factors enabling transcription exclusively or preferentially in particular cells, tissues, or organelles. These types of regulatory elements are normally associated with genes that are expressed in a “cell-specific,” “tissue-specific,” or “organelle-specific” manner. For example, the Zserp11 regulatory element preferentially induces gene expression in spleen, thymus, spinal cord, and lymph node tissues, as opposed to placenta, lung, and liver tissues.
[0035] An “enhancer” is a type of regulatory element that can increase the efficiency of transcription, regardless of the distance or orientation of the enhancer relative to the start site of transcription.
[0036] “Heterologous DNA” refers to a DNA molecule, or a population of DNA molecules, that does not exist naturally within a given host cell. DNA molecules heterologous to a particular host cell may contain DNA derived from the host cell species (i.e., endogenous DNA) so long as that host DNA is combined with non-host DNA (i.e., exogenous DNA). For example, a DNA molecule containing a non-host DNA segment encoding a polypeptide operably linked to a host DNA segment comprising a transcription promoter is considered to be a heterologous DNA molecule. Conversely, a heterologous DNA molecule can comprise an endogenous gene operably linked with an exogenous promoter. As another illustration, a DNA molecule comprising a gene derived from a wild-type cell is considered to be heterologous DNA if that DNA molecule is introduced into a mutant cell that lacks the wild-type gene.
[0037] A “polypeptide” is a polymer of amino acid residues joined by peptide bonds, whether produced naturally or synthetically. Polypeptides of less than about 10 amino acid residues are commonly referred to as “peptides.”
[0038] A “protein” is a macromolecule comprising one or more polypeptide chains. A protein may also comprise non-peptidic components, such as carbohydrate groups. Carbohydrates and other non-peptidic substituents may be added to a protein by the cell in which the protein is produced, and will vary with the type of cell. Proteins are defined herein in terms of their amino acid backbone structures; substituents such as carbohydrate groups are generally not specified, but may be present nonetheless.
[0039] A peptide or polypeptide encoded by a non-host DNA molecule is a “heterologous” peptide or polypeptide.
[0040] An “integrated genetic element” is a segment of DNA that has been incorporated into a chromosome of a host cell after that element is introduced into the cell through human manipulation. Within the present invention, integrated genetic elements are most commonly derived from linearized plasmids that are introduced into the cells by electroporation or other techniques. Integrated genetic elements are passed from the original host cell to its progeny.
[0041] A “cloning vector” is a nucleic acid molecule, such as a plasmid, cosmid, or bacteriophage, that has the capability of replicating autonomously in a host cell. Cloning vectors typically contain one or a small number of restriction endonuclease recognition sites that allow insertion of a nucleic acid molecule in a determinable fashion without loss of an essential biological function of the vector, as well as nucleotide sequences encoding a marker gene that is suitable for use in the identification and selection of cells transformed with the cloning vector. Marker genes typically include genes that provide tetracycline resistance or ampicillin resistance.
[0042] An “expression vector” is a nucleic acid molecule encoding a gene that is expressed in a host cell. Typically, an expression vector comprises a transcription promoter, a gene, and a transcription terminator. Gene expression is usually placed under the control of a promoter, and such a gene is said to be “operably linked to” the promoter. Similarly, a regulatory element and a core promoter are operably linked if the regulatory element modulates the activity of the core promoter.
[0043] A “recombinant host” is a cell that contains a heterologous nucleic acid molecule, such as a cloning vector or expression vector. In the present context, an example of a recombinant host is a cell that produces Zserp11 from an expression vector. In contrast, Zserp11 can be produced by a cell that is a “natural source” of Zserp11, and that lacks an expression vector.
[0044] “Integrative transformants” are recombinant host cells, in which heterologous DNA has become integrated into the genomic DNA of the cells.
[0045] A “fusion protein” is a hybrid protein expressed by a nucleic acid molecule comprising nucleotide sequences of at least two genes. For example, a fusion protein can comprise at least part of a Zserp11 polypeptide fused with a polypeptide that binds an affinity matrix. Such a fusion protein provides a means to isolate large quantities of Zserp11 using affinity chromatography.
[0046] The term “receptor” denotes a cell-associated protein that binds to a bioactive molecule termed a “ligand.” This interaction mediates the effect of the ligand on the cell. Receptors can be membrane bound, cytosolic or nuclear; monomeric (e.g., thyroid stimulating hormone receptor, beta-adrenergic receptor) or multimeric (e.g., PDGF receptor, growth hormone receptor, IL-3 receptor, GM-CSF receptor, G-CSF receptor, erythropoietin receptor and IL-6 receptor). Membrane-bound receptors are characterized by a multi-domain structure comprising an extracellular ligand-binding domain and an intracellular effector domain that is typically involved in signal transduction. In certain membrane-bound receptors, the extracellular ligand-binding domain and the intracellular effector domain are located in separate polypeptides that comprise the complete functional receptor.
[0047] In general, the binding of ligand to receptor results in a conformational change in the receptor that causes an interaction between the effector domain and other molecule(s) in the cell, which in turn leads to an alteration in the metabolism of the cell. Metabolic events that are often linked to receptor-ligand interactions include gene transcription, phosphorylation, dephosphorylation, increases in cyclic AMP production, mobilization of cellular calcium, mobilization of membrane lipids, cell adhesion, hydrolysis of inositol lipids and hydrolysis of phospholipids.
[0048] The term “secretory signal sequence” denotes a nucleotide sequence that encodes a peptide (a “secretory peptide”) that, as a component of a larger polypeptide, directs the larger polypeptide through a secretory pathway of a cell in which it is synthesized. The larger polypeptide is commonly cleaved to remove the secretory peptide during transit through the secretory pathway.
[0049] An “isolated polypeptide” is a polypeptide that is essentially free from contaminating cellular components, such as carbohydrate, lipid, or other proteinaceous impurities associated with the polypeptide in nature. Typically, a preparation of isolated polypeptide contains the polypeptide in a highly purified form, i.e., at least about 80% pure, at least about 90% pure, at least about 95% pure, greater than 95% pure, or greater than 99% pure. One way to show that a particular protein preparation contains an isolated polypeptide is by the appearance of a single band following sodium dodecyl sulfate (SDS)-polyacrylamide gel electrophoresis of the protein preparation and Coomassie Brilliant Blue staining of the gel. However, the term “isolated” does not exclude the presence of the same polypeptide in alternative physical forms, such as dimers or alternatively glycosylated or derivatized forms.
[0050] The terms “amino-terminal” and “carboxyl-terminal” are used herein to denote positions within polypeptides. Where the context allows, these terms are used with reference to a particular sequence or portion of a polypeptide to denote proximity or relative position. For example, a certain sequence positioned carboxyl-terminal to a reference sequence within a polypeptide is located proximal to the carboxyl terminus of the reference sequence, but is not necessarily at the carboxyl terminus of the complete polypeptide.
[0051] The term “expression” refers to the biosynthesis of a gene product. For example, in the case of a structural gene, expression involves transcription of the structural gene into mRNA and the translation of mRNA into one or more polypeptides.
[0052] The term “splice variant” is used herein to denote alternative forms of RNA transcribed from a gene. Splice variation arises naturally through use of alternative splicing sites within a transcribed RNA molecule, or less commonly between separately transcribed RNA molecules, and may result in several mRNAs transcribed from the same gene. Splice variants may encode polypeptides having altered amino acid sequence. The term splice variant is also used herein to denote a polypeptide encoded by a splice variant of an mRNA transcribed from a gene.
[0053] As used herein, the term “immunomodulator” includes cytokines, stem cell growth factors, lymphotoxins, co-stimulatory molecules, hematopoietic factors, and synthetic analogs of these molecules.
[0054] The term “complement/anti-complement pair” denotes non-identical moieties that form a non-covalently associated, stable pair under appropriate conditions. For instance, biotin and avidin (or streptavidin) are prototypical members of a complement/anti-complement pair. Other exemplary complement/anti-complement pairs include receptor/ligand pairs, antibody/antigen (or hapten or epitope) pairs, sense/antisense polynucleotide pairs, and the like. Where subsequent dissociation of the complement/anti-complement pair is desirable, the complement/anti-complement pair preferably has a binding affinity of less than 10 9 M −1 .
[0055] An “anti-idiotype antibody” is an antibody that binds with the variable region domain of an immunoglobulin. In the present context, an anti-idiotype antibody binds with the variable region of an anti-Zserp11 antibody, and thus, an anti-idiotype antibody mimics an epitope of Zserp11. Particular Zserp11 anti-idiotype antibodies possess serine protease inhibitor activity.
[0056] An “antibody fragment” is a portion of an antibody such as F(ab′) 2 , F(ab) 2 , Fab′, Fab, and the like. Regardless of structure, an antibody fragment binds with the same antigen that is recognized by the intact antibody. For example, an anti-Zserp11 monoclonal antibody fragment binds with an epitope of Zserp11.
[0057] The term “antibody fragment” also includes a synthetic or a genetically engineered polypeptide that binds to a specific antigen, such as polypeptides consisting of the light chain variable region, “Fv” fragments consisting of the variable regions of the heavy and light chains, recombinant single chain polypeptide molecules in which light and heavy variable regions are connected by a peptide linker (“scFv proteins”), and minimal recognition units consisting of the amino acid residues that mimic the hypervariable region.
[0058] A “chimeric antibody” is a recombinant protein that contains the variable domains and complementary determining regions derived from a rodent antibody, while the remainder of the antibody molecule is derived from a human antibody.
[0059] “Humanized antibodies” are recombinant proteins in which murine complementarity determining regions of a monoclonal antibody have been transferred from heavy and light variable chains of the murine immunoglobulin into a human variable domain.
[0060] As used herein, a “therapeutic agent” is a molecule or atom which is conjugated to an antibody moiety to produce a conjugate which is useful for therapy. Examples of therapeutic agents include drugs, toxins, immunomodulators, chelators, boron compounds, photoactive agents or dyes, and radioisotopes.
[0061] A “detectable label” is a molecule or atom which can be conjugated to an antibody moiety to produce a molecule useful for diagnosis. Examples of detectable labels include chelators, photoactive agents, radioisotopes, fluorescent agents, paramagnetic ions, or other marker moieties.
[0062] The term “affinity tag” is used herein to denote a polypeptide segment that can be attached to a second polypeptide to provide for purification or detection of the second polypeptide or provide sites for attachment of the second polypeptide to a substrate. In principal, any peptide or protein for which an antibody or other specific binding agent is available can be used as an affinity tag. Affinity tags include a poly-histidine tract, protein A (Nilsson et al., EMBO J. 4:1075 (1985); Nilsson et al., Methods Enzymol. 198:3 (1991)), glutathione S transferase (Smith and Johnson, Gene 67:31 (1988)), Glu-Glu affinity tag (Grussenmeyer et al., Proc. Natl. Acad. Sci. USA 82:7952 (1985)), substance P, FLAG peptide (Hopp et al., Biotechnology 6:1204 (1988)), streptavidin binding peptide, or other antigenic epitope or binding domain. See, in general, Ford et al., Protein Expression and Purification 2:95 (1991). Nucleic acid molecules encoding affinity tags are available from commercial suppliers (e.g., Pharmacia Biotech, Piscataway, N.J.).
[0063] A “naked antibody” is an entire antibody, as opposed to an antibody fragment, which is not conjugated with a therapeutic agent. Naked antibodies include both polyclonal and monoclonal antibodies, as well as certain recombinant antibodies, such as chimeric and humanized antibodies.
[0064] As used herein, the term “antibody component” includes both an entire antibody and an antibody fragment.
[0065] An “immunoconjugate” is a conjugate of an antibody component with a therapeutic agent or a detectable label.
[0066] As used herein, the term “antibody fusion protein” refers to a recombinant molecule that comprises an antibody component and a therapeutic agent. Examples of therapeutic agents suitable for such fusion proteins include immunomodulators (“antibody-immunomodulator fusion protein”) and toxins (“antibody-toxin fusion protein”).
[0067] A “target polypeptide” or a “target peptide” is an amino acid sequence that comprises at least one epitope, and that is expressed on a target cell,. such as a tumor cell, or a cell that carries an infectious agent antigen. T cells recognize peptide epitopes presented by a major histocompatibility complex molecule to a target polypeptide or target peptide and typically lyse the target cell or recruit other immune cells to the site of the target cell, thereby killing the target cell.
[0068] An “antigenic peptide” is a peptide, which will bind a major histocompatibility complex molecule to form an MHC-peptide complex which is recognized by a T cell, thereby inducing a cytotoxic lymphocyte response upon presentation to the T cell. Thus, antigenic peptides are capable of binding to an appropriate major histocompatibility complex molecule and inducing a cytotoxic T cells response, such as cell lysis or specific cytokine release against the target cell which binds or expresses the antigen. The antigenic peptide can be bound in the context of a class I or class II major histocompatibility complex molecule, on an antigen presenting cell or on a target cell.
[0069] In eukaryotes, RNA polymerase II catalyzes the transcription of a structural gene to produce mRNA. A nucleic acid molecule can be designed to contain an RNA polymerase II template in which the RNA transcript has a sequence that is complementary to that of a specific mRNA. The RNA transcript is termed an “anti-sense RNA” and a nucleic acid molecule that encodes the anti-sense RNA is termed an “anti-sense gene.” Anti-sense RNA molecules are capable of binding to mRNA molecules, resulting in an inhibition of mRNA translation.
[0070] An “anti-sense oligonucleotide specific for Zserp11” or an “Zserp11 anti-sense oligonucleotide” is an oligonucleotide having a sequence (a) capable of forming a stable triplex with a portion of the Zserp11 gene, or (b) capable of forming a stable duplex with a portion of an mRNA transcript of the Zserp11 gene.
[0071] A “ribozyme” is a nucleic acid molecule that contains a catalytic center. The term includes RNA enzymes, self-splicing RNAs, self-cleaving RNAs, and nucleic acid molecules that perform these catalytic functions. A nucleic acid molecule that encodes a ribozyme is termed a “ribozyme gene.”
[0072] An “external guide sequence” is a nucleic acid molecule that directs the endogenous ribozyme, RNase P, to a particular species of intracellular mRNA, resulting in the cleavage of the mRNA by RNase P. A nucleic acid molecule that encodes an external guide sequence is termed an “external guide sequence gene.”
[0073] The term “variant Zserp11 gene” refers to nucleic acid molecules that encode a polypeptide having an amino acid sequence that is a modification of SEQ ID NO:2. Such variants include naturally-occurring polymorphisms of Zserp11 genes, as well as synthetic genes that contain conservative amino acid substitutions of the amino acid sequence of SEQ ID NO:2. Additional variant forms of Zserp11 genes are nucleic acid molecules that contain insertions or deletions of the nucleotide sequences described herein. A variant Zserp11 gene can be identified by determining whether the gene hybridizes with a nucleic acid molecule having the nucleotide sequence of SEQ ID NO:1, or its complement, under stringent conditions.
[0074] Alternatively, variant Zserp11 genes can be identified by sequence comparison. Two amino acid sequences have “100% amino acid sequence identity” if the amino acid residues of the two amino acid sequences are the same when aligned for maximal correspondence. Similarly, two nucleotide sequences have “100% nucleotide sequence identity” if the nucleotide residues of the two nucleotide sequences are the same when aligned for maximal correspondence. Sequence comparisons can be performed using standard software programs such as those included in the LASERGENE bioinformatics computing suite, which is produced by DNASTAR (Madison, Wis.). Other methods for comparing two nucleotide or amino acid sequences by determining optimal alignment are well-known to those of skill in the art (see, for example, Peruski and Peruski, The Internet and the New Biology: Tools for Genomic and Molecular Research (ASM Press, Inc. 1997), Wu et al. (eds.), “Information Superhighway and Computer Databases of Nucleic Acids and Proteins,” in Methods in Gene Biotechnology , pages 123-151 (CRC Press, Inc. 1997), and Bishop (ed.), Guide to Human Genome Computing, 2nd Edition (Academic Press, Inc. 1998)). Particular methods for determining sequence identity are described below.
[0075] Regardless of the particular method used to identify a variant Zserp11 gene or variant Zserp11 polypeptide, a variant gene or polypeptide encoded by a variant gene may be characterized by at least one of: the ability to bind specifically to an anti-Zserp11 antibody, and serine protease inhibitor activity.
[0076] The term “allelic variant” is used herein to denote any of two or more alternative forms of a gene occupying the same chromosomal locus. Allelic variation arises naturally through mutation, and may result in phenotypic polymorphism within populations. Gene mutations can be silent (no change in the encoded polypeptide) or may encode polypeptides having altered amino acid sequence. The term allelic variant is also used herein to denote a protein encoded by an allelic variant of a gene.
[0077] The term “ortholog” denotes a polypeptide or protein obtained from one species that is the functional counterpart of a polypeptide or protein from a different species. Sequence differences among orthologs are the result of speciation.
[0078] “Paralogs” are distinct but structurally related proteins made by an organism. Paralogs are believed to arise through gene duplication. For example, α-globin, β-globin, and myoglobin are paralogs of eachother.
[0079] The present invention includes functional fragments of Zserp11 genes. Within the context of this invention, a “functional fragment” of a Zserp11 gene refers to a nucleic acid molecule that encodes a portion of a Zserp11 polypeptide which specifically binds with an anti-Zserp11 antibody or possesses serine protease inhibitor activity. For example, a functional fragment of a Zserp11 gene described herein comprises a portion of the nucleotide sequence of SEQ ID NO:1, and encodes a polypeptide that specifically binds with an anti-Zserp11 antibody.
[0080] Due to the imprecision of standard analytical methods, molecular weights and lengths of polymers are understood to be approximate values. When such a value is expressed as “about” X or “approximately” X, the stated value of X will be understood to be accurate to ±10%.
[0000] 3. Production of a Human Zserp11 Gene
[0081] Nucleic acid molecules encoding a human Zserp11 gene can be obtained by screening a human cDNA or genomic library using polynucleotide probes based upon SEQ ID NO:1. These techniques are standard and well-established.
[0082] As an illustration, a nucleic acid molecule that encodes a human Zserp11 gene can be isolated from a human cDNA library. In this case, the first step would be to prepare the cDNA library using methods well-known to those of skill in the art. In general, RNA isolation techniques must provide a method for breaking cells, a means of inhibiting RNase-directed degradation of RNA, and a method of separating RNA from DNA, protein, and polysaccharide contaminants. For example, total RNA can be isolated by freezing tissue in liquid nitrogen, grinding the frozen tissue with a mortar and pestle to lyse the cells, extracting the ground tissue with a solution of phenol/chloroform to remove proteins, and separating RNA from the remaining impurities by selective precipitation with lithium chloride (see, for example, Ausubel et al. (eds.), Short Protocols in Molecular Biology, 3 rd Edition , pages 4-1 to 4-6 (John Wiley & Sons 1995) [“Ausubel (1995)”]; Wu et al., Methods in Gene Biotechnology , pages 33-41 (CRC Press, Inc. 1997) [“Wu (1997)”]). Alternatively, total RNA can be by extracting ground tissue with guanidinium isothiocyanate, extracting with organic solvents, and separating RNA from contaminants using differential centrifugation (see, for example, Chirgwin et al., Biochemistry 18:52 (1979); Ausubel (1995) at pages 4-1 to 4-6; Wu (1997) at pages 33-41).
[0083] In order to construct a cDNA library, poly(A) + RNA must be isolated from a total RNA preparation. Poly(A) + RNA can be isolated from total RNA using the standard technique of oligo(dT)-cellulose chromatography (see, for example, Aviv and Leder, Proc. Nat'l Acad. Sci. USA 69:1408 (1972); Ausubel (1995) at pages 4-11 to 4-12).
[0084] Double-stranded cDNA molecules are synthesized from poly(A) + RNA using techniques well-known to those in the art. (see, for example, Wu (1997) at pages 41-46). Moreover, commercially available kits can be used to synthesize double-stranded cDNA molecules. For example, such kits are available from Life Technologies, Inc. (Gaithersburg, Md.), CLONTECH Laboratories, Inc. (Palo Alto, Calif.), Promega Corporation (Madison, Wis.) and STRATAGENE (La Jolla, Calif.).
[0085] Various cloning vectors are appropriate for the construction of a cDNA library. For example, a cDNA library can be prepared in a vector derived from bacteriophage, such as a λgt10 vector. See, for example, Huynh et al., “Constructing and Screening cDNA Libraries in λgt10 and λgt11,” in DNA Cloning: A Practical Approach Vol. I , Glover (ed.), page 49 (IRL Press, 1985); Wu (1997) at pages 47-52.
[0086] Alternatively, double-stranded cDNA molecules can be inserted into a plasmid vector, such as a PBLUESCRIPT vector (STRATAGENE; La Jolla, Calif.), a LAMDAGEM-4 (Promega Corp.) or other commercially available vectors. Suitable cloning vectors also can be obtained from the American Type Culture Collection (Manassas, Va.).
[0087] To amplify the cloned cDNA molecules, the cDNA library is inserted into a prokaryotic host, using standard techniques. For example, a cDNA library can be introduced into competent E. coli DH5 cells, which can be obtained, for example, from Life Technologies, Inc. (Gaithersburg, Md.).
[0088] A human genomic library can be prepared by means well-known in the art (see, for example, Ausubel (1995) at pages 5-1 to 5-6; Wu (1997) at pages 307-327). Genomic DNA can be isolated by lysing tissue with the detergent Sarkosyl, digesting the lysate with proteinase K, clearing insoluble debris from the lysate by centrifugation, precipitating nucleic acid from the lysate using isopropanol, and purifying resuspended DNA on a cesium chloride density gradient.
[0089] DNA fragments that are suitable for the production of a genomic library can be obtained by the random shearing of genomic DNA or by the partial digestion of genomic DNA with restriction endonucleases. Genomic DNA fragments can be inserted into a vector, such as a bacteriophage or cosmid vector, in accordance with conventional techniques, such as the use of restriction enzyme digestion to provide appropriate termini, the use of alkaline phosphatase treatment to avoid undesirable joining of DNA molecules, and ligation with appropriate ligases. Techniques for such manipulation are well-known in the art (see, for example, Ausubel (1995) at pages 5-1 to 5-6; Wu (1997) at pages 307-327).
[0090] Nucleic acid molecules that encode a human Zserp11 gene can also be obtained using the polymerase chain reaction (PCR) with oligonucleotide primers having nucleotide sequences that are based upon the nucleotide sequences of the human Zserp11 gene, as described herein. General methods for screening libraries with PCR are provided by, for example, Yu et al., “Use of the Polymerase Chain Reaction to Screen Phage Libraries,” in Methods in Molecular Biology, Vol. 15: PCR Protocols: Current Methods and Applications , White (ed.), pages 211-215 (Humana Press, Inc. 1993). Moreover, techniques for using PCR to isolate related genes are described by, for example, Preston, “Use of Degenerate Oligonucleotide Primers and the Polymerase Chain Reaction to Clone Gene Family Members,” in Methods in Molecular Biology, Vol. 15: PCR Protocols: Current Methods and Applications , White (ed.), pages 317-337 (Humana Press, Inc. 1993).
[0091] Alternatively, human genomic libraries can be obtained from commercial sources such as Research Genetics (Huntsville, Ala.) and the American Type Culture Collection (Manassas, Va.).
[0092] A library containing cDNA or genomic clones can be screened with one or more polynucleotide probes based upon SEQ ID NO:1, using standard methods (see, for example, Ausubel (1995) at pages 6-1 to 6-11).
[0093] Anti-Zserp11 antibodies, produced as described below, can also be used to isolate DNA sequences that encode human Zserp11 genes from cDNA libraries. For example, the antibodies can be used to screen λgt11 expression libraries, or the antibodies can be used for immunoscreening following hybrid selection and translation (see, for example, Ausubel (1995) at pages 6-12 to 6-16; Margolis et al., “Screening λ expression libraries with antibody and protein probes,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), pages 1-14 (Oxford University Press 1995)).
[0094] As an alternative, a Zserp11 gene can be obtained by synthesizing nucleic acid molecules using mutually priming long oligonucleotides and the nucleotide sequences described herein (see, for example, Ausubel (1995) at pages 8-8 to 8-9). Established techniques using the polymerase chain reaction provide the ability to synthesize DNA molecules at least two kilobases in length (Adang et al., Plant Molec. Biol. 21:1131 (1993), Bambot et al., PCR Methods and Applications 2:266 (1993), Dillon et al., “Use of the Polymerase Chain Reaction for the Rapid Construction of Synthetic Genes,” in Methods in Molecular Biology, Vol. 15: PCR Protocols: Current Methods and Applications , White (ed.), pages 263-268, (Humana Press, Inc. 1993), and Holowachuk et al., PCR Methods Appl. 4:299 (1995)).
[0095] The nucleic acid molecules of the present invention can also be synthesized with “gene machines” using protocols such as the phosphoramidite method. If chemically-synthesized double stranded DNA is required for an application such as the synthesis of a gene or a gene fragment, then each complementary strand is made separately. The production of short genes (60 to 80 base pairs) is technically straightforward and can be accomplished by synthesizing the complementary strands and then annealing them. For the production of longer genes (>300 base pairs), however, special strategies may be required, because the coupling efficiency of each cycle during chemical DNA synthesis is seldom 100%. To overcome this problem, synthetic genes (double-stranded) are assembled in modular form from single-stranded fragments that are from 20 to 100 nucleotides in length. For reviews on polynucleotide synthesis, see, for example, Glick and Pasternak, Molecular Biotechnology, Principles and Applications of Recombinant DNA (ASM Press 1994), Itakura et al., Annu. Rev. Biochem. 53:323 (1984), and Climie et al., Proc. Nat'l Acad. Sci. USA 87:633 (1990).
[0096] The sequence of a Zserp11 cDNA or Zserp11 genomic fragment can be determined using standard methods. Zserp11 polynucleotide sequences disclosed herein can also be used as probes or primers to clone 5′ non-coding regions of a Zserp11 gene. Promoter elements from a Zserp11 gene can be used to direct the expression of heterologous genes in, for example, transgenic animals or patients undergoing gene therapy. The identification of genomic fragments containing a Zserp11 promoter or regulatory element can be achieved using well-established techniques, such as deletion analysis (see, generally, Ausubel (1995)).
[0097] Cloning of 5′ flanking sequences also facilitates production of Zserp11 proteins by “gene activation,” as disclosed in U.S. Pat. No. 5,641,670. Briefly, expression of an endogenous Zserp11 gene in a cell is altered by introducing into the Zserp11 locus a DNA construct comprising at least a targeting sequence, a regulatory sequence, an exon, and an unpaired splice donor site. The targeting sequence is a Zserp11 5′ non-coding sequence that permits homologous recombination of the construct with the endogenous Zserp11 locus, whereby the sequences within the construct become operably linked with the endogenous Zserp11 coding sequence. In this way, an endogenous Zserp11 promoter can be replaced or supplemented with other regulatory sequences to provide enhanced, tissue-specific, or otherwise regulated expression.
[0000] 4. Production of Zserp11 Gene Variants
[0098] The present invention provides a variety of nucleic acid molecules, including DNA and RNA molecules, that encode the Zserp11 polypeptides disclosed herein. Those skilled in the art will readily recognize that, in view of the degeneracy of the genetic code, considerable sequence variation is possible among these polynucleotide molecules. SEQ ID NO:3 is a degenerate nucleotide sequence that encompasses all nucleic acid molecules that encode the Zserp11 polypeptide of SEQ ID NO:2. Those skilled in the art will recognize that the degenerate sequence of SEQ ID NO:3 also provides all RNA sequences encoding SEQ ID NO:2, by substituting U for T. Thus, the present invention contemplates. Zserp11 polypeptide-encoding nucleic acid molecules comprising nucleotides 1 to 1098 of SEQ ID NO:1, and their RNA equivalents.
[0099] Table 1 sets forth the one-letter codes used within SEQ ID NO:3 to denote degenerate nucleotide positions. “Resolutions” are the nucleotides denoted by a code letter. “Complement” indicates the code for the complementary nucleotide(s). For example, the code Y denotes either C or T, and its complement R denotes A or G, A being complementary to T, and G being complementary to C.
TABLE 1 Nucleotide Resolution Complement Resolution A A T T C C G G G G C C T T A A R A|G Y C|T Y C|T R A|G M A|C K G|T K G|T M A|C S C|G S C|G W A|T W A|T H A|C|T D A|G|T B C|G|T V A|C|G V A|C|G B C|G|T D A|G|T H A|C|T N A|C|G|T N A|C|G|T
[0100] The degenerate codons used in SEQ ID NO:3, encompassing all possible codons for a given amino acid, are set forth in Table 2.
TABLE 2 One Amino Letter Degenerate Acid Code Codons Codon Cys C TGC TGT TGY Ser S AGC AGT TCA TCC TCG TCT WSN Thr T ACA ACC ACG ACT ACN Pro P CCA CCC CCG CCT CCN Ala A GCA GCC GCG GCT GCN Gly G GGA GGC GGG GGT GGN Asn N AAC AAT AAY Asp D GAC GAT GAY Glu E GAA GAG GAR Gln Q CAA CAG CAR His H CAC CAT CAY Arg R AGA AGG CGA CGC CGG CGT MGN Lys K AAA AAG AAR Met M ATG ATG Ile I ATA ATC ATT ATH Leu L CTA CTC CTG CTT TTA TTG YTN Val V GTA GTC GTG GTT GTN Phe F TTC TTT TTY Tyr Y TAC TAT TAY Trp W TGG TGG Ter TAA TAG TGA TRR Asn|Asp B RAY Glu|Gln Z SAR Any X NNN
[0101] One of ordinary skill in the art will appreciate that some ambiguity is introduced in determining a degenerate codon, representative of all possible codons encoding an amino acid. For example, the degenerate codon for serine (WSN) can, in some circumstances, encode arginine (AGR), and the degenerate codon for arginine (MGN) can, in some circumstances, encode serine (AGY). A similar relationship exists between codons encoding phenylalanine and leucine. Thus, some polynucleotides encompassed by the degenerate sequence may encode variant amino acid sequences, but one of ordinary skill in the art can easily identify such variant sequences by reference to the amino acid sequence of SEQ ID NOs:2 and 4. Variant sequences can be readily tested for functionality as described herein.
[0102] Different species can exhibit “preferential codon usage.” In general, see, Grantham et al., Nuc. Acids Res. 8:1893 (1980), Haas et al. Curr. Biol. 6:315 (1996), Wain-Hobson et al., Gene 13:355 (1981), Grosjean and Fiers, Gene 18:199 (1982), Holm, Nuc. Acids Res. 14:3075 (1986), Ikemura, J. Mol. Biol. 158:573 (1982), Sharp and Matassi, Curr. Opin. Genet. Dev. 4:851 (1994), Kane, Curr. Opin. Biotechnol. 6:494 (1995), and Makrides, Microbiol. Rev. 60:512 (1996). As used herein, the term “preferential codon usage” or “preferential codons” is a term of art referring to protein translation codons that are most frequently used in cells of a certain species, thus favoring one or a few representatives of the possible codons encoding each amino acid (see Table 2). For example, the amino acid Threonine (Thr) may be encoded by ACA, ACC, ACG, or ACT, but in mammalian cells ACC is the most commonly used codon; in other species, for example, insect cells, yeast, viruses or bacteria, different Thr codons may be preferential. Preferential codons for a particular species can be introduced into the polynucleotides of the present invention by a variety of methods known in the art. Introduction of preferential codon sequences into recombinant DNA can, for example, enhance production of the protein by making protein translation more efficient within a particular cell type or species. Therefore, the degenerate codon sequence disclosed in SEQ ID NO:3 serves as a template for optimizing expression of polynucleotides in various cell types and species commonly used in the art and disclosed herein. Sequences containing preferential codons can be tested and optimized for expression in various species, and tested for functionality as disclosed herein.
[0103] The present invention further provides variant polypeptides and nucleic acid molecules that represent counterparts from other species (orthologs). These species include, but are not limited to mammalian, avian, amphibian, reptile, fish, insect and other vertebrate and invertebrate species. Of particular interest are Zserp11 polypeptides from other mammalian species, including porcine, ovine, bovine, canine, feline, equine, and other primate polypeptides. Orthologs of human Zserp11 can be cloned using information and compositions provided by the present invention in combination with conventional cloning techniques. For example, a cDNA can be cloned using mRNA obtained from a tissue or cell type that expresses Zserp11 as disclosed herein. Suitable sources of mRNA can be identified by probing northern blots with probes designed from the sequences disclosed herein. A library is then prepared from mRNA of a positive tissue or cell line.
[0104] A Zserp11-encoding cDNA can then be isolated by a variety of methods, such as by probing with a complete or partial human cDNA or with one or more sets of degenerate probes based on the disclosed sequences. A cDNA can also be cloned using the polymerase chain reaction with primers designed from the representative human Zserp11 sequences disclosed herein. Within an additional method, the cDNA library can be used to transform or transfect host cells, and expression of the cDNA of interest can be detected with an antibody to Zserp11 polypeptide. Similar techniques can also be applied to the isolation of genomic clones.
[0105] Those skilled in the art will recognize that the sequence disclosed in SEQ ID NO:1 represents a single allele of human Zserp11, and that allelic variation and alternative splicing are expected to occur. Allelic variants of this sequence can be cloned by probing cDNA or genomic libraries from different individuals according to standard procedures. Allelic variants of the nucleotide sequence shown in SEQ ID NO:1, including those containing silent mutations and those in which mutations result in amino acid sequence changes, are within the scope of the present invention, as are proteins which are allelic variants of SEQ ID NO:2. cDNA molecules generated from alternatively spliced mRNAs, which retain the properties of the Zserp11 polypeptide are included within the scope of the present invention, as are polypeptides encoded by such cDNAs and mRNAs. Allelic variants and splice variants of these sequences can be cloned by probing cDNA or genomic libraries from different individuals or tissues according to standard procedures known in the art.
[0106] Within certain embodiments of the invention, the isolated nucleic acid molecules can hybridize under stringent conditions to nucleic acid molecules comprising nucleotide sequences disclosed herein. For example, such nucleic acid molecules can hybridize under stringent conditions to nucleic acid molecules comprising the nucleotide sequence of SEQ ID NO:1, to nucleic acid molecules consisting of the nucleotide sequence of SEQ ID NO:1, or to nucleic acid molecules consisting of a nucleotide sequence complementary to SEQ ID NO:1. In general, stringent conditions are selected to be about 5° C. lower than the thermal melting point (T m ) for the specific sequence at a defined ionic strength and pH. The T m is the temperature (under defined ionic strength and pH) at which 50% of the target sequence hybridizes to a perfectly matched probe.
[0107] A pair of nucleic acid molecules, such as DNA-DNA, RNA-RNA and DNA-RNA, can hybridize if the nucleotide sequences have some degree of complementarity. Hybrids can tolerate mismatched base pairs in the double helix, but the stability of the hybrid is influenced by the degree of mismatch. The T m of the mismatched hybrid decreases by 1° C. for every 1-1.5% base pair mismatch. Varying the stringency of the hybridization conditions allows control over the degree of mismatch that will be present in the hybrid. The degree of stringency increases as the hybridization temperature increases and the ionic strength of the hybridization buffer decreases. Stringent hybridization conditions encompass temperatures of about 5-25° C. below the T m of the hybrid and a hybridization buffer having up to 1 M Na + . Higher degrees of stringency at lower temperatures can be achieved with the addition of formamide which reduces the T m of the hybrid about 1° C. for each 1% formamide in the buffer solution. Generally, such stringent conditions include temperatures of 20-70° C. and a hybridization buffer containing up to 6×SSC and 0-50% formamide. A higher degree of stringency can be achieved at temperatures of from 40-70° C. with a hybridization buffer having up to 4×SSC and from 0-50% formamide. Highly stringent conditions typically encompass temperatures of 42-70° C. with a hybridization buffer having up to 1×SSC and 0-50% formamide. Different degrees of stringency can be used during hybridization and washing to achieve maximum specific binding to the target sequence. Typically, the washes following hybridization are performed at increasing degrees of stringency to remove non-hybridized polynucleotide probes from hybridized complexes.
[0108] The above conditions are meant to serve as a guide and it is well within the abilities of one skilled in the art to adapt these conditions for use with a particular polypeptide hybrid. The T m for a specific target sequence is the temperature (under defined conditions) at which 50% of the target sequence will hybridize to a perfectly matched probe sequence. Those conditions which influence the T m include, the size and base pair content of the polynucleotide probe, the ionic strength of the hybridization solution, and the presence of destabilizing agents in the hybridization solution. Numerous equations for calculating T m are known in the art, and are specific for DNA, RNA and DNA-RNA hybrids and polynucleotide probe sequences of varying length (see, for example, Sambrook et al., Molecular Cloning: A Laboratory Manual , Second Edition (Cold Spring Harbor Press 1989); Ausubel et al., (eds.), Current Protocols in Molecular Biology (John Wiley and Sons, Inc. 1987); Berger and Kimmel (eds.), Guide to Molecular Cloning Techniques , (Academic Press, Inc. 1987); and Wetmur, Crit. Rev. Biochem. Mol. Biol. 26:227 (1990)). Sequence analysis software such as OLIGO 6.0 (LSR; Long Lake, Minn.) and Primer Premier 4.0 (Premier Biosoft International; Palo Alto, Calif.), as well as sites on the Internet, are available tools for analyzing a given sequence and calculating T m based on user defined criteria. Such programs can also analyze a given sequence under defined conditions and identify suitable probe sequences. Typically, hybridization of longer polynucleotide sequences, >50 base pairs, is performed at temperatures of about 20-25° C. below the calculated T m . For smaller probes, <50 base pairs, hybridization is typically carried out at the T m or 5-10° C. below. This allows for the maximum rate of hybridization for DNA-DNA and DNA-RNA hybrids.
[0109] The length of the polynucleotide sequence influences the rate and stability of hybrid formation. Smaller probe sequences, <50 base pairs, reach equilibrium with complementary sequences rapidly, but may form less stable hybrids. Incubation times of anywhere from minutes to hours can be used to achieve hybrid formation. Longer probe sequences come to equilibrium more slowly, but form more stable complexes even at lower temperatures. Incubations are allowed to proceed overnight or longer. Generally, incubations are carried out for a period equal to three times the calculated Cot time. Cot time, the time it takes for the polynucleotide sequences to reassociate, can be calculated for a particular sequence by methods known in the art.
[0110] The base pair composition of polynucleotide sequence will effect the thermal stability of the hybrid complex, thereby influencing the choice of hybridization temperature and the ionic strength of the hybridization buffer. A-T pairs are less stable than G-C pairs in aqueous solutions containing sodium chloride. Therefore, the higher the G-C content, the more stable the hybrid. Even distribution of G and C residues within the sequence also contribute positively to hybrid stability. In addition, the base pair composition can be manipulated to alter the T m of a given sequence. For example, 5-methyldeoxycytidine can be substituted for deoxycytidine and 5-bromodeoxuridine can be substituted for thymidine to increase the T m , whereas 7-deazz-2′-deoxyguanosine can be substituted for guanosine to reduce dependence on T m .
[0111] The ionic concentration of the hybridization buffer also affects the stability of the hybrid. Hybridization buffers generally contain blocking agents such as Denhardt's solution (Sigma Chemical Co., St. Louis, Mo.), denatured salmon sperm DNA, tRNA, milk powders (BLOTTO), heparin or SDS, and a Na + source, such as SSC (1×SSC: 0.15 M sodium chloride, 15 mM sodium citrate) or SSPE (1×SSPE: 1.8 M NaCl, 10 mM NaH 2 PO 4 , 1 mM EDTA, pH 7.7). By decreasing the ionic concentration of the buffer, the stability of the hybrid is increased. Typically, hybridization buffers contain from between 10 mM-1 M Na + . The addition of destabilizing or denaturing agents such as formamide, tetralkylammonium salts, guanidinium cations or thiocyanate cations to the hybridization solution will alter the T m of a hybrid. Typically, formamide is used at a concentration of up to 50% to allow incubations to be carried out at more convenient and lower temperatures. Formamide also acts to reduce non-specific background when using RNA probes.
[0112] As an illustration, a nucleic acid molecule encoding a variant Zserp11 polypeptide can be hybridized with a nucleic acid molecule having the nucleotide sequence of SEQ ID NO:1 (or its complement) at 42° C. overnight in a solution comprising 50% formamide, 5×SSC (1×SSC: 0.15 M sodium chloride and 15 mM sodium citrate), 50 mM sodium phosphate (pH 7.6), 5× Denhardt's solution (100× Denhardt's solution: 2% (w/v) Ficoll 400, 2% (w/v) polyvinylpyrrolidone, and 2% (w/v) bovine serum albumin, 10% dextran sulfate, and 20 μg/ml denatured, sheared salmon sperm DNA. One of skill in the art can devise variations of these hybridization conditions. For example, the hybridization mixture can be incubated at a higher temperature, such as about 65° C., in a solution that does not contain formamide. Moreover, premixed hybridization solutions are available (e.g., EXPRESSHYB Hybridization Solution from CLONTECH Laboratories, Inc.), and hybridization can be performed according to the manufacturer's instructions.
[0113] Following hybridization, the nucleic acid molecules can be washed to remove non-hybridized nucleic acid molecules under stringent conditions, or under highly stringent conditions. Typical stringent washing conditions include washing in a solution of 0.5×-2×SSC with 0.1% sodium dodecyl sulfate (SDS) at 55-65° C. For example, certain nucleic acid molecules encoding a variant Zserp11 polypeptide remained hybridized following stringent washing conditions with a nucleic acid molecule consisting of the nucleotide sequence of SEQ ID NO:1 (or its complement), in which the wash stringency is equivalent to 0.5×-2×SSC with 0.1% SDS at 55-65° C., including 0.5×SSC with 0.1% SDS at 55° C., or 2×SSC with 0.1% SDS at 65° C. One of skill in the art can readily devise equivalent conditions, for example, by substituting the SSPE for SSC in the wash solution.
[0114] Typical highly stringent washing conditions include washing in a solution of 0.1×-0.2×SSC with 0.1% sodium dodecyl sulfate (SDS) at 50-65° C. As an illustration, particular nucleic acid molecules encoding a variant Zserp11 polypeptide remained hybridized following stringent washing conditions with a nucleic acid molecule consisting of the nucleotide sequence of SEQ ID NO:1 (or its complement), in which the wash stringency is equivalent to 0.1×-0.2×SSC with 0.1% SDS at 50-65° C., including 0.1×SSC with 0.1% SDS at 50° C., or 0.2×SSC with 0.1% SDS at 65° C.
[0115] The present invention also provides isolated Zserp11 polypeptides that have a substantially similar sequence identity to the polypeptide of SEQ ID NO:2, or orthologs. The term “substantially similar sequence identity” is used herein to denote polypeptides having 70%, 80%, 90%, 95%, 96%, 97%, 98%, or 99% sequence identity to the sequence shown in SEQ ID NO:2.
[0116] The present invention also contemplates Zserp11 variant nucleic acid molecules that can be identified using two criteria: a determination of the similarity between the encoded polypeptide with the amino acid sequence of SEQ ID NO:2, and a hybridization assay, as described above. Such Zserp11 variants include nucleic acid molecules (1) that remain hybridized following stringent washing conditions with a nucleic acid molecule consisting of the nucleotide sequence of SEQ ID NO:1 (or its complement), in which the wash stringency is equivalent to 0.5×-2×SSC with 0.1% SDS at 55-65° C., and (2) that encode a polypeptide having 70%, 80%, 90%, 95% 96%, 97%, 98% or 99% sequence identity to the amino acid sequence of SEQ ID NO:2.
[0117] Alternatively, Zserp11 variants can be characterized as nucleic acid molecules (1) that remain hybridized following highly stringent washing conditions with a nucleic acid molecule consisting of the nucleotide sequence of SEQ ID NO:1 (or its complement), in which the wash stringency is equivalent to 0.1×-0.2×SSC with 0.1% SDS at 50-65° C., and (2) that encode a polypeptide having 70%, 80%, 90%, 95%, 96%, 97%, 98% or 99% sequence identity to the amino acid sequence of SEQ ID NO:2.
[0118] The present invention also includes Zserp11 variants that possess serine protease inhibitor activity. Moreover, particular Zserp11 variants are characterized using hybridization analysis with a reference nucleic acid molecule that is a fragment of a nucleic acid molecule consisting of the nucleotide sequence of SEQ ID NO:1, or its complement. For example, such reference nucleic acid molecules include nucleic acid molecules consisting of the following nucleotide sequences, or complements thereof, of SEQ ID NO:1: nucleotides 36 to 411, nucleotides 460 to 855, and nucleotides 886 to 1092.
[0119] Percent sequence identity is determined by conventional methods. See, for example, Altschul et al., Bull Math. Bio. 48:603 (1986), and Henikoff and Henikoff, Proc. Nat'l Acad. Sci. USA 89:10915 (1992). Briefly, two amino acid sequences are aligned to optimize the alignment scores using a gap opening penalty of 10, a gap extension penalty of 1, and the “BLOSUM62” scoring matrix of Henikoff and Henikoff (ibid.) as shown in Table 3 (amino acids are indicated by the standard one-letter codes). The percent identity is then calculated as: ([Total number of identical matches]/[length of the longer sequence plus the number of gaps introduced into the longer sequence in order to align the two sequences])(100).
TABLE 3 A R N D C Q E G H I L K M F P S T W Y V A 4 R −1 5 N −2 0 6 D −2 −2 1 6 C 0 −3 −3 −3 9 Q −1 1 0 0 −3 5 E −1 0 0 2 −4 2 5 G 0 −2 0 −1 −3 −2 −2 6 H −2 0 1 −1 −3 0 0 −2 8 I −1 −3 −3 −3 −1 −3 −3 −4 −3 4 L −1 −2 −3 −4 −1 −2 −3 −4 −3 2 4 K −1 2 0 −1 −3 1 1 −2 −1 −3 −2 5 M −1 −1 −2 −3 −1 0 −2 −3 −2 1 2 −1 5 F −2 −3 −3 −3 −2 −3 −3 −3 −1 0 0 −3 0 6 P −1 −2 −2 −1 −3 −1 −1 −2 −2 −3 −3 −1 −2 −4 7 S 1 −1 1 0 −1 0 0 0 −1 −2 −2 0 −1 −2 −1 4 T 0 −1 0 −1 −1 −1 −1 −2 −2 −1 −1 −1 −1 −2 −1 1 5 W −3 −3 −4 −4 −2 −2 −3 −2 −2 −3 −2 −3 −1 1 −4 −3 −2 11 Y −2 −2 −2 −3 −2 −1 −2 −3 2 −1 −1 −2 −1 3 −3 −2 −2 2 7 V 0 −3 −3 −3 −1 −2 −2 −3 −3 3 1 −2 1 −1 −2 −2 0 −3 −1 4
[0120] Those skilled in the art appreciate that there are many established algorithms available to align two amino acid sequences. The “FASTA” similarity search algorithm of Pearson and Lipman is a suitable protein alignment method for examining the level of identity shared by an amino acid sequence disclosed herein and the amino acid sequence of a putative Zserp11 variant. The FASTA algorithm is described by Pearson and Lipman, Proc. Nat'l Acad. Sci. USA 85:2444 (1988), and by Pearson, Meth. Enzymol. 183:63 (1990). Briefly, FASTA first characterizes sequence similarity by identifying regions shared by the query sequence (e.g., SEQ ID NO:2) and a test sequence that have either the highest density of identities (if the ktup variable is 1) or pairs of identities (if ktup=2), without considering conservative amino acid substitutions, insertions, or deletions. The ten regions with the highest density of identities are then rescored by comparing the similarity of all paired amino acids using an amino acid substitution matrix, and the ends of the regions are “trimmed” to include only those residues that contribute to the highest score. If there are several regions with scores greater than the “cutoff” value (calculated by a predetermined formula based upon the length of the sequence and the ktup value), then the trimmed initial regions are examined to determine whether the regions can be joined to form an approximate alignment with gaps. Finally, the highest scoring regions of the two amino acid sequences are aligned using a modification of the Needleman-Wunsch-Sellers algorithm (Needleman and Wunsch, J. Mol. Biol. 48:444 (1970); Sellers, SIAM J. Appl. Math. 26:787 (1974)), which allows for amino acid insertions and deletions. Ilustrative parameters for FASTA analysis are: ktup=1, gap opening penalty=10, gap extension penalty=1, and substitution matrix=BLOSUM62. These parameters can be introduced into a FASTA program by modifying the scoring matrix file (“SMATRIX”), as explained in Appendix 2 of Pearson, Meth. Enzymol. 183:63 (1990).
[0121] FASTA can also be used to determine the sequence identity of nucleic acid molecules using a ratio as disclosed above. For nucleotide sequence comparisons, the ktup value can range between one to six, preferably from three to six, most preferably three, with other parameters set as described above.
[0122] The present invention includes nucleic acid molecules that encode a polypeptide having a conservative amino acid change, compared with the amino acid sequence of SEQ ID NO:2. That is, variants can be obtained that contain one or more amino acid substitutions of SEQ ID NO:2, in which an alkyl amino acid is substituted for an alkyl amino acid in a Zserp11 amino acid sequence, an aromatic amino acid is substituted for an aromatic amino acid in a Zserp11 amino acid sequence, a sulfur-containing amino acid is substituted for a sulfur-containing amino acid in a Zserp11 amino acid sequence, a hydroxy-containing amino acid is substituted for a hydroxy-containing amino acid in a Zserp11 amino acid sequence, an acidic amino acid is substituted for an acidic amino acid in a Zserp11 amino acid sequence, a basic amino acid is substituted for a basic amino acid in a Zserp11 amino acid sequence, or a dibasic monocarboxylic amino acid is substituted for a dibasic monocarboxylic amino acid in a Zserp11 amino acid sequence.
[0123] Among the common amino acids, for example, a “conservative amino acid substitution” is illustrated by a substitution among amino acids within each of the following groups: (1) glycine, alanine, valine, leucine, and isoleucine, (2) phenylalanine, tyrosine, and tryptophan, (3) serine and threonine, (4) aspartate and glutamate, (5) glutamine and asparagine, and (6) lysine, arginine and histidine.
[0124] The BLOSUM62 table is an amino acid substitution matrix derived from about 2,000 local multiple alignments of protein sequence segments, representing highly conserved regions of more than 500 groups of related proteins (Henikoff and Henikoff, Proc. Nat'l Acad. Sci. USA 89:10915 (1992)). Accordingly, the BLOSUM62 substitution frequencies can be used to define conservative amino acid substitutions that may be introduced into the amino acid sequences of the present invention. Although it is possible to design amino acid substitutions based solely upon chemical properties (as discussed above), the language “conservative amino acid substitution” preferably refers to a substitution represented by a BLOSUM62 value of greater than −1. For example, an amino acid substitution is conservative if the substitution is characterized by a BLOSUM62 value of 0, 1, 2, or 3. According to this system, preferred conservative amino acid substitutions are characterized by a BLOSUM62 value of at least 1 (e.g., 1, 2 or 3), while more preferred conservative amino acid substitutions are characterized by a BLOSUM62 value of at least 2 (e.g., 2 or 3).
[0125] Particular variants of Zserp11 are characterized by having greater than 96%, at least 97%, at least 98%, or at least 99% sequence identity to the corresponding amino acid sequence (e.g., SEQ ID NO:2), wherein the variation in amino acid sequence is due to one or more conservative amino acid substitutions.
[0126] Conservative amino acid changes in a Zserp11 gene can be introduced by substituting nucleotides for the nucleotides recited in SEQ ID NO:1. Such “conservative amino acid” variants can be obtained, for example, by oligonucleotide-directed mutagenesis, linker-scanning mutagenesis, mutagenesis using the polymerase chain reaction, and the like (see Ausubel (1995) at pages 8-10 to 8-22; and McPherson (ed.), Directed Mutagenesis: A Practical Approach (IRL Press 1991)).
[0127] The proteins of the present invention can also comprise non-naturally occurring amino acid residues. Non-naturally occurring amino acids include, without limitation, trans-3-methylproline, 2,4-methanoproline, cis-4-hydroxyproline, trans-4-hydroxyproline, N-methylglycine, allo-threonine, methylthreonine, hydroxyethylcysteine, hydroxyethylhomocysteine, nitroglutamine, homoglutamine, pipecolic acid, thiazolidine carboxylic acid, dehydroproline, 3- and 4-methylproline, 3,3-dimethylproline, tert-leucine, norvaline, 2-azaphenylalanine, 3-azaphenylalanine, 4-azaphenylalanine, and 4-fluorophenylalanine. Several methods are known in the art for incorporating non-naturally occurring amino acid residues into proteins. For example, an in vitro system can be employed wherein nonsense mutations are suppressed using chemically aminoacylated suppressor tRNAs. Methods for synthesizing amino acids and aminoacylating tRNA are known in the art. Transcription and translation of plasmids containing nonsense mutations is typically carried out in a cell-free system comprising an E. coli S30 extract and commercially available enzymes and other reagents. Proteins are purified by chromatography. See, for example, Robertson et al., J. Am. Chem. Soc. 113:2722 (1991), Ellman et al., Methods Enzymol. 202:301 (1991), Chung et al., Science 259:806 (1993), and Chung et al., Proc. Nat'l Acad. Sci. USA 90:10145 (1993).
[0128] In a second method, translation is carried out in Xenopus oocytes by microinjection of mutated mRNA and chemically aminoacylated suppressor tRNAs (Turcatti et al., J. Biol. Chem. 271:19991 (1996)). Within a third method, E. coli cells are cultured in the absence of a natural amino acid that is to be replaced (e.g., phenylalanine) and in the presence of the desired non-naturally occurring amino acid(s) (e.g., 2-azaphenylalanine, 3-azaphenylalanine, 4-azaphenylalanine, or 4-fluorophenylalanine). The non-naturally occurring amino acid is incorporated into the protein in place of its natural counterpart. See, Koide et al., Biochem. 33:7470 (1994). Naturally occurring amino acid residues can be converted to non-naturally occurring species by in vitro chemical modification. Chemical modification can be combined with site-directed mutagenesis to further expand the range of substitutions (Wynn and Richards, Protein Sci. 2:395 (1993)).
[0129] A limited number of non-conservative amino acids, amino acids that are not encoded by the genetic code, non-naturally occurring amino acids, and unnatural amino acids may be substituted for Zserp11 amino acid residues.
[0130] Essential amino acids in the polypeptides of the present invention can be identified according to procedures known in the art, such as site-directed mutagenesis or alanine-scanning mutagenesis (Cunningham and Wells, Science 244:1081 (1989), Bass et al., Proc. Nat'l Acad. Sci. USA 88:4498 (1991), Coombs and Corey, “Site-Directed Mutagenesis and Protein Engineering,” in Proteins: Analysis and Design , Angeletti (ed.), pages 259-311 (Academic Press, Inc. 1998)). In the latter technique, single alanine mutations are introduced at every residue in the molecule, and the resultant mutant molecules are tested for biological activity as disclosed below to identify amino acid residues that are critical to the activity of the molecule. See also, Hilton et al., J. Biol. Chem. 271:4699 (1996). The identities of essential amino acids can also be inferred from analysis of homologies with other serine protease inhibitors.
[0131] The location of Zserp11 activity domains can also be determined by physical analysis of structure, as determined by such techniques as nuclear magnetic resonance, crystallography, electron diffraction or photoaffinity labeling, in conjunction with mutation of putative contact site amino acids. See, for example, de Vos et al., Science 255:306 (1992), Smith et al., J. Mol. Biol. 224:899 (1992), and Wlodaver et al., FEBS Lett. 309:59 (1992). Moreover, Zserp11 labeled with biotin or FITC can be used for expression cloning of Zserp11 substrates and inhibitors.
[0132] Multiple amino acid substitutions can be made and tested using known methods of mutagenesis and screening, such as those disclosed by Reidhaar-Olson and Sauer ( Science 241:53 (1988)) or Bowie and Sauer ( Proc. Nat'l Acad. Sci. USA 86:2152 (1989)). Briefly, these authors disclose methods for simultaneously randomizing two or more positions in a polypeptide, selecting for functional polypeptide, and then sequencing the mutagenized polypeptides to determine the spectrum of allowable substitutions at each position. Other methods that can be used include phage display (e.g., Lowman et al., Biochem. 30:10832 (1991), Ladner et al., U.S. Pat. No. 5,223,409, Huse, international publication No. WO 92/06204, and region-directed mutagenesis (Derbyshire et al., Gene 46:145 (1986), and Ner et al., DNA 7:127, (1988)).
[0133] Variants of the disclosed Zserp11 nucleotide and polypeptide sequences can also be generated through DNA shuffling as disclosed by Stemmer, Nature 370:389 (1994), Stemmer, Proc. Nat'l Acad Sci. USA 91:10747 (1994), and international publication No. WO 97/20078. Briefly, variant DNA molecules are generated by in vitro homologous recombination by random fragmentation of a parent DNA followed by reassembly using PCR, resulting in randomly introduced point mutations. This technique can be modified by using a family of parent DNA molecules, such as allelic variants or DNA molecules from different species, to introduce additional variability into the process. Selection or screening for the desired activity, followed by additional iterations of mutagenesis and assay provides for rapid “evolution” of sequences by selecting for desirable mutations while simultaneously selecting against detrimental changes.
[0134] Mutagenesis methods as disclosed herein can be combined with high-throughput, automated screening methods to detect activity of cloned, mutagenized polypeptides in host cells. Mutagenized DNA molecules that encode biologically active polypeptides, or polypeptides that bind with anti-Zserp11 antibodies, can be recovered from the host cells and rapidly sequenced using modern equipment. These methods allow the rapid determination of the importance of individual amino acid residues in a polypeptide of interest, and can be applied to polypeptides of unknown structure.
[0135] The present invention also includes “functional fragments” of Zserp11 polypeptides and nucleic acid molecules encoding such functional fragments. Routine deletion analyses of nucleic acid molecules can be performed to obtain functional fragments of a nucleic acid molecule that encodes a Zserp11 polypeptide. As an illustration, DNA molecules having the nucleotide sequence of SEQ ID NO:1 can be digested with Bal31 nuclease to obtain a series of nested deletions. The fragments can then inserted into expression vectors in proper reading frame, and the expressed polypeptides can be isolated and tested for the ability to bind anti-Zserp11 antibodies, or for enzyme activity. One alternative to exonuclease digestion is to use oligonucleotide-directed mutagenesis to introduce deletions or stop codons to specify production of a desired fragment. Alternatively, particular fragments of a Zserp11 gene can be synthesized using the polymerase chain reaction.
[0136] Methods for identifying functional domains are well-known to those of skill in the art. For example, studies on the truncation at either or both termini of interferons have been summarized by Horisberger and Di Marco, Pharmac. Ther. 66:507 (1995). Moreover, standard techniques for functional analysis of proteins are described by, for example, Treuter et al., Molec. Gen. Genet. 240:113 (1993), Content et al., “Expression and preliminary deletion analysis of the 42 kDa 2-5A synthetase induced by human interferon,” in Biological Interferon Systems, Proceedings of ISIR - TNO Meeting on Interferon Systems , Cantell (ed.), pages 65-72 (Nijhoff 1987), Herschman, “The EGF Receptor,” in Control of Animal Cell Proliferation, Vol. 1, Boynton et al., (eds.) pages 169-199 (Academic Press 1985), Coumailleau et al., J. Biol. Chem. 270:29270 (1995); Fukunaga et al., J. Biol. Chem. 270:25291 (1995); Yamaguchi et al., Biochem. Pharmacol. 50:1295 (1995), and Meisel et al., Plant Molec. Biol. 30:1 (1996).
[0137] The present invention also contemplates functional fragments of a Zserp11 gene that has amino acid changes, compared with the amino acid sequence of SEQ ID NO:2. A variant Zserp11 gene can be identified on the basis of structure by determining the level of identity with nucleotide and amino acid sequences of SEQ ID NOs:1 and 2, as discussed above. An alternative approach to identifying a variant gene on the basis of structure is to determine whether a nucleic acid molecule encoding a potential variant Zserp11 gene can hybridize to a nucleic acid molecule having the nucleotide sequence of SEQ ID NO:1, as discussed above.
[0138] The present invention also provides polypeptide fragments or peptides comprising an epitope-bearing portion of a Zserp11 polypeptide described herein. Such fragments or peptides may comprise an “immunogenic epitope,” which is a part of a protein that elicits an antibody response when the entire protein is used as an immunogen. Immunogenic epitope-bearing peptides can be identified using standard methods (see, for example, Geysen et al., Proc. Nat'l Acad. Sci. USA 81:3998 (1983)).
[0139] In contrast, polypeptide fragments or peptides may comprise an “antigenic epitope,” which is a region of a protein molecule to which an antibody can specifically bind. Certain epitopes consist of a linear or contiguous stretch of amino acids, and the antigenicity of such an epitope is not disrupted by denaturing agents. It is known in the art that relatively short synthetic peptides that can mimic epitopes of a protein can be used to stimulate the production of antibodies against the protein (see, for example, Sutcliffe et al., Science 219:660 (1983)). Accordingly, antigenic epitope-bearing peptides and polypeptides of the present invention are useful to raise antibodies that bind with the polypeptides described herein.
[0140] Antigenic epitope-bearing peptides and polypeptides can contain at least four to ten amino acids, at least ten to fifteen amino acids, or about 15 to about 30 amino acids of SEQ ID NO:2. Such epitope-bearing peptides and polypeptides can be produced by fragmenting a Zserp11 polypeptide, or by chemical peptide synthesis, as described herein. Moreover, epitopes can be selected by phage display of random peptide libraries (see, for example, Lane and Stephen, Curr. Opin. Immunol. 5:268 (1993), and Cortese et al., Curr. Opin. Biotechnol. 7:616 (1996)). Standard methods for identifying epitopes and producing antibodies from small peptides that comprise an epitope are described, for example, by Mole, “Epitope Mapping,” in Methods in Molecular Biology, Vol. 10, Manson (ed.), pages 105-116 (The Humana Press, Inc. 1992), Price, “Production and Characterization of Synthetic Peptide-Derived Antibodies,” in Monoclonal Antibodies: Production, Engineering, and Clinical Application , Ritter and Ladyman (eds.), pages 60-84 (Cambridge University Press 1995), and Coligan et al. (eds.), Current Protocols in Immunology , pages 9.3.1-9.3.5 and pages 9.4.1-9.4.11 (John Wiley & Sons 1997).
[0141] For any Zserp11 polypeptide, including variants and fusion proteins, one of ordinary skill in the art can readily generate a fully degenerate polynucleotide sequence encoding that variant using the information set forth in Tables 1 and 2 above. Moreover, those of skill in the art can use standard software to devise Zserp11 variants based upon the nucleotide and amino acid sequences described herein. Accordingly, the present invention includes a computer-readable medium encoded with a data structure that provides at least one of SEQ ID NO:1, SEQ ID NO:2, and SEQ ID NO:3. Suitable forms of computer-readable media include magnetic media and optically-readable media. Examples of magnetic media include a hard or fixed drive, a random access memory (RAM) chip, a floppy disk, digital linear tape (DLT), a disk cache, and a ZIP disk. Optically readable media are exemplified by compact discs (e.g., CD-read only memory (ROM), CD-rewritable (RW), and CD-recordable), and digital versatile/video discs (DVD) (e.g., DVD-ROM, DVD-RAM, and DVD+RW).
[0000] 5. Production of Zserp11 Fusion Proteins
[0142] Fusion proteins of Zserp11 can be used to express Zserp11 in a recombinant host, and to isolate expressed Zserp11. One type of fusion protein comprises a peptide that guides a Zserp11 polypeptide from a recombinant host cell. To direct a Zserp11 polypeptide into the secretory pathway of a eukaryotic host cell, a secretory signal sequence (also known as a signal peptide, a leader sequence, prepro sequence or pre sequence) is provided in the Zserp11 expression vector. While the secretory signal sequence may be derived from Zserp11, a suitable signal sequence may also be derived from another secreted protein or synthesized de novo. The secretory signal sequence is operably linked to a Zserp11-encoding sequence such that the two sequences are joined in the correct reading frame and positioned to direct the newly synthesized polypeptide into the secretory pathway of the host cell. Secretory signal sequences are commonly positioned 5′ to the nucleotide sequence encoding the polypeptide of interest, although certain secretory signal sequences may be positioned elsewhere in the nucleotide sequence of interest (see, e.g., Welch et al., U.S. Pat. No. 5,037,743; Holland et al., U.S. Pat. No. 5,143,830).
[0143] While the secretory signal sequence of Zserp11 or another protein produced by mammalian cells (e.g., tissue-type plasminogen activator signal sequence, as described, for example, in U.S. Pat. No. 5,641,655) is useful for expression of Zserp11 in recombinant mammalian hosts, a yeast signal sequence can be used for expression in yeast cells. Examples of suitable yeast signal sequences are those derived from yeast mating phermone α-factor (encoded by the MFα1 gene), invertase (encoded by the SUC2 gene), or acid phosphatase (encoded by the PHO5 gene). See, for example, Romanos et al., “Expression of Cloned Genes in Yeast,” in DNA Cloning 2: A Practical Approach, 2 nd Edition, Glover and Hames (eds.), pages 123-167 (Oxford University Press 1995).
[0144] In bacterial cells, it is often desirable to express a heterologous protein as a fusion protein to decrease toxicity, increase stability, and to enhance recovery of the expressed protein. For example, Zserp11 can be expressed as a fusion protein comprising a glutathione S-transferase polypeptide. Glutathione S-transferease fusion proteins are typically soluble, and easily purifiable from E. coli lysates on immobilized glutathione columns. In similar approaches, a Zserp11 fusion protein comprising a maltose binding protein polypeptide can be isolated with an amylose resin column, while a fusion protein comprising the C-terminal end of a truncated Protein A gene can be purified using IgG-Sepharose. Established techniques for expressing a heterologous polypeptide as a fusion protein in a bacterial cell are described, for example, by Williams et al., “Expression of Foreign Proteins in E. coli Using Plasmid Vectors and Purification of Specific Polyclonal Antibodies,” in DNA Cloning 2: A Practical Approach, 2 nd Edition, Glover and Hames (Eds.), pages 15-58 (Oxford University Press 1995). In addition, commercially available expression systems are available. For example, the PINPOINT Xa protein purification system (Promega Corporation; Madison, Wis.) provides a method for isolating a fusion protein comprising a polypeptide that becomes biotinylated during expression with a resin that comprises avidin.
[0145] Peptide tags that are useful for isolating heterologous polypeptides expressed by either prokaryotic or eukaryotic cells include polyHistidine tags (which have an affinity for nickel-chelating resin), c-myc tags, calmodulin binding protein (isolated with calmodulin affinity chromatography), substance P, the RYIRS tag (which binds with anti-RYIRS antibodies), the Glu-Glu tag, and the FLAG tag (which binds with anti-FLAG antibodies). See, for example, Luo et al., Arch. Biochem. Biophys. 329:215 (1996), Morganti et al., Biotechnol. Appl. Biochem. 23:67 (1996), and Zheng et al., Gene 186:55 (1997). Nucleic acid molecules encoding such peptide tags are available, for example, from Sigma-Aldrich Corporation (St. Louis, Mo.).
[0146] Another form of fusion protein comprises a Zserp11 polypeptide and an immunoglobulin heavy chain constant region, typically an Fc fragment, which contains two constant region domains and a hinge region but lacks the variable region. As an illustration, Chang et al., U.S. Pat. No. 5,723,125, describe a fusion protein comprising a human interferon and a human immunoglobulin Fc fragment, in which the C-terminal of the interferon is linked to the N-terminal of the Fc fragment by a peptide linker moiety. An example of a peptide linker is a peptide comprising primarily a T cell inert sequence, which is immunologically inert. An exemplary peptide linker has the amino acid sequence: GGSGG SGGGG SGGGG S (SEQ ID NO:4). In such a fusion protein, an illustrative Fc moiety is a human γ4 chain, which is stable in solution and has little or no complement activating activity. Accordingly, the present invention contemplates a Zserp11 fusion protein that comprises a Zserp11 moiety and a human Fc fragment, wherein the C-terminus of the Zserp11 moiety is attached to the N-terminus of the Fc fragment via a peptide linker, such as a peptide consisting of the amino acid sequence of SEQ ID NO:4. The Zserp11 moiety can be a Zserp11 molecule or a fragment thereof.
[0147] In another variation, a Zserp11 fusion protein comprises an IgG sequence, a Zserp11 moiety covalently joined to the aminoterminal end of the IgG sequence, and a signal peptide that is covalently joined to the aminoterminal of the Zserp11 moiety, wherein the IgG sequence consists of the following elements in the following order: a hinge region, a CH 2 domain, and a CH 3 domain. Accordingly, the IgG sequence lacks a CH 1 domain. The Zserp11 moiety displays a Zserp11 activity, as described herein, such as the ability to bind with a Zserp11 antibody or the ability to inhibit serine protease activity. This general approach to producing fusion proteins that comprise both antibody and nonantibody portions has been described by LaRochelle et al., EP 742830 (WO 95/21258).
[0148] Fusion proteins comprising a Zserp11 moiety and an Fc moiety can be used, for example, as an in vitro assay tool. For example, the presence of a Zserp11 protease substrate or inhibitor in a biological sample can be detected using a Zserp11-antibody fusion protein, in which the Zserp11 moiety is used to target the substrate or inhibitor, and a macromolecule, such as Protein A or anti-Fc antibody, is used to detect the bound fusion protein-receptor complex. Furthermore, such fusion proteins can be used to identify molecules that interfere with the binding of Zserp11 and a substrate.
[0149] Moreover, using methods described in the art, hybrid Zserp11 proteins can be constructed using regions or domains of the inventive Zserp11 in combination with those of other serine protease inhibitors (e.g., α1-antitrypsin, antithrombin, α2-antiplasmin, plasminogen activator inhibitors-1 and -2, tissue kallikrein inhibitor, neuroserpin, C1 inhibitor, α1-antichymotrypsin, etc.), or heterologous proteins (see, for example, Picard, Cur. Opin. Biology 5:511 (1994)). These methods allow the determination of the biological importance of larger domains or regions in a polypeptide of interest. Such hybrids may alter reaction kinetics, binding, constrict or expand the substrate specificity, or alter tissue and cellular localization of a polypeptide, and can be applied to polypeptides of unknown structure. For example Horisberger and DiMarco, Pharmac. Ther. 66:507 (1995), describe the construction of fusion protein hybrids comprising different interferon-α subtypes, as well as hybrids comprising interferon-α domains from different species.
[0150] Fusion proteins can be prepared by methods known to those skilled in the art by preparing each component of the fusion protein and chemically conjugating the components. Alternatively, a polynucleotide encoding both components of the fusion protein in the proper reading frame can be generated using known techniques and expressed by the methods described herein. General methods for enzymatic and chemical cleavage of fusion proteins are described, for example, by Ausubel (1995) at pages 16-19 to 16-25.
[0000] 6. Zserp11 Analogs and Zserp11 Inhibitors
[0151] One general class of Zserp11 analogs are variants having an amino acid sequence that is a mutation of the amino acid sequence disclosed herein. Another general class of Zserp11 analogs is provided by anti-idiotype antibodies, and fragments thereof, as described below. Moreover, recombinant antibodies comprising anti-idiotype variable domains can be used as analogs (see, for example, Monfardini et al., Proc. Assoc. Am. Physicians 108:420 (1996)). Since the variable domains of anti-idiotype Zserp11 antibodies mimic Zserp11, these domains can provide Zserp11 activity. Methods of producing anti-idiotypic catalytic antibodies are known to those of skill in the art (see, for example, Joron et al., Ann. N Y Acad. Sci. 672:216 (1992), Friboulet et al., Appl. Biochem. Biotechnol. 47:229 (1994), and Avalle et al., Ann. N Y Acad. Sci. 864:118 (1998)).
[0152] Another approach to identifying Zserp11 analogs is provided by the use of combinatorial libraries. Methods for constructing and screening phage display and other combinatorial libraries are provided, for example, by Kay et al., Phage Display of Peptides and Proteins (Academic Press 1996), Verdine, U.S. Pat. No. 5,783,384, Kay, et. al., U.S. Pat. No. 5,747,334, and Kauffman et al., U.S. Pat. No. 5,723,323.
[0153] Serine proteases can be used to produce labeled polypeptide fragments from a labeled protein substrate. Therefore, an illustrative in vitro use of Zserp11 and its analogs is to control the generation of such proteolysis cleavage products. Serine proteases are also used in cleaning solutions, such as solutions to clean and to disinfect contact lenses (see, for example, Aaslyng et al., U.S. Pat. No. 5,985,629). Such cleaning solutions also include protease inhibitors. Those of skill in the art can devise other uses for molecules having Zserp11 activity.
[0154] The activity of Zserp11 molecules of the present invention can be measured using a variety of assays that measure serine protease activity. For example, Zserp11 activity can be assessed by measuring inhibition in a standard in vitro serine protease assay (see, for example, Stief and Heimburger, U.S. Pat. No. 5,057,414 (1991)). Those of skill in the art are aware of a variety of substrates suitable for in vitro assays, such as Suc-Ala-Ala-Pro-Phe-pNA, fluorescein mono-p-guanidinobenzoate hydrochloride, benzyloxycarbonyl-L-Arginyl-S-benzylester, Nalpha-Benzoyl-L-arginine ethyl ester hydrochloride, and the like. In addition, protease assay kits available from commercial sources, such as Calbiochem® (San Diego, Calif.). For general references, see Barrett (Ed.), Methods in Enzymology, Proteolytic Enzymes: Serine and Cysteine Peptidases (Academic Press Inc. 1994), and Barrett et al., (Eds.), Handbook of Proteolytic Enzymes (Academic Press Inc. 1998).
[0155] Solution in vitro assays can be used to identify a Zserp11 substrate or inhibitor. Solid phase systems can also be used to identify a substrate or inhibitor of a Zserp11 polypeptide. For example, a Zserp11 polypeptide or Zserp11 fusion protein can be immobilized onto the surface of a receptor chip of a commercially available biosensor instrument (BIACORE, Biacore AB; Uppsala, Sweden). The use of this instrument is disclosed, for example, by Karlsson, Immunol. Methods 145:229 (1991), and Cunningham and Wells, J. Mol. Biol. 234:554 (1993).
[0156] In brief, a Zserp11 polypeptide or fusion protein is covalently attached, using amine or sulfhydryl chemistry, to dextran fibers that are attached to gold film within a flow cell. A test sample is then passed through the cell. If a Zserp11 serine protease substrate or inhibitor is present in the sample, it will bind to the immobilized polypeptide or fusion protein, causing a change in the refractive index of the medium, which is detected as a change in surface plasmon resonance of the gold film. This system allows the determination on- and off-rates, from which binding affinity can be calculated, and assessment of the stoichiometry of binding, as well as the kinetic effects of Zserp11 mutation. This system can also be used to examine antibody-antigen interactions, and the interactions of other complement/anti-complement pairs.
[0000] 7. Production of Zserp11 Polypeptides in Cultured Cells
[0157] The polypeptides of the present invention, including full-length polypeptides, functional fragments, and fusion proteins, can be produced in recombinant host cells following conventional techniques. To express a Zserp11 gene, a nucleic acid molecule encoding the polypeptide must be operably linked to regulatory sequences that control transcriptional expression in an expression vector and then, introduced into a host cell. In addition to transcriptional regulatory sequences, such as promoters and enhancers, expression vectors can include translational regulatory sequences and a marker gene which is suitable for selection of cells that carry the expression vector.
[0158] Expression vectors that are suitable for production of a foreign protein in eukaryotic cells typically contain (1) prokaryotic DNA elements coding for a bacterial replication origin and an antibiotic resistance marker to provide for the growth and selection of the expression vector in a bacterial host; (2) eukaryotic DNA elements that control initiation of transcription, such as a promoter; and (3) DNA elements that control the processing of transcripts, such as a transcription ternination/polyadenylation sequence. As discussed above, expression vectors can also include nucleotide sequences encoding a secretory sequence that directs the heterologous polypeptide into the secretory pathway of a host cell. For example, a Zserp11 expression vector may comprise a Zserp11 gene and a secretory sequence derived from a Zserp11 gene or another secreted gene.
[0159] Zserp11 proteins of the present invention may be expressed in mammalian cells. Examples of suitable mammalian host cells include African green monkey kidney cells (Vero; ATCC CRL 1587), human embryonic kidney cells (293-HEK; ATCC CRL 1573), baby hamster kidney cells (BHK-21, BHK-570; ATCC CRL 8544, ATCC CRL 10314), canine kidney cells (MDCK; ATCC CCL 34), Chinese hamster ovary cells (CHO-K1; ATCC CCL61; CHO DG44 (Chasin et al., Som. Cell. Molec. Genet. 12:555, 1986)), rat pituitary cells (GH1; ATCC CCL82), HeLa S3 cells (ATCC CCL2.2), rat hepatoma cells (H-4-II-E; ATCC CRL 1548) SV40-transformed monkey kidney cells (COS-1; ATCC CRL 1650) and murine embryonic cells (NIH-3T3; ATCC CRL 1658).
[0160] For a mammalian host, the transcriptional and translational regulatory signals may be derived from viral sources, such as adenovirus, bovine papilloma virus, simian virus, or the like, in which the regulatory signals are associated with a particular gene which has a high level of expression. Suitable transcriptional and translational regulatory sequences also can be obtained from mammalian genes, such as actin, collagen, myosin, and metallothionein genes.
[0161] Transcriptional regulatory sequences include a promoter region sufficient to direct the initiation of RNA synthesis. Suitable eukaryotic promoters include the promoter of the mouse metallothionein I gene (Hamer et al., J. Molec. Appl. Genet. 1:273 (1982)), the TK promoter of Herpes virus (McKnight, Cell 31:355 (1982)), the SV40 early promoter (Benoist et al., Nature 290:304 (1981)), the Rous sarcoma virus promoter (Gorman et al., Proc. Nat'l Acad. Sci. USA 79:6777 (1982)), the cytomegalovirus promoter (Foecking et al., Gene 45:101 (1980)), and the mouse mammary tumor virus promoter (see, generally, Etcheverry, “Expression of Engineered Proteins in Mammalian Cell Culture,” in Protein Engineering: Principles and Practice , Cleland et al. (eds.), pages 163-181 (John Wiley & Sons, Inc. 1996)).
[0162] Alternatively, a prokaryotic promoter, such as the bacteriophage T3 RNA polymerase promoter, can be used to control Zserp11 gene expression in mammalian cells if the prokaryotic promoter is regulated by a eukaryotic promoter (Zhou et al., Mol. Cell. Biol. 10:4529 (1990), and Kaufman et al., Nucl. Acids Res. 19:4485 (1991)).
[0163] An expression vector can be introduced into host cells using a variety of standard techniques including calcium phosphate transfection, liposome-mediated transfection, microprojectile-mediated delivery, electroporation, and the like. The transfected cells can be selected and propagated to provide recombinant host cells that comprise the expression vector stably integrated in the host cell genome. Techniques for introducing vectors into eukaryotic cells and techniques for selecting such stable transformants using a dominant selectable marker are described, for example, by Ausubel (1995) and by Murray (ed.), Gene Transfer and Expression Protocols (Humana Press 1991).
[0164] For example, one suitable selectable marker is a gene that provides resistance to the antibiotic neomycin. In this case, selection is carried out in the presence of a neomycin-type drug, such as G-418 or the like. Selection systems can also be used to increase the expression level of the gene of interest, a process referred to as “amplification.” Amplification is carried out by culturing transfectants in the presence of a low level of the selective agent and then increasing the amount of selective agent to select for cells that produce high levels of the products of the introduced genes. An exemplary amplifiable selectable marker is dihydrofolate reductase, which confers resistance to methotrexate. Other drug resistance genes (e.g., hygromycin resistance, multi-drug resistance, puromycin acetyltransferase) can also be used. Alternatively, markers that introduce an altered phenotype, such as green fluorescent protein, or cell surface proteins (e.g., CD4, CD8, Class I MHC, and placental alkaline phosphatase) may be used to sort transfected cells from untransfected cells by such means as FACS sorting or magnetic bead separation technology.
[0165] Zserp11 polypeptides can also be produced by cultured cells using a viral delivery system. Exemplary viruses for this purpose include adenovirus, herpesvirus, vaccinia virus and adeno-associated virus (AAV). Adenovirus, a double-stranded DNA virus, is currently the best studied gene transfer vector for delivery of heterologous nucleic acid (for a review, see Becker et al., Meth. Cell Biol. 43:161 (1994), and Douglas and Curiel, Science & Medicine 4:44 (1997)). Advantages of the adenovirus system include the accommodation of relatively large DNA inserts, the ability to grow to high-titer, the ability to infect a broad range of mammalian cell types, and flexibility that allows use with a large number of available vectors containing different promoters.
[0166] By deleting portions of the adenovirus genome, larger inserts (up to 7 kb) of heterologous DNA can be accommodated. These inserts can be incorporated into the viral DNA by direct ligation or by homologous recombination with a co-transfected plasmid. An option is to delete the essential E1 gene from the viral vector, which results in the inability to replicate unless the E1 gene is provided by the host cell. For example, adenovirus vector infected human 293 cells (ATCC Nos. CRL-1573, 45504, 45505) can be grown as adherent cells or in suspension culture at relatively high cell density to produce significant amounts of protein (see Garnier et al., Cytotechnol. 15:145 (1994)).
[0167] Zserp11 genes may also be expressed in other higher eukaryotic cells, such as avian, fungal, insect, yeast, or plant cells. The baculovirus system provides an efficient means to introduce cloned Zserp11 genes into insect cells. Suitable expression vectors are based upon the Autographa californica multiple nuclear polyhedrosis virus (AcMNPV), and contain well-known promoters such as Drosophila heat shock protein (hsp) 70 promoter, Autographa californica nuclear polyhedrosis virus immediate-early gene promoter (ie-1) and the delayed early 39K promoter, baculovirus p10 promoter, and the Drosophila metallothionein promoter. A second method of making recombinant baculovirus utilizes a transposon-based system described by Luckow (Luckow, et al., J. Virol. 67:4566 (1993)). This system, which utilizes transfer vectors, is sold in the BAC-to-BAC kit (Life Technologies, Rockville, Md.). This system utilizes a transfer vector, PFASTBAC (Life Technologies) containing a Tn7 transposon to move the DNA encoding the Zserp11 polypeptide into a baculovirus genome maintained in E. coli as a large plasmid called a “bacmid.” See, Hill-Perkins and Possee, J. Gen. Virol. 71:971 (1990), Bonning, et al., J. Gen. Virol. 75:1551 (1994), and Chazenbalk, and Rapoport, J. Biol. Chem. 270:1543 (1995). In addition, transfer vectors can include an in-frame fusion with DNA encoding an epitope tag at the C- or N-terminus of the expressed Zserp11 polypeptide, for example, a Glu-Glu epitope tag (Grussenmeyer et al., Proc. Nat'l Acad. Sci. 82:7952 (1985)). Using a technique known in the art, a transfer vector containing a Zserp11 gene is transformed into E. coli , and screened for bacmids which contain an interrupted lacZ gene indicative of recombinant baculovirus. The bacmid DNA containing the recombinant baculovirus genome is then isolated using common techniques.
[0168] The illustrative PFASTBAC vector can be modified to a considerable degree. For example, the polyhedrin promoter can be removed and substituted with the baculovirus basic protein promoter (also known as Pcor, p6.9 or MP promoter) which is expressed earlier in the baculovirus infection, and has been shown to be advantageous for expressing secreted proteins (see, for example, Hill-Perkins and Possee, J. Gen. Virol. 71:971 (1990), Bonning, et al., J. Gen. Virol. 75:1551 (1994), and Chazenbalk and Rapoport, J. Biol. Chem. 270:1543 (1995). In such transfer vector constructs, a short or long version of the basic protein promoter can be used. Moreover, transfer vectors can be constructed which replace the native Zserp11 secretory signal sequences with secretory signal sequences derived from insect proteins. For example, a secretory signal sequence from Ecdysteroid Glucosyltransferase (EGT), honey bee Melittin (Invitrogen Corporation; Carlsbad, Calif.), or baculovirus gp67 (PharMingen: San Diego, Calif.) can be used in constructs to replace the native Zserp11 secretory signal sequence.
[0169] The recombinant virus or bacmid is used to transfect host cells. Suitable insect host cells include cell lines derived from IPLB-Sf-21, a Spodoptera frugiperda pupal ovarian cell line, such as Sf9 (ATCC CRL 1711), Sf21AE, and Sf21 (Invitrogen Corporation; San Diego, Calif.), as well as Drosophila Schneider-2 cells, and the HIGH FIVEO cell line (Invitrogen) derived from Trichoplusia ni (U.S. Pat. No. 5,300,435). Commercially available serum-free media can be used to grow and to maintain the cells. Suitable media are Sf900 II™ (Life Technologies) or ESF 921™ (Expression Systems) for the Sf9 cells; and Ex-cellO405™ (JRH Biosciences, Lenexa, Kans.) or Express FiveO™ (Life Technologies) for the T. ni cells. When recombinant virus is used, the cells are typically grown up from an inoculation density of approximately 2-5×10 5 cells to a density of 1-2×10 6 cells at which time a recombinant viral stock is added at a multiplicity of infection (MOI) of 0.1 to 10, more typically near 3.
[0170] Established techniques for producing recombinant proteins in baculovirus systems are provided by Bailey et al., “Manipulation of Baculovirus Vectors,” in Methods in Molecular Biology, Volume 7: Gene Transfer and Expression Protocols , Murray (ed.), pages 147-168 (The Humana Press, Inc. 1991), by Patel et al., “The baculovirus expression system,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), pages 205-244 (Oxford University Press 1995), by Ausubel (1995) at pages 16-37 to 16-57, by Richardson (ed.), Baculovirus Expression Protocols (The Humana Press, Inc. 1995), and by Lucknow, “Insect Cell Expression Technology,” in Protein Engineering: Principles and Practice , Cleland et al. (eds.), pages 183-218 (John Wiley & Sons, Inc. 1996).
[0171] Fungal cells, including yeast cells, can also be used to express the genes described herein. Yeast species of particular interest in this regard include Saccharomyces cerevisiae, Pichia pastoris , and Pichia methanolica . Suitable promoters for expression in yeast include promoters from GAL1 (galactose), PGK (phosphoglycerate kinase), ADH (alcohol dehydrogenase), AOX1 (alcohol oxidase), HIS4 (histidinol dehydrogenase), and the like. Many yeast cloning vectors have been designed and are readily available. These vectors include YIp-based vectors, such as YIp5, YRp vectors, such as YRp17, YEp vectors such as YEp13 and YCp vectors, such as YCp19. Methods for transforming S. cerevisiae cells with exogenous DNA and producing recombinant polypeptides therefrom are disclosed by, for example, Kawasaki, U.S. Pat. No. 4,599,311, Kawasaki et al., U.S. Pat. No. 4,931,373, Brake, U.S. Pat. No. 4,870,008, Welch et al., U.S. Pat. No. 5,037,743, and Murray et al., U.S. Pat. No. 4,845,075. Transformed cells are selected by phenotype determined by the selectable marker, commonly drug resistance or the ability to grow in the absence of a particular nutrient (e.g., leucine). An illustrative vector system for use in Saccharomyces cerevisiae is the POT1 Vector system disclosed by Kawasaki et al. (U.S. Pat. No. 4,931,373), which allows transformed cells to be selected by growth in glucose-containing media. Additional suitable promoters and terminators for use in yeast include those from glycolytic enzyme genes (see, e.g., Kawasaki, U.S. Pat. No. 4,599,311, Kingsman et al., U.S. Pat. No. 4,615,974, and Bitter, U.S. Pat. No. 4,977,092) and alcohol dehydrogenase genes. See also U.S. Pat. Nos. 4,990,446, 5,063,154, 5,139,936, and 4,661,454.
[0172] Transformation systems for other yeasts, including Hansenula polymorpha, Schizosaccharomyces pombe, Kluyveromyces lactis, Kluyveromyces fragilis, Ustilago maydis, Pichia pastoris, Pichia methanolica, Pichia guillermondii and Candida maltosa are known in the art. See, for example, Gleeson et al., J. Gen. Microbiol. 132:3459 (1986), and Cregg, U.S. Pat. No. 4,882,279. Aspergillus cells may be utilized according to the methods of McKnight et al., U.S. Pat. No. 4,935,349. Methods for transforming Acremonium chrysogenum are disclosed by Sumino et al., U.S. Pat. No. 5,162,228. Methods for transforming Neurospora are disclosed by Lambowitz, U.S. Pat. No. 4,486,533.
[0173] For example, the use of Pichia methanolica as host for the production of recombinant proteins is disclosed by Raymond, U.S. Pat. No. 5,716,808, Raymond, U.S. Pat. No. 5,736,383, Raymond et al., Yeast 14:11-23 (1998), and in international publication Nos. WO 97/17450, WO 97/17451, WO 98/02536, and WO 98/02565. DNA molecules for use in transforming P. methanolica will commonly be prepared as double-stranded, circular plasmids, which can be linearized prior to transformation. For polypeptide production in P. methanolica , the promoter and terminator in the plasmid can be provided by a P. methanolica gene, such as a P. methanolica alcohol utilization gene (AUG1 or AUG2). Other useful promoters include those of the dihydroxyacetone synthase (DHAS), formate dehydrogenase (FMD), and catalase (CAT) genes. To facilitate integration of the DNA into the host chromosome, the entire expression segment of the plasmid can be flanked at both ends by host DNA sequences. An illustrative selectable marker for use in Pichia methanolica is a P. methanolica ADE2 gene, which encodes phosphoribosyl-5-aminoimidazole carboxylase (AIRC; EC 4.1.1.21), and which allows ade2 host cells to grow in the absence of adenine. For large-scale, industrial processes where it is desirable to minimize the use of methanol, it is possible to use host cells in which both methanol utilization genes (AUG1 and AUG2) are deleted. For production of secreted proteins, host cells deficient in vacuolar protease genes (PEP4 and PRB1) can be used. Electroporation is used to facilitate the introduction of a plasmid containing DNA encoding a polypeptide of interest into P. methanolica cells. P. methanolica cells can be transformed by electroporation using an exponentially decaying, pulsed electric field having a field strength of from 2.5 to 4.5 kV/cm, preferably about 3.75 kV/cm, and a time constant (t) of from 1 to 40 milliseconds, most preferably about 20 milliseconds.
[0174] Expression vectors can also be introduced into plant protoplasts, intact plant tissues, or isolated plant cells. Methods for introducing expression vectors into plant tissue include the direct infection or co-cultivation of plant tissue with Agrobacterium tumefaciens , microprojectile-mediated delivery, DNA injection, electroporation, and the like. See, for example, Horsch et al., Science 227:1229 (1985), Klein et al., Biotechnology 10:268 (1992), and Miki et al., “Procedures for Introducing Foreign DNA into Plants,” in Methods in Plant Molecular Biology and Biotechnology , Glick et al. (eds.), pages 67-88 (CRC Press, 1993).
[0175] Alternatively, Zserp11 genes can be expressed in prokaryotic host cells. Suitable promoters that can be used to express Zserp11 polypeptides in a prokaryotic host are well-known to those of skill in the art and include promoters capable of recognizing the T4, T3, Sp6 and T7 polymerases, the P R and P L promoters of bacteriophage lambda, the trp, recA, heat shock, lacUV5, tac, lpp-lacSpr, phoA, and lacZ promoters of E. coli , promoters of B. subtilis , the promoters of the bacteriophages of Bacillus, Streptomyces promoters, the int promoter of bacteriophage lambda, the bla promoter of pBR322, and the CAT promoter of the chloramphenicol acetyl transferase gene. Prokaryotic promoters have been reviewed by Glick, J. Ind. Microbiol. 1:277 (1987), Watson et al., Molecular Biology of the Gene, 4 th Ed . (Benjamin Cummins 1987), and by Ausubel et al. (1995).
[0176] Useful prokaryotic hosts include E. coli and Bacillus subtilus . Suitable strains of E. coli include BL21(DE3), BL21(DE3)pLysS, BL21(DE3)pLysE, DH1, DH4I, DH5, DH5I, DH5IF′, DH5IMCR, DH10B, DH10B/p3, DH11S, C600, HB101, JM101, JM105, JM109, JM110, K38, RR1, Y1088, Y1089, CSH18, ER1451, and ER1647 (see, for example, Brown (ed.), Molecular Biology Labfax (Academic Press 1991)). Suitable strains of Bacillus subtilus include BR151, YB886, MI119, MI120, and B170 (see, for example, Hardy, “Bacillus Cloning Methods,” in DNA Cloning: A Practical Approach , Glover (ed.) (IRL Press 1985)).
[0177] When expressing a Zserp11 polypeptide in bacteria such as E. coli , the polypeptide may be retained in the cytoplasm, typically as insoluble granules, or may be directed to the periplasmic space by a bacterial secretion sequence. In the former case, the cells are lysed, and the granules are recovered and denatured using, for example, guanidine isothiocyanate or urea. The denatured polypeptide can then be refolded and dimerized by diluting the denaturant, such as by dialysis against a solution of urea and a combination of reduced and oxidized glutathione, followed by dialysis against a buffered saline solution. In the latter case, the polypeptide can be recovered from the periplasmic space in a soluble and functional form by disrupting the cells (by, for example, sonication or osmotic shock) to release the contents of the periplasmic space and recovering the protein, thereby obviating the need for denaturation and refolding.
[0178] Methods for expressing proteins in prokaryotic hosts are well-known to those of skill in the art (see, for example, Williams et al., “Expression of foreign proteins in E. coli using plasmid vectors and purification of specific polyclonal antibodies,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), page 15 (Oxford University Press 1995), Ward et al., “Genetic Manipulation and Expression of Antibodies,” in Monoclonal Antibodies: Principles and Applications , page 137 (Wiley-Liss, Inc. 1995), and Georgiou, “Expression of Proteins in Bacteria,” in Protein Engineering: Principles and Practice , Cleland et al. (eds.), page 101 (John Wiley & Sons, Inc. 1996)).
[0179] Standard methods for introducing expression vectors into bacterial, yeast, insect, and plant cells are provided, for example, by Ausubel (1995).
[0180] General methods for expressing and recovering foreign protein produced by a mammalian cell system are provided by, for example, Etcheverry, “Expression of Engineered Proteins in Mammalian Cell Culture,” in Protein Engineering: Principles and Practice , Cleland et al. (eds.), pages 163 (Wiley-Liss, Inc. 1996). Standard techniques for recovering protein produced by a bacterial system is provided by, for example, Grisshammer et al., “Purification of over-produced proteins from E. coli cells,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), pages 59-92 (Oxford University Press 1995). Established methods for isolating recombinant proteins from a baculovirus system are described by Richardson (ed.), Baculovirus Expression Protocols (The Humana Press, Inc. 1995).
[0181] As an alternative, polypeptides of the present invention can be synthesized by exclusive solid phase synthesis, partial solid phase methods, fragment condensation or classical solution synthesis. These synthesis methods are well-known to those of skill in the art (see, for example, Merrifield, J. Am. Chem. Soc. 85:2149 (1963), Stewart et al., “Solid Phase Peptide Synthesis” (2nd Edition), (Pierce Chemical Co. 1984), Bayer and Rapp, Chem. Pept. Prot. 3:3 (1986), Atherton et al., Solid Phase Peptide Synthesis: A Practical Approach (IRL Press 1989), Fields and Colowick, “Solid-Phase Peptide Synthesis,” Methods in Enzymology Volume 289 (Academic Press 1997), and Lloyd-Williams et al., Chemical Approaches to the Synthesis of Peptides and Proteins (CRC Press, Inc. 1997)). Variations in total chemical synthesis strategies, such as “native chemical ligation” and “expressed protein ligation” are also standard (see, for example, Dawson et al., Science 266:776 (1994), Hackeng et al., Proc. Nat'l Acad. Sci. USA 94:7845 (1997), Dawson, Methods Enzymol. 287: 34 (1997), Muir et al, Proc. Nat'l Acad. Sci. USA 95:6705 (1998), and Severinov and Muir, J. Biol. Chem. 273:16205 (1998)).
[0000] 8. Isolation of Zserp11 Polypeptides
[0182] The polypeptides of the present invention can be purified to at least about 80% purity, to at least about 90% purity, to at least about 95% purity, or greater than 95% purity with respect to contaminating macromolecules, particularly other proteins and nucleic acids, and free of infectious and pyrogenic agents. The polypeptides of the present invention may also be purified to a pharmaceutically pure state, which is greater than 99.9% pure. Certain purified polypeptide preparations are substantially free of other polypeptides, particularly other polypeptides of animal origin.
[0183] Fractionation and/or conventional purification methods can be used to obtain preparations of Zserp11 purified from natural sources, and recombinant Zserp11 polypeptides and fusion Zserp11 polypeptides purified from recombinant host cells. In general, ammonium sulfate precipitation and acid or chaotrope extraction may be used for fractionation of samples. Exemplary purification steps may include hydroxyapatite, size exclusion, FPLC and reverse-phase high performance liquid chromatography. Suitable chromatographic media include derivatized dextrans, agarose, cellulose, polyacrylamide, specialty silicas, and the like. PEI, DEAE, QAE and Q derivatives are preferred. Exemplary chromatographic media include those media derivatized with phenyl, butyl, or octyl groups, such as Phenyl-Sepharose FF (Pharmacia), Toyopearl butyl 650 (Toso Haas, Montgomeryville, Pa.), Octyl-Sepharose (Pharmacia) and the like; or polyacrylic resins, such as Amberchrom CG 71 (Toso Haas) and the like. Suitable solid supports include glass beads, silica-based resins, cellulosic resins, agarose beads, cross-linked agarose beads, polystyrene beads, cross-linked polyacrylamide resins and the like that are insoluble under the conditions in which they are to be used. These supports may be modified with reactive groups that allow attachment of proteins by amino groups, carboxyl groups, sulfhydryl groups, hydroxyl groups and/or carbohydrate moieties.
[0184] Examples of coupling chemistries include cyanogen bromide activation, N-hydroxysuccinimide activation, epoxide activation, sulfhydryl activation, hydrazide activation, and carboxyl and amino derivatives for carbodiimide coupling chemistries. These and other solid media are well known and widely used in the art, and are available from commercial suppliers. Selection of a particular method for polypeptide isolation and purification is a matter of routine design and is determined in part by the properties of the chosen support. See, for example, Affinity Chromatography: Principles & Methods (Pharmacia LKB Biotechnology 1988), and Doonan, Protein Purification Protocols (The Humana Press 1996).
[0185] Additional variations in Zserp11 isolation and purification can be devised by those of skill in the art. For example, anti-Zserp11 antibodies, obtained as described below, can be used to isolate large quantities of protein by immunoaffinity purification.
[0186] The polypeptides of the present invention can also be isolated by exploitation of particular properties. For example, immobilized metal ion adsorption (IMAC) chromatography can be used to purify histidine-rich proteins, including those comprising polyhistidine tags. Briefly, a gel is first charged with divalent metal ions to form a chelate (Sulkowski, Trends in Biochem. 3:1 (1985)). Histidine-rich proteins will be adsorbed to this matrix with differing affinities, depending upon the metal ion used, and will be eluted by competitive elution, lowering the pH, or use of strong chelating agents. Other methods of purification include purification of glycosylated proteins by lectin affinity chromatography and ion exchange chromatography (M. Deutscher, (ed.), Meth. Enzymol. 182:529 (1990)). Within additional embodiments of the invention, a fusion of the polypeptide of interest and an affinity tag (e.g., maltose-binding protein, an immunoglobulin domain) may be constructed to facilitate purification.
[0187] Zserp11 polypeptides or fragments thereof may also be prepared through chemical synthesis, as described above. Zserp11 polypeptides may be monomers or multimers; glycosylated or non-glycosylated; PEGylated or non-PEGylated; and may or may not include an initial methionine amino acid residue.
[0188] The present invention also contemplates chemically modified Zserp11 compositions, in which a Zserp11 polypeptide is linked with a polymer. Typically, the polymer is water soluble so that the Zserp11 conjugate does not precipitate in an aqueous environment, such as a physiological environment. An example of a suitable polymer is one that has been modified to have a single reactive group, such as an active ester for acylation, or an aldehyde for alkylation, In this way, the degree of polymerization can be controlled. An example of a reactive aldehyde is polyethylene glycol propionaldehyde, or mono-(C1-C10) alkoxy, or aryloxy derivatives thereof (see, for example, Harris, et al., U.S. Pat. No. 5,252,714). The polymer may be branched or unbranched. Moreover, a mixture of polymers can be used to produce Zserp11 conjugates.
[0189] Zserp11 conjugates used for therapy can comprise pharmaceutically acceptable water-soluble polymer moieties. Suitable water-soluble polymers include polyethylene glycol (PEG), monomethoxy-PEG, mono-(C1-C10)alkoxy-PEG, aryloxy-PEG, poly-(N-vinyl pyrrolidone)PEG, tresyl monomethoxy PEG, PEG propionaldehyde, bis-succinimidyl carbonate PEG, propylene glycol homopolymers, a polypropylene oxide/ethylene oxide co-polymer, polyoxyethylated polyols (e.g., glycerol), polyvinyl alcohol, dextran, cellulose, or other carbohydrate-based polymers. Suitable PEG may have a molecular weight from about 600 to about 60,000, including, for example, 5,000, 12,000, 20,000 and 25,000. A Zserp11 conjugate can also comprise a mixture of such water-soluble polymers. Anti-Zserp11 antibodies or anti-idiotype antibodies can also be conjugated with a water-soluble polymer.
[0190] The present invention contemplates compositions comprising a peptide or polypeptide described herein. Such compositions can further comprise a carrier. The carrier can be a conventional organic or inorganic carrier. Examples of carriers include water, buffer solution, alcohol, propylene glycol, macrogol, sesame oil, corn oil, and the like.
[0191] Peptides and polypeptides of the present invention comprise at least six, at least nine, or at least 15 contiguous amino acid residues of SEQ ID NO:2. Within certain embodiments of the invention, the polypeptides comprise 20, 30, 40, 50, 100, or more contiguous residues of these amino acid sequences. For example, polypeptides can comprise the following regions of SEQ ID NO:2: amino acid residues 46 to 137, amino acid residues 154 to 285, and amino acid residues 296 to 364. Additional polypeptides can comprise at least 15, at least 30, at least 40, or at least 50 contiguous amino acids of such regions of SEQ ID NO:2. As another example, peptides can comprise amino acid residues 322 to 327 of SEQ ID NO:2. Nucleic acid molecules encoding such peptides and polypeptides are useful as polymerase chain reaction primers and probes.
[0192] In addition to the uses described above, polynucleotides and polypeptides of the present invention are useful as educational tools in laboratory practicum kits for courses related to genetics and molecular biology, protein chemistry, and antibody production and analysis. Due to its unique polynucleotide and polypeptide sequences, molecules of Zserp11 can be used as standards or as “unknowns” for testing purposes. For example, Zserp11 polynucleotides can be used as an aid, such as, for example, to teach a student how to prepare expression constructs for bacterial, viral, or mammalian expression, including fusion constructs, wherein Zserp11 is the gene to be expressed; for determining the restriction endonuclease cleavage sites of the polynucleotides; determining mRNA and DNA localization of Zserp11 polynucleotides in tissues (i.e., by northern and Southern blotting as well as polymerase chain reaction); and for identifying related polynucleotides and polypeptides by nucleic acid hybridization. As an illustration, students will find that PvuII digestion of a nucleic acid molecule consisting of the nucleotide sequence of nucleotides 1 to 1098 of SEQ ID NO:1 provides fragments of about 302 base pairs, and 796 base pairs, and that HindIII digestion yields fragments of about 278 base pairs, and 1020 base pairs.
[0193] Zserp11 polypeptides can be used as an aid to teach preparation of antibodies; identifying proteins by western blotting; protein purification; determining the weight of expressed Zserp11 polypeptides as a ratio to total protein expressed; identifying peptide cleavage sites; coupling amino and carboxyl terminal tags; amino acid sequence analysis, as well as, but not limited to monitoring biological activities of both the native and tagged protein (ie., protease inhibition) in vitro and in vivo. For example, students will find that digestion of unglycosylated Zserp11 with hydroxylamine yields fragments having approximate molecular weights of 7320, and 33624, whereas digestion of unglycosylated Zserp11 with NTCB yields fragments having approximate molecular weights of 2070, 2703, 22036, and 14167.
[0194] Zserp11 polypeptides can also be used to teach analytical skills such as mass spectrometry, circular dichroism, to determine conformation, especially of the four alpha helices, x-ray crystallography to determine the three-dimensional structure in atomic detail, nuclear magnetic resonance spectroscopy to reveal the structure of proteins in solution. For example, a kit containing the Zserp11 can be given to the student to analyze. Since the amino acid sequence would be known by the instructor, the protein can be given to the student as a test to determine the skills or develop the skills of the student, the instructor would then know whether or not the student has correctly analyzed the polypeptide. Since every polypeptide is unique, the educational utility of Zserp11 would be unique unto itself.
[0195] The antibodies which bind specifically to Zserp11 can be used as a teaching aid to instruct students how to prepare affinity chromatography columns to purify Zserp11, cloning and sequencing the polynucleotide that encodes an antibody and thus as a practicum for teaching a student how to design humanized antibodies. The Zserp11 gene, polypeptide, or antibody would then be packaged by reagent companies and sold to educational institutions so that the students gain skill in art of molecular biology. Because each gene and protein is unique, each gene and protein creates unique challenges and learning experiences for students in a lab practicum. Such educational kits containing the Zserp11 gene, polypeptide, or antibody are considered within the scope of the present invention.
[0000] 9. Production of Antibodies to Zserp11 Proteins
[0196] Antibodies to Zserp11 can be obtained, for example, using as an antigen the product of a Zserp11 expression vector or Zserp11 isolated from a natural source. Particularly useful anti-Zserp11 antibodies “bind specifically” with Zserp11. Antibodies are considered to be specifically binding if the antibodies exhibit at least one of the following two properties: (1) antibodies bind to Zserp11 with a threshold level of binding activity, and (2) antibodies do not significantly cross-react with polypeptides related to Zserp11.
[0197] With regard to the first characteristic, antibodies specifically bind if they bind to a Zserp11 polypeptide, peptide or epitope with a binding affinity (K a ) of 10 6 M −1 or greater, preferably 10 7 M −1 or greater, more preferably 10 8 M −1 or greater, and most preferably 10 9 M −1 or greater. The binding affinity of an antibody can be readily determined by one of ordinary skill in the art, for example, by Scatchard analysis (Scatchard, Ann. NY Acad. Sci. 51:660 (1949)). With regard to the second characteristic, antibodies do not significantly cross-react with related polypeptide molecules, for example, if they detect Zserp11, but not known related polypeptides using a standard Western blot analysis. Examples of known related polypeptides are orthologs and proteins from the same species that are members of a protein family. For example, specifically-binding anti-Zserp11 antibodies bind with Zserp11, but not with known serine protease inhibitors, such as α1-antitrypsin, tissue kallikrein inhibitor, antithrombin, α2-antiplasmin, plasminogen activator inhibitors-1 and -2, neuroserpin, C1 inhibitor, α1-antichymotrypsin, and the like.
[0198] Anti-Zserp11 antibodies can be produced using antigenic Zserp11 epitope-bearing peptides and polypeptides. Antigenic epitope-bearing peptides and polypeptides of the present invention contain a sequence of at least nine, or between 15 to about 30 amino acids contained within SEQ ID NO:2. However, peptides or polypeptides comprising a larger portion of an amino acid sequence of the invention, containing from 30 to 50 amino acids, or any length up to and including the entire amino acid sequence of a polypeptide of the invention, also are useful for inducing antibodies that bind with Zserp11. It is desirable that the amino acid sequence of the epitope-bearing peptide is selected to provide substantial solubility in aqueous solvents (i.e., the sequence includes relatively hydrophilic residues, while hydrophobic residues are preferably avoided). Moreover, amino acid sequences containing proline residues may be also be desirable for antibody production.
[0199] As an illustration, potential antigenic sites in Zserp11 were identified using the Jameson-Wolf method, Jameson and Wolf, CABIOS 4:181, (1988), as implemented by the PROTEAN program (version 3.14) of LASERGENE (DNASTAR; Madison, Wis.). Default parameters were used in this analysis.
[0200] The Jameson-Wolf method predicts potential antigenic determinants by combining six major subroutines for protein structural prediction. Briefly, the Hopp-Woods method, Hopp et al., Proc. Nat'l Acad. Sci. USA 78:3824 (1981), was first used to identify amino acid sequences representing areas of greatest local hydrophilicity (parameter: seven residues averaged). In the second step, Emini's method, Emini et al., J. Virology 55:836 (1985), was used to calculate surface probabilities (parameter: surface decision threshold (0.6)=1). Third, the Karplus-Schultz method, Karplus and Schultz, Naturwissenschaften 72:212 (1985), was used to predict backbone chain flexibility (parameter: flexibility threshold (0.2)=1). In the fourth and fifth steps of the analysis, secondary structure predictions were applied to the data using the methods of Chou-Fasman, Chou, “Prediction of Protein Structural Classes from Amino Acid Composition,” in Prediction of Protein Structure and the Principles of Protein Conformation , Fasman (ed.), pages 549-586 (Plenum Press 1990), and Garnier-Robson, Garnier et al., J. Mol. Biol. 120:97 (1978) (Chou-Fasman parameters: conformation table=64 proteins; α region threshold=103; β region threshold=105; Garnier-Robson parameters: α and β decision constants=0). In the sixth subroutine, flexibility parameters and hydropathy/solvent accessibility factors were combined to determine a surface contour value, designated as the “antigenic index.” Finally, a peak broadening function was applied to the antigenic index, which broadens major surface peaks by adding 20, 40, 60, or 80% of the respective peak value to account for additional free energy derived from the mobility of surface regions relative to interior regions. This calculation was not applied, however, to any major peak that resides in a helical region, since helical regions tend to be less flexible.
[0201] The results of this analysis indicated that the following amino acid sequences of SEQ ID NO:2 would provide suitable antigenic molecules: amino acids 24 to 30, amino acids 34 to 41, amino acids 68 to 73, amino acids 111 to 117, amino acids 126 to 133, amino acids 137 to 144, amino acids 150 to 172, amino acids 176 to 184, amino acids 201 to 210, amino acids 224 to 230, amino acids 246 to 251, amino acids 259 to 268, amino acids 282 to 294, amino acids 307 to 313, amino acids 323 to 331, and amino acids 335 to 341. The present invention contemplates the use of any one of these antigenic molecules to generate antibodies to Zserp11. The present invention also contemplates polypeptides comprising at least one of these antigenic molecules.
[0202] Polyclonal antibodies to recombinant Zserp11 protein or to Zserp11 isolated from natural sources can be prepared using methods well-known to those of skill in the art. Antibodies can also be generated using a Zserp11-glutathione transferase fusion protein, which is similar to a method described by Burrus and McMahon, Exp. Cell. Res. 220:363 (1995). General methods for producing polyclonal antibodies are described, for example, by Green et al., “Production of Polyclonal Antisera,” in Immunochemical Protocols (Manson, ed.), pages 1-5 (Humana Press 1992), and Williams et al., “Expression of foreign proteins in E. coli using plasmid vectors and purification of specific polyclonal antibodies,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), page 15 (Oxford University Press 1995).
[0203] The immunogenicity of a Zserp11 polypeptide can be increased through the use of an adjuvant, such as alum (aluminum hydroxide) or Freund's complete or incomplete adjuvant. Polypeptides useful for immunization also include fusion polypeptides, such as fusions of Zserp11 or a portion thereof with an immunoglobulin polypeptide or with maltose binding protein. The polypeptide immunogen may be a full-length molecule or a portion thereof. If the polypeptide portion is “hapten-like,” such portion may be advantageously joined or linked to a macromolecular carrier (such as keyhole limpet hemocyanin (KLH), bovine serum albumin (BSA) or tetanus toxoid) for immunization.
[0204] Although polyclonal antibodies are typically raised in animals such as horse, cow, dog, chicken, rat, mouse, rabbit, goat, guinea pig, or sheep, an anti-Zserp11 antibody of the present invention may also be derived from a subhuman primate antibody. General techniques for raising diagnostically and therapeutically useful antibodies in baboons may be found, for example, in Goldenberg et al., international patent publication No. WO 91/11465, and in Losman et al., Int. J. Cancer 46:310 (1990).
[0205] Alternatively, monoclonal anti-Zserp11 antibodies can be generated. Rodent monoclonal antibodies to specific antigens may be obtained by methods known to those skilled in the art (see, for example, Kohler et al., Nature 256:495 (1975), Coligan et al. (eds.), Current Protocols in Immunology, Vol. 1, pages 2.5.1-2.6.7 (John Wiley & Sons 1991) [“Coligan”], Picksley et al., “Production of monoclonal antibodies against proteins expressed in E. coli ,” in DNA Cloning 2: Expression Systems, 2 nd Edition , Glover et al. (eds.), page 93 (Oxford University Press 1995)).
[0206] Briefly, monoclonal antibodies can be obtained by injecting mice with a composition comprising a Zserp11 gene product, verifying the presence of antibody production by removing a serum sample, removing the spleen to obtain B-lymphocytes, fusing the B-lymphocytes with myeloma cells to produce hybridomas, cloning the hybridomas, selecting positive clones which produce antibodies to the antigen, culturing the clones that produce antibodies to the antigen, and isolating the antibodies from the hybridoma cultures.
[0207] In addition, an anti-Zserp11 antibody of the present invention may be derived from a human monoclonal antibody. Human monoclonal antibodies are obtained from transgenic mice that have been engineered to produce specific human antibodies in response to antigenic challenge. In this technique, elements of the human heavy and light chain locus are introduced into strains of mice derived from embryonic stem cell lines that contain targeted disruptions of the endogenous heavy chain and light chain loci. The transgenic mice can synthesize human antibodies specific for human antigens, and the mice can be used to produce human antibody-secreting hybridomas. Methods for obtaining human antibodies from transgenic mice are described, for example, by Green et al., Nature Genet. 7:13 (1994), Lonberg et al., Nature 368:856 (1994), and Taylor et al., Int. Immun. 6:579 (1994).
[0208] Monoclonal antibodies can be isolated and purified from hybridoma cultures by a variety of well-established techniques. Such isolation techniques include affinity chromatography with Protein-A Sepharose, size-exclusion chromatography, and ion-exchange chromatography (see, for example, Coligan at pages 2.7.1-2.7.12 and pages 2.9.1-2.9.3; Baines et al., “Purification of Immunoglobulin G (IgG),” in Methods in Molecular Biology, Vol. 10, pages 79-104 (The Humana Press, Inc. 1992)).
[0209] For particular uses, it may be desirable to prepare fragments of anti-Zserp11 antibodies. Such antibody fragments can be obtained, for example, by proteolytic hydrolysis of the antibody. Antibody fragments can be obtained by pepsin or papain digestion of whole antibodies by conventional methods. As an illustration, antibody fragments can be produced by enzymatic cleavage of antibodies with pepsin to provide a 5S fragment denoted F(ab′) 2 . This fragment can be further cleaved using a thiol reducing agent to produce 3.5S Fab′ monovalent fragments. Optionally, the cleavage reaction can be performed using a blocking group for the sulfhydryl groups that result from cleavage of disulfide linkages. As an alternative, an enzymatic cleavage using pepsin produces two monovalent Fab fragments and an Fc fragment directly. These methods are described, for example, by Goldenberg, U.S. Pat. No. 4,331,647, Nisonoff et al., Arch Biochem. Biophys. 89:230 (1960), Porter, Biochem. J. 73:119 (1959), Edelman et al., in Methods in Enzymology Vol. 1, page 422 (Academic Press 1967), and by Coligan at pages 2.8.1-2.8.10 and 2.10.-2.10.4.
[0210] Other methods of cleaving antibodies, such as separation of heavy chains to form monovalent light-heavy chain fragments, further cleavage of fragments, or other enzymatic, chemical or genetic techniques may also be used, so long as the fragments bind to the antigen that is recognized by the intact antibody.
[0211] For example, Fv fragments comprise an association of V H and V L chains. This association can be noncovalent, as described by Inbar et al., Proc. Nat'l Acad. Sci. USA 69:2659 (1972). Alternatively, the variable chains can be linked by an intermolecular disulfide bond or cross-linked by chemicals such as glutaraldehyde (see, for example, Sandhu, Crit. Rev. Biotech. 12:437 (1992)).
[0212] The Fv fragments may comprise V H and V L chains which are connected by a peptide linker. These single-chain antigen binding proteins (scFv) are prepared by constructing a structural gene comprising DNA sequences encoding the V H and V L domains which are connected by an oligonucleotide. The structural gene is inserted into an expression vector which is subsequently introduced into a host cell, such as E. coli . The recombinant host cells synthesize a single polypeptide chain with a linker peptide bridging the two V domains. Methods for producing scFvs are described, for example, by Whitlow et al., Methods: A Companion to Methods in Enzymology 2:97 (1991) (also see, Bird et al., Science 242:423 (1988), Ladner et al., U.S. Pat. No. 4,946,778, Pack et al., Bio/Technology 11:1271 (1993), and Sandhu, supra).
[0213] As an illustration, a scFV can be obtained by exposing lymphocytes to Zserp11 polypeptide in vitro, and selecting antibody display libraries in phage or similar vectors (for instance, through use of immobilized or labeled Zserp11 protein or peptide). Genes encoding polypeptides having potential Zserp11 polypeptide binding domains can be obtained by screening random peptide libraries displayed on phage (phage display) or on bacteria, such as E. coli . Nucleotide sequences encoding the polypeptides can be obtained in a number of ways, such as through random mutagenesis and random polynucleotide synthesis. These random peptide display libraries can be used to screen for peptides which interact with a known target which can be a protein or polypeptide, such as a ligand or receptor, a biological or synthetic macromolecule, or organic or inorganic substances. Techniques for creating and screening such random peptide display libraries are known in the art (Ladner et al., U.S. Pat. No. 5,223,409, Ladner et al., U.S. Pat. No. 4,946,778, Ladner et al., U.S. Pat. No. 5,403,484, Ladner et al., U.S. Pat. No. 5,571,698, and Kay et al., Phage Display of Peptides and Proteins (Academic Press, Inc. 1996)) and random peptide display libraries and kits for screening such libraries are available commercially, for instance from CLONTECH Laboratories, Inc. (Palo Alto, Calif.), Invitrogen Inc. (San Diego, Calif.), New England Biolabs, Inc. (Beverly, Mass.), and Pharmacia LKB Biotechnology Inc. (Piscataway, N.J.). Random peptide display libraries can be screened using the Zserp11 sequences disclosed herein to identify proteins which bind to Zserp11.
[0214] Another form of an antibody fragment is a peptide coding for a single complementarity-determining region (CDR). CDR peptides (“minimal recognition units”) can be obtained by constructing genes encoding the CDR of an antibody of interest. Such genes are prepared, for example, by using the polymerase chain reaction to synthesize the variable region from RNA of antibody-producing cells (see, for example, Larrick et al., Methods: A Companion to Methods in Enzymology 2:106 (1991), Courtenay-Luck, “Genetic Manipulation of Monoclonal Antibodies,” in Monoclonal Antibodies: Production, Engineering and Clinical Application , Ritter et al. (eds.), page 166 (Cambridge University Press 1995), and Ward et al., “Genetic Manipulation and Expression of Antibodies,” in Monoclonal Antibodies: Principles and Applications , Birch et al., (eds.), page 137 (Wiley-Liss, Inc. 1995)).
[0215] Alternatively, an anti-Zserp11 antibody may be derived from a “humanized” monoclonal antibody. Humanized monoclonal antibodies are produced by transferring mouse complementary determining regions from heavy and light variable chains of the mouse immunoglobulin into a human variable domain. Typical residues of human antibodies are then substituted in the framework regions of the murine counterparts. The use of antibody components derived from humanized monoclonal antibodies obviates potential problems associated with the immunogenicity of murine constant regions. General techniques for cloning murine immunoglobulin variable domains are described, for example, by Orlandi et al., Proc. Nat'l Acad. Sci. USA 86:3833 (1989). Techniques for producing humanized monoclonal antibodies are described, for example, by Jones et al., Nature 321:522 (1986), Carter et al., Proc. Nat'l Acad. Sci. USA 89:4285 (1992), Sandhu, Crit. Rev. Biotech. 12:437 (1992), Singer et al., J. Immun. 150:2844 (1993), Sudhir (ed.), Antibody Engineering Protocols (Humana Press, Inc. 1995), Kelley, “Engineering Therapeutic Antibodies,” in Protein Engineering: Principles and Practice , Cleland et al. (eds.), pages 399-434 (John Wiley & Sons, Inc. 1996), and by Queen et al., U.S. Pat. No. 5,693,762 (1997).
[0216] Polyclonal anti-idiotype antibodies can be prepared by immunizing animals with anti-Zserp11 antibodies or antibody fragments, using standard techniques. See, for example, Green et al., “Production of Polyclonal Antisera,” in Methods In Molecular Biology: Immunochemical Protocols , Manson (ed.), pages 1-12 (Humana Press 1992). Also, see Coligan at pages 2.4.1-2.4.7. Alternatively, monoclonal anti-idiotype antibodies can be prepared using anti-Zserp11 antibodies or antibody fragments as immunogens with the techniques, described above. As another alternative, humanized anti-idiotype antibodies or subhuman primate anti-idiotype antibodies can be prepared using the above-described techniques. Methods for producing anti-idiotype antibodies are described, for example, by Irie, U.S. Pat. No. 5,208,146, Greene, et. al., U.S. Pat. No. 5,637,677, and Varthakavi and Minocha, J. Gen. Virol. 77:1875 (1996).
[0217] Anti-idiotype Zserp11 antibodies, as well as Zserp11 polypeptides can be used to identify and to isolate Zserp11 substrates and inhibitors. For example, proteins and peptides of the present invention can be immobilized on a column and used to bind substrate and inhibitor proteins from biological samples that are run over the column (Hermanson et al. (eds.), Immobilized Affinity Ligand Techniques , pages 195-202 (Academic Press 1992)). Radiolabeled or affinity labeled Zserp11 polypeptides can also be used to identify or to localize Zserp11 substrates and inhibitors in a biological sample (see, for example, Deutscher (ed.), Methods in Enzymol ., vol. 182, pages 721-37 (Academic Press 1990); Brunner et al., Ann. Rev. Biochem. 62:483 (1993); Fedan et al., Biochem. Pharmacol. 33:1167 (1984)).
[0000] 10. Use of Zserp11 Nucleotide Sequences to Detect Zserp11 Gene Expression and to Examine Zserp21 Gene Structure
[0218] Nucleic acid molecules can be used to detect the expression of a Zserp11 gene in a biological sample. Such probe molecules include double-stranded nucleic acid molecules comprising the nucleotide sequence of SEQ ID NO:1, or a fragment thereof, as well as single-stranded nucleic acid molecules having the complement of the nucleotide sequence of SEQ ID NO:1, or a fragment thereof. Probe molecules may be DNA, RNA, oligonucleotides, and the like. Certain probes bind with regions of a Zserp11 gene that have a low sequence similarity to comparable regions in other serine protease inhibitors.
[0219] Illustrative probes include portions of the following nucleotide sequences of SEQ ID NO:1, or complements thereof: nucleotides 36 to 411, nucleotides 460 to 855, and nucleotides 886 to 1092. As used herein, the term “portion” refers to at least eight nucleotides to at least 20 or more nucleotides. For example, an illustrative portion of nucleotides 886 to 1092 of SEQ ID NO:1 is represented by nucleotides 964 to 981.
[0220] In a basic assay, a single-stranded probe molecule is incubated with RNA, isolated from a biological sample, under conditions of temperature and ionic strength that promote base pairing between the probe and target Zserp11 RNA species. After separating unbound probe from hybridized molecules, the amount of hybrids is detected.
[0221] Well-established hybridization methods of RNA detection include northern analysis and dot/slot blot hybridization (see, for example, Ausubel (1995) at pages 4-1 to 4-27, and Wu et al. (eds.), “Analysis of Gene Expression at the RNA Level,” in Methods in Gene Biotechnology , pages 225-239 (CRC Press, Inc. 1997)). Nucleic acid probes can be detectably labeled with radioisotopes such as 32 P or 35 S. Alternatively, Zserp11 RNA can be detected with a nonradioactive hybridization method (see, for example, Isaac (ed.), Protocols for Nucleic Acid Analysis by Nonradioactive Probes (Humana Press, Inc. 1993)). Typically, nonradioactive detection is achieved by enzymatic conversion of chromogenic or chemiluminescent substrates. Illustrative nonradioactive moieties include biotin, fluorescein, and digoxigenin.
[0222] Zserp11 oligonucleotide probes are also useful for in vivo diagnosis. As an illustration, 18 F-labeled oligonucleotides can be administered to a subject and visualized by positron emission tomography (Tavitian et al., Nature Medicine 4:467 (1998)).
[0223] Numerous diagnostic procedures take advantage of the polymerase chain reaction (PCR) to increase sensitivity of detection methods. Standard techniques for performing PCR are well-known (see, generally, Mathew (ed.), Protocols in Human Molecular Genetics (Humana Press, Inc. 1991), White (ed.), PCR Protocols: Current Methods and Applications (Humana Press, Inc. 1993), Cotter (ed.), Molecular Diagnosis of Cancer (Humana Press, Inc. 1996), Hanausek and Walaszek (eds.), Tumor Marker Protocols (Humana Press, Inc. 1998), Lo (ed.), Clinical Applications of PCR (Humana Press, Inc. 1998), and Meltzer (ed.), PCR in Bioanalysis (Humana Press, Inc. 1998)).
[0224] As an illustration, PCR primers can be designed to amplify any of the following nucleotide sequences of SEQ ID NO:1 nucleotides 36 to 411, nucleotides 460 to 855, and nucleotides 886 to 1092. Particular PCR primers are designed to amplify a portion of the Zserp11 gene that has a low sequence similarity to a comparable region in other serine protease inhibitors.
[0225] One variation of PCR for diagnostic assays is reverse transcriptase-PCR (RT-PCR). In the RT-PCR technique, RNA is isolated from a biological sample, reverse transcribed to cDNA, and the cDNA is incubated with Zserp11 primers (see, for example, Wu et al. (eds.), “Rapid Isolation of Specific cDNAs or Genes by PCR,” in Methods in Gene Biotechnology , pages 15-28 (CRC Press, Inc. 1997)). PCR is then performed and the products are analyzed using standard techniques.
[0226] As an illustration, RNA is isolated from biological sample using, for example, the guanidinium-thiocyanate cell lysis procedure described above. Alternatively, a solid-phase technique can be used to isolate mRNA from a cell lysate. A reverse transcription reaction can be primed with the isolated RNA using random oligonucleotides, short homopolymers of dT, or Zserp11 anti-sense oligomers. Oligo-dT primers offer the advantage that various mRNA nucleotide sequences are amplified that can provide control target, sequences. Zserp11 sequences are amplified by the polymerase chain reaction using two flanking oligonucleotide primers that are typically 20 bases in length.
[0227] PCR amplification products can be detected using a variety of approaches. For example, PCR products can be fractionated by gel electrophoresis, and visualized by ethidium bromide staining. Alternatively, fractionated PCR products can be transferred to a membrane, hybridized with a detectably-labeled Zserp11 probe, and examined by autoradiography. Additional alternative approaches include the use of digoxigenin-labeled deoxyribonucleic acid triphosphates to provide chemiluminescence detection, and the C-TRAK colorimetric assay.
[0228] Another approach for detection of Zserp11 expression is cycling probe technology (CPT), in which a single-stranded DNA target binds with an excess of DNA-RNA-DNA chimeric probe to form a complex, the RNA portion is cleaved with RNAase H, and the presence of cleaved chimeric probe is detected (see, for example, Beggs et al., J. Clin. Microbiol. 34:2985 (1996), Bekkaoui et al., Biotechniques 20:240 (1996)). Alternative methods for detection of Zserp11 sequences can utilize approaches such as nucleic acid sequence-based amplification (NASBA), cooperative amplification of templates by cross-hybridization (CATCH), and the ligase chain reaction (LCR) (see, for example, Marshall et al., U.S. Pat. No. 5,686,272 (1997), Dyer et al., J. Virol. Methods 60:161 (1996), Ehricht et al., Eur. J. Biochem. 243:358 (1997), and Chadwick et al., J. Virol. Methods 70:59 (1998)). Other standard methods are known to those of skill in the art.
[0229] Zserp11 probes and primers can also be used to detect and to localize Zserp11 gene expression in tissue samples. Methods for such in situ hybridization are well-known to those of skill in the art (see, for example, Choo (ed.), In Situ Hybridization Protocols (Humana Press, Inc. 1994), Wu et al. (eds.), “Analysis of Cellular DNA or Abundance of mRNA by Radioactive In Situ Hybridization (RISH),” in Methods in Gene Biotechnology , pages 259-278 (CRC Press, Inc. 1997), and Wu et al. (eds.), “Localization of DNA or Abundance of mRNA by Fluorescence In Situ Hybridization (RISH),” in Methods in Gene Biotechnology , pages 279-289 (CRC Press, Inc. 1997)). Various additional diagnostic approaches are well-known to those of skill in the art (see, for example, Mathew (ed.), Protocols in Human Molecular Genetics (Humana Press, Inc. 1991), Coleman and Tsongalis, Molecular Diagnostics (Humana Press, Inc. 1996), and Elles, Molecular Diagnosis of Genetic Diseases (Humana Press, Inc., 1996)). Suitable test samples include blood, urine, saliva, tissue biopsy, and autopsy material.
[0230] The Zserp11 gene resides in human chromosome 14q32.1. This region is associated with various disorders, including protein C inhibitor deficiency, emphysema, cirrhosis, leukemia, and lymphoma. In addition, mutations of serine protease inhibitors are associated with particular diseases. For example, polymorphisms of α1-antichymotrypsin are associated with pulmonary disease and occlusive cerebrovascular disease, mutations of the α1-antitrypsin gene are associated with liver disease, emphysema, and a bleeding disorder. Thus, Zserp11 nucleotide sequences can be used in linkage-based testing for various diseases, and to determine whether a subject's chromosomes contain a mutation in the Zserp11 gene. Detectable chromosomal aberrations at the Zserp11 gene locus include, but are not limited to, aneuploidy, gene copy number changes, insertions, deletions, restriction site changes and rearrangements. Of particular interest are genetic alterations that inactivate a Zserp11 gene.
[0231] Aberrations associated with a Zserp11 locus can be detected using nucleic acid molecules of the present invention by employing molecular genetic techniques, such as restriction fragment length polymorphism analysis, short tandem repeat analysis employing PCR techniques, amplification-refractory mutation system analysis, single-strand conformation polymorphism detection, RNase cleavage methods, denaturing gradient gel electrophoresis, fluorescence-assisted mismatch analysis, and other genetic analysis techniques known in the art (see, for example, Mathew (ed.), Protocols in Human Molecular Genetics (Humana Press, Inc. 1991), Marian, Chest 108:255 (1995), Coleman and Tsongalis, Molecular Diagnostics (Human Press, Inc. 1996), Elles (ed.) Molecular Diagnosis of Genetic Diseases (Humana Press, Inc. 1996), Landegren (ed.), Laboratory Protocols for Mutation Detection (Oxford University Press 1996), Birren et al. (eds.), Genome Analysis, Vol. 2: Detecting Genes (Cold Spring Harbor Laboratory Press 1998), Dracopoli et al. (eds.), Current Protocols in Human Genetics (John Wiley & Sons 1998), and Richards and Ward, “Molecular Diagnostic Testing,” in Principles of Molecular Medicine , pages 83-88 (Humana Press, Inc. 1998)).
[0232] The protein truncation test is also useful for detecting the inactivation of a gene in which translation-terminating mutations produce only portions of the encoded protein (see, for example, Stoppa-Lyonnet et al., Blood 91:3920 (1998)). According to this approach, RNA is isolated from a biological sample, and used to synthesize cDNA. PCR is then used to amplify the Zserp11 target sequence and to introduce an RNA polymerase promoter, a translation initiation sequence, and an in-frame ATG triplet. PCR products are transcribed using an RNA polymerase, and the transcripts are translated in vitro with a T7-coupled reticulocyte lysate system. The translation products are then fractionated by SDS-PAGE to determine the lengths of the translation products. The protein truncation test is described, for example, by Dracopoli et al. (eds.), Current Protocols in Human Genetics , pages 9.11.1-9.11.18 (John Wiley & Sons 1998).
[0233] The present invention also contemplates kits for performing a diagnostic assay for Zserp11 gene expression or to analyze the Zserp11 locus of a subject. Such kits comprise nucleic acid probes, such as double-stranded nucleic acid molecules comprising the nucleotide sequence of SEQ ID NO:1, or a fragment thereof, as well as single-stranded nucleic acid molecules having the complement of the nucleotide sequence of SEQ ID NO:1, or a fragment thereof. Illustrative fragments reside within nucleotides 36 to 411 of SEQ ID NO:1, nucleotides 460 to 855 of SEQ ID NO:1, or nucleotides 886 to 1092 of SEQ ID NO:1. Probe molecules may be DNA, RNA, oligonucleotides, and the like. Kits may comprise nucleic acid primers for performing PCR.
[0234] Such a kit can contain all the necessary elements to perform a nucleic acid diagnostic assay described above. A kit will comprise at least one container comprising a Zserp11 probe or primer. The kit may also comprise a second container comprising one or more reagents capable of indicating the presence of Zserp11 sequences. Examples of such indicator reagents include detectable labels such as radioactive labels, fluorochromes, chemiluminescent agents, and the like. A kit may also comprise a means for conveying to the user that the Zserp11 probes and primers are used to detect Zserp11 gene expression. For example, written instructions may state that the enclosed nucleic acid molecules can be used to detect either a nucleic acid molecule that encodes Zserp11, or a nucleic acid molecule having a nucleotide sequence that is complementary to a Zserp11-encoding nucleotide sequence, or to analyze chromosomal sequences associated with the Zserp11 locus. The written material can be applied directly to a container, or the written material can be provided in the form of a packaging insert.
[0000] 11. Use of Anti-Zserp11 Antibodies to Detect Zserp11 Protein
[0235] The present invention contemplates the use of anti-Zserp11 antibodies to screen biological samples in vitro for the presence of Zserp11. In one type of in vitro assay, anti-Zserp11 antibodies are used in liquid phase. For example, the presence of Zserp11 in a biological sample can be tested by mixing the biological sample with a trace amount of labeled Zserp11 and an anti-Zserp11 antibody under conditions that promote binding between Zserp11 and its antibody. Complexes of Zserp11 and anti-Zserp11 in the sample can be separated from the reaction mixture by contacting the complex with an immobilized protein which binds with the antibody, such as an Fc antibody or Staphylococcus protein A. The concentration of Zserp11 in the biological sample will be inversely proportional to the amount of labeled Zserp11 bound to the antibody and directly related to the amount of free labeled Zserp11.
[0236] Alternatively, in vitro assays can be performed in which anti-Zserp11 antibody is bound to a solid-phase carrier. For example, antibody can be attached to a polymer, such as aminodextran, in order to link the antibody to an insoluble support such as a polymer-coated bead, a plate or a tube. Other suitable in vitro assays will be readily apparent to those of skill in the art.
[0237] In another approach, anti-Zserp11 antibodies can be used to detect Zserp11 in tissue sections prepared from a biopsy specimen. Such immunochemical detection can be used to determine the relative abundance of Zserp11 and to determine the distribution of Zserp11 in the examined tissue. General immunochemistry techniques are well established (see, for example, Ponder, “Cell Marking Techniques and Their Application,” in Mammalian Development: A Practical Approach , Monk (ed.), pages 115-38 (IRL Press 1987), Coligan at pages 5.8.1-5.8.8, Ausubel (1995) at pages 14.6.1 to 14.6.13 (Wiley Interscience 1990), and Manson (ed.), Methods In Molecular Biology, Vol. 10: Immunochemical Protocols (The Humana Press, Inc. 1992)).
[0238] Immunochemical detection can be performed by contacting a biological sample with an anti-Zserp11 antibody, and then contacting the biological sample with a detectably labeled molecule which binds to the antibody. For example, the detectably labeled molecule can comprise an antibody moiety that binds to anti-Zserp11 antibody. Alternatively, the anti-Zserp11 antibody can be conjugated with avidin/streptavidin (or biotin) and the detectably labeled molecule can comprise biotin (or avidin/streptavidin). Numerous variations of this basic technique are well-known to those of skill in the art.
[0239] Alternatively, an anti-Zserp11 antibody can be conjugated with a detectable label to form an anti-Zserp11 immunoconjugate. Suitable detectable labels include, for example, a radioisotope, a fluorescent label, a chemiluminescent label, an enzyme label, a bioluminescent label or colloidal gold. Methods of making and detecting such detectably-labeled immunoconjugates are well-known to those of ordinary skill in the art, and are described in more detail below.
[0240] The detectable label can be a radioisotope that is detected by autoradiography. Isotopes that are particularly useful for the purpose of the present invention are 3 H, 125 I, 131 I, 35 S and 14 C.
[0241] Anti-Zserp11 immunoconjugates can also be labeled with a fluorescent compound. The presence of a fluorescently-labeled antibody is determined by exposing the immunoconjugate to light of the proper wavelength and detecting the resultant fluorescence. Fluorescent labeling compounds include fluorescein isothiocyanate, rhodamine, phycoerytherin, phycocyanin, allophycocyanin, o-phthaldehyde and fluorescanine.
[0242] Alternatively, anti-Zserp11 immunoconjugates can be detectably labeled by coupling an antibody component to a chemiluminescent compound. The presence of the chemiluminescent-tagged immunoconjugate is determined by detecting the presence of luminescence that arises during the course of a chemical reaction. Examples of chemiluminescent labeling compounds include luminol, isoluminol, an aromatic acridinium ester, an imidazole, an acridinium salt and an oxalate ester.
[0243] Similarly, a bioluminescent compound can be used to label anti-Zserp11 immunoconjugates of the present invention. Bioluminescence is a type of chemiluminescence found in biological systems in which a catalytic protein increases the efficiency of the chemiluminescent reaction. The presence of a bioluminescent protein is determined by detecting the presence of luminescence. Bioluminescent compounds that are useful for labeling include luciferin, luciferase and aequorin.
[0244] Alternatively, anti-Zserp11 immunoconjugates can be detectably labeled by linking an anti-Zserp11 antibody component to an enzyme. When the anti-Zserp11-enzyme conjugate is incubated in the presence of the appropriate substrate, the enzyme moiety reacts with the substrate to produce a chemical moiety which can be detected, for example, by spectrophotometric, fluorometric or visual means. Examples of enzymes that can be used to detectably label polyspecific immunoconjugates include β-galactosidase, glucose oxidase, peroxidase and alkaline phosphatase.
[0245] Those of skill in the art will know of other suitable labels which can be employed in accordance with the present invention. The binding of marker moieties to anti-Zserp11 antibodies can be accomplished using standard techniques known to the art. Typical methodology in this regard is described by Kennedy et al., Clin. Chim. Acta 70:1 (1976), Schurs et al., Clin. Chim. Acta 81:1 (1977), Shih et al., Int'l J. Cancer 46:1101 (1990), Stein et al., Cancer Res. 50:1330 (1990), and Coligan, supra.
[0246] Moreover, the convenience and versatility of immunochemical detection can be enhanced by using anti-Zserp11 antibodies that have been conjugated with avidin, streptavidin, and biotin (see, for example, Wilchek et al. (eds.), “Avidin-Biotin Technology,” Methods In Enzymology, Vol. 184 (Academic Press 1990), and Bayer et al., “Immunochemical Applications of Avidin-Biotin Technology,” in Methods In Molecular Biology, Vol. 10, Manson (ed.), pages 149-162 (The Humana Press, Inc. 1992).
[0247] Methods for performing immunoassays are well-established. See, for example, Cook and Self, “Monoclonal Antibodies in Diagnostic Immununoassays,” in Monoclonal Antibodies: Production, Engineering, and Clinical Application , Ritter and Ladyman (eds.), pages 180-208, (Cambridge University Press, 1995), Perry, “The Role of Monoclonal Antibodies in the Advancement of Immunoassay Technology,” in Monoclonal Antibodies: Principles and Applications , Birch and Lennox (eds.), pages 107-120 (Wiley-Liss, Inc. 1995), and Diamandis, Immunoassay (Academic Press, Inc. 1996).
[0248] In a related approach, biotin- or FITC-labeled Zserp11 can be used to identify cells that bind Zserp11. Such can binding can be detected, for example, using flow cytometry.
[0249] The present invention also contemplates kits for performing an immunological diagnostic assay for Zserp11 gene expression. Such kits comprise at least one container comprising an anti-Zserp11 antibody, or antibody fragment. A kit may also comprise a second container comprising one or more reagents capable of indicating the presence of Zserp11 antibody or antibody fragments. Examples of such indicator reagents include detectable labels such as a radioactive label, a fluorescent label, a chemiluminescent label, an enzyme label, a bioluminescent label, colloidal gold, and the like. A kit may also comprise a means for conveying to the user that Zserp11 antibodies or antibody fragments are used to detect Zserp11 protein. For example, written instructions may state that the enclosed antibody or antibody fragment can be used to detect Zserp11. The written material can be applied directly to a container, or the written material can be provided in the form of a packaging insert.
[0000] 12. Therapeutic Uses of Polypeptides Having Zserp11 Activity
[0250] The present invention includes the use of proteins, polypeptides, and peptides having Zserp11 activity (such as Zserp11 polypeptides, anti-idiotype anti-Zserp11 antibodies, and Zserp11 fusion proteins) to a subject who lacks an adequate amount of this serine protease inhibitor. For example, molecules having Zserp11 activity may be used to stimulate vasodilation (e.g., to reduce hypertension), whereas molecules that inhibit Zserp11 activity may be used to decrease the formation of neointima in injured blood vessels.
[0251] These molecules can be administered to any subject in need of treatment, and the present invention contemplates both veterinary and human therapeutic uses. Illustrative subjects include mammalian subjects, such as farm animals, domestic animals, and human patients.
[0252] Generally, the dosage of administered polypeptide, protein or peptide will vary depending upon such factors as the subject's age, weight, height, sex, general medical condition and previous medical history. Typically, it is desirable to provide the recipient with a dosage of a molecule having Zserp11 activity, which is in the range of from about 1 pg/kg to 10 mg/kg (amount of agent/body weight of subject), although a lower or higher dosage also may be administered as circumstances dictate.
[0253] Administration of a molecule having Zserp11 activity to a subject can be intravenous, intraarterial, intraperitoneal, intramuscular, subcutaneous, intrapleural, intrathecal, by perfusion through a regional catheter, or by direct intralesional injection. When administering therapeutic proteins by injection, the administration may be by continuous infusion or by single or multiple boluses.
[0254] A pharmaceutical composition comprising a protein, polypeptide, or peptide having Zserp11 activity can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby the therapeutic proteins are combined in a mixture with a pharmaceutically acceptable carrier. A composition is said to be a “pharmaceutically acceptable carrier” if its administration can be tolerated by a recipient patient. Sterile phosphate-buffered saline is one example of a pharmaceutically acceptable carrier. Other suitable carriers are well-known to those in the art. See, for example, Gennaro (ed.), Remington's Pharmaceutical Sciences, 19th Edition (Mack Publishing Company 1995).
[0255] For purposes of therapy, molecules having Zserp11 activity and a pharmaceutically acceptable carrier are administered to a patient in a therapeutically effective amount. A combination of a protein, polypeptide, or peptide having Zserp11 activity and a pharmaceutically acceptable carrier is said to be administered in a “therapeutically effective amount” if the amount administered is physiologically significant. An agent is physiologically significant if its presence results in a detectable change in the physiology of a recipient patient.
[0256] A pharmaceutical composition comprising molecules having Zserp11 activity can be furnished in liquid form, or in solid form. Liquid forms, including liposome-encapsulated formulations, are illustrated by injectable solutions and oral suspensions. Exemplary solid forms include capsules, tablets, and controlled-release forms, such as a miniosmotic pump or an implant. Other dosage forms can be devised by those skilled in the art, as shown, for example, by Ansel and Popovich, Pharmaceutical Dosage Forms and Drug Delivery Systems, 5 th Edition (Lea & Febiger 1990), Gennaro (ed.), Remington's Pharmaceutical Sciences, 19 th Edition (Mack Publishing Company 1995), and by Ranade and Hollinger, Drug Delivery Systems (CRC Press 1996).
[0257] As an illustration, Zserp11 pharmaceutical compositions may be supplied as a kit comprising a container that comprises Zserp11. Zserp11 can be provided in the form of an injectable solution for single or multiple doses, or as a sterile powder that will be reconstituted before injection. Such a kit may further comprise written information on indications and usage of the pharmaceutical composition. Moreover, such information may include a statement that the Zserp11 composition is contraindicated in patients with known hypersensitivity to Zserp11.
[0000] 13. Therapeutic Uses of Zserp11 Nucleotide Sequences
[0258] The present invention includes the use of Zserp11 nucleotide sequences to provide Zserp11 to a subject in need of such treatment. In addition, a therapeutic expression vector can be provided that inhibits Zserp11 gene expression, such as an anti-sense molecule, a ribozyme, or an external guide sequence molecule.
[0259] There are numerous approaches to introduce a Zserp11 gene to a subject, including the use of recombinant host cells that express Zserp11, delivery of naked nucleic acid encoding Zserp11, use of a cationic lipid carrier with a nucleic acid molecule that encodes Zserp11, and the use of viruses that express Zserp11, such as recombinant retroviruses, recombinant adeno-associated viruses, recombinant adenoviruses, and recombinant Herpes simplex viruses (see, for example, Mulligan, Science 260:926 (1993), Rosenberg et al., Science 242:1575 (1988), LaSalle et al., Science 259:988 (1993), Wolff et al., Science 247:1465 (1990), Breakfield and Deluca, The New Biologist 3:203 (1991)). In an ex vivo approach, for example, cells are isolated from a subject, transfected with a vector that expresses a Zserp11 gene, and then transplanted into the subject.
[0260] In order to effect expression of a Zserp11 gene, an expression vector is constructed in which a nucleotide sequence encoding a Zserp11 gene is operably linked to a core promoter, and optionally a regulatory element, to control gene transcription. The general requirements of an expression vector are described above.
[0261] Alternatively, a Zserp11 gene can be delivered using recombinant viral vectors, including for example, adenoviral vectors (e.g., Kass-Eisler et al., Proc. Nat'l Acad. Sci. USA 90:11498 (1993), Kolls et al., Proc. Nat'l Acad. Sci. USA 91:215 (1994), Li et al., Hum. Gene Ther. 4:403 (1993), Vincent et al., Nat. Genet. 5:130 (1993), and Zabner et al., Cell 75:207 (1993)), adenovirus-associated viral vectors (Flotte et al., Proc. Nat'l Acad. Sci. USA 90:10613 (1993)), alphaviruses such as Semliki Forest Virus and Sindbis Virus (Hertz and Huang, J. Vir. 66:857 (1992), Raju and Huang, J. Vir. 65:2501 (1991), and Xiong et al., Science 243:1188 (1989)), herpes viral vectors (e.g., U.S. Pat. Nos. 4,769,331, 4,859,587, 5,288,641 and 5,328,688), parvovirus vectors (Koering et al., Hum. Gene Therap. 5:457 (1994)), pox virus vectors (Ozaki et al., Biochem. Biophys. Res. Comm. 193:653 (1993), Panicali and Paoletti, Proc. Nat'l Acad. Sci. USA 79:4927 (1982)), pox viruses, such as canary pox virus or vaccinia virus (Fisher-Hoch et al., Proc. Nat'l Acad. Sci. USA 86:317 (1989), and Flexner et al., Ann. N.Y. Acad. Sci. 569:86 (1989)), and retroviruses (e.g., Baba et al., J. Neurosurg 79:729 (1993), Ram et al., Cancer Res. 53:83 (1993), Takamiya et al., J. Neurosci. Res 33:493 (1992), Vile, and Hart, Cancer Res. 53:962 (1993), Vile and Hart, Cancer Res. 53:3860 (1993), and Anderson et al., U.S. Pat. No. 5,399,346). Within various embodiments, either the viral vector itself, or a viral particle which contains the viral vector may be utilized in the methods and compositions described below.
[0262] As an illustration of one system, adenovirus, a double-stranded DNA virus, is a well-characterized gene transfer vector for delivery of a heterologous nucleic acid molecule (for a review, see Becker et al., Meth. Cell Biol. 43:161 (1994); Douglas and Curiel, Science & Medicine 4:44 (1997)). The adenovirus system offers several advantages including: (i) the ability to accommodate relatively large DNA inserts, (ii) the ability to be grown to high-titer, (iii) the ability to infect a broad range of mammalian cell types, and (iv) the ability to be used with many different promoters including ubiquitous, tissue specific, and regulatable promoters. In addition, adenoviruses can be administered by intravenous injection, because the viruses are stable in the bloodstream.
[0263] Using adenovirus vectors where portions of the adenovirus genome are deleted, inserts are incorporated into the viral DNA by direct ligation or by homologous recombination with a co-transfected plasmid. In an exemplary system, the essential E1 gene is deleted from the viral vector, and the virus will not replicate unless the E1 gene is provided by the host cell. When intravenously administered to intact animals, adenovirus primarily targets the liver. Although an adenoviral delivery system with an E1 gene deletion cannot replicate in the host cells, the host's tissue will express and process an encoded heterologous protein. Host cells will also secrete the heterologous protein if the corresponding gene includes a secretory signal sequence. Secreted proteins will enter the circulation from tissue that expresses the heterologous gene (e.g., the highly vascularized liver).
[0264] Moreover, adenoviral vectors containing various deletions of viral genes can be used to reduce or eliminate immune responses to the vector. Such adenoviruses are E1-deleted, and in addition, contain deletions of E2A or E4 (Lusky et al., J. Virol. 72:2022 (1998); Raper et al., Human Gene Therapy 9:671 (1998)). The deletion of E2b has also been reported to reduce immune responses (Amalfitano et al., J. Virol. 72:926 (1998)). By deleting the entire adenovirus genome, very large inserts of heterologous DNA can be accommodated. Generation of so called “gutless” adenoviruses, where all viral genes are deleted, are particularly advantageous for insertion of large inserts of heterologous DNA (for a review, see Yeh. and Perricaudet, FASEB J. 11:615 (1997)).
[0265] High titer stocks of recombinant viruses capable of expressing a therapeutic gene can be obtained from infected mammalian cells using standard methods. For example, recombinant HSV can be prepared in Vero cells, as described by Brandt et al., J. Gen. Virol. 72:2043 (1991), Herold et al., J. Gen. Virol. 75:1211 (1994), Visalli and Brandt, Virology 185:419 (1991), Grau et al., Invest. Ophthalmol. Vis. Sci. 30:2474 (1989), Brandt et al., J. Virol. Meth. 36:209 (1992), and by Brown and MacLean (eds.), HSV Virus Protocols (Humana Press 1997).
[0266] Alternatively, an expression vector comprising a Zserp11 gene can be introduced into a subject's cells by lipofection in vivo using liposomes. Synthetic cationic lipids can be used to prepare liposomes for in vivo transfection of a gene encoding a marker (Felgner et al., Proc. Nat'l Acad. Sci. USA 84:7413 (1987); Mackey et al., Proc. Nat'l Acad. Sci. USA 85:8027 (1988)). The use of lipofection to introduce exogenous genes into specific organs in vivo has certain practical advantages. Liposomes can be used to direct transfection to particular cell types, which is particularly advantageous in a tissue with cellular heterogeneity, such as the pancreas, liver, kidney, and brain. Lipids may be chemically coupled to other molecules for the purpose of targeting. Targeted peptides (e.g., hormones or neurotransmitters), proteins such as antibodies, or non-peptide molecules can be coupled to liposomes chemically.
[0267] Electroporation is another alternative mode of administration of a Zserp11 nucleic acid molecules. For example, Aihara and Miyazaki, Nature Biotechnology 16:867 (1998), have demonstrated the use of in vivo electroporation for gene transfer into muscle.
[0268] In an alternative approach to gene therapy, a therapeutic gene may encode a Zserp11 anti-sense RNA that inhibits the expression of Zserp11. Methods of preparing anti-sense constructs are known to those in the art. See, for example, Erickson et al., Dev. Genet. 14:274 (1993) [transgenic mice], Augustine et al., Dev. Genet. 14:500 (1993) [murine whole embryo culture], and Olson and Gibo, Exp. Cell Res. 241:134 (1998) [cultured cells]. Suitable sequences for Zserp11 anti-sense molecules can be derived from the nucleotide sequences of Zserp11 disclosed herein.
[0269] Alternatively, an expression vector can be constructed in which a regulatory element is operably linked to a nucleotide sequence that encodes a ribozyme. Ribozymes can be designed to express endonuclease activity that is directed to a certain target sequence in a mRNA molecule (see, for example, Draper and Macejak, U.S. Pat. No. 5,496,698, McSwiggen, U.S. Pat. No. 5,525,468, Chowrira and McSwiggen, U.S. Pat. No. 5,631,359, and Robertson and Goldberg, U.S. Pat. No. 5,225,337). In the context of the present invention, ribozymes include nucleotide sequences that bind with Zserp11 mRNA.
[0270] In another approach, expression vectors can be constructed in which a regulatory element directs the production of RNA transcripts capable of promoting RNase P-mediated cleavage of mRNA molecules that encode a Zserp11 gene. According to this approach, an external guide sequence can be constructed for directing the endogenous ribozyme, RNase P, to a particular species of intracellular mRNA, which is subsequently cleaved by the cellular ribozyme (see, for example, Altman et al., U.S. Pat. No. 5,168,053, Yuan et al., Science 263:1269 (1994), Pace et al., international publication No. WO 96/18733, George et al., international publication No. WO 96/21731, and Werner et al., international publication No. WO 97/33991). Preferably, the external guide sequence comprises a ten to fifteen nucleotide sequence complementary to Zserp11 mRNA, and a 3′-NCCA nucleotide sequence, wherein N is preferably a purine. The external guide sequence transcripts bind to the targeted mRNA species by the formation of base pairs between the mRNA and the complementary external guide sequences, thus promoting cleavage of mRNA by RNase P at the nucleotide located at the 5′-side of the base-paired region.
[0271] In general, the dosage of a composition comprising a therapeutic vector having a Zserp11 nucleotide acid sequence, such as a recombinant virus, will vary depending upon such factors as the subject's age, weight, height, sex, general medical condition and previous medical history. Suitable routes of administration of therapeutic vectors include intravenous injection, intraarterial injection, intraperitoneal injection, intramuscular injection, intratumoral injection, and injection into a cavity that contains a tumor.
[0272] A composition comprising viral vectors, non-viral vectors, or a combination of viral and non-viral vectors of the present invention can be formulated according to known methods to prepare pharmaceutically useful compositions, whereby vectors or viruses are combined in a mixture with a pharmaceutically acceptable carrier. As noted above, a composition, such as phosphate-buffered saline is said to be a “pharmaceutically acceptable carrier” if its administration can be tolerated by a recipient subject. Other suitable carriers are well-known to those in the art (see, for example, Remington's Pharmaceutical Sciences, 19 th Ed . (Mack Publishing Co. 1995), and Gilman's the Pharmacological Basis of Therapeutics, 7 th Ed . (MacMillan Publishing Co. 1985)).
[0273] For purposes of therapy, a therapeutic gene expression vector, or a recombinant virus comprising such a vector, and a pharmaceutically acceptable carrier are administered to a subject in a therapeutically effective amount. A combination of an expression vector (or virus) and a pharmaceutically acceptable carrier is said to be administered in a “therapeutically effective amount” if the amount administered is physiologically significant. An agent is physiologically significant if its presence results in a detectable change in the physiology of a recipient subject.
[0274] When the subject treated with a therapeutic gene expression vector or a recombinant virus is a human, then the therapy is preferably somatic cell gene therapy. That is, the preferred treatment of a human with a therapeutic gene expression vector or a recombinant virus does not entail introducing into cells a nucleic acid molecule that can form part of a human germ line and be passed onto successive generations (i.e., human germ line gene therapy).
[0000] 14. Production of Transgenic Mice
[0275] Transgenic mice can be engineered to over-express the Zserp11 gene in all tissues or under the control of a tissue-specific or tissue-preferred regulatory element. These over-producers of Zserp11 can be used to characterize the phenotype that results from over-expression, and the transgenic animals can serve as models for human disease caused by excess Zserp11. Transgenic mice that over-express Zserp11 also provide model bioreactors for production of Zserp11 in the milk or blood of larger animals. Methods for producing transgenic mice are well-known to those of skill in the art (see, for example, Jacob, “Expression and Knockout of Interferons in Transgenic Mice,” in Overexpression and Knockout of Cytokines in Transgenic Mice , Jacob (ed.), pages 111-124 (Academic Press, Ltd. 1994), Monastersky and Robl (eds.), Strategies in Transgenic Animal Science (ASM Press 1995), and Abbud and Nilson, “Recombinant Protein Expression in Transgenic Mice,” in Gene Expression Systems: Using Nature for the Art of Expression , Fernandez and Hoeffler (eds.), pages 367-397 (Academic Press, Inc. 1999)).
[0276] For example, a method for producing a transgenic mouse that expresses a Zserp11 gene can begin with adult, fertile males (studs) (B6C3f1, 2-8 months of age (Taconic Farms, Germantown, N.Y.)), vasectomized males (duds) (B6D2f1, 2-8 months, (Taconic Farms)), prepubescent fertile females (donors) (B6C3f1, 4-5 weeks, (Taconic Farms)) and adult fertile females (recipients) (B6D2f1, 2-4 months, (Taconic Farms)). The donors are acclimated for one week and then injected with approximately 8 IU/mouse of Pregnant Mare's Serum gonadotrophin (Sigma Chemical Company; St. Louis, Mo.) I.P., and 4647 hours later, 8 IU/mouse of human Chorionic Gonadotropin (hCG (Sigma)) I.P. to induce superovulation. Donors are mated with studs subsequent to hormone injections. Ovulation generally occurs within 13 hours of hCG injection. Copulation is confirmed by the presence of a vaginal plug the morning following mating.
[0277] Fertilized eggs are collected under a surgical scope. The oviducts are collected and eggs are released into urinanalysis slides containing hyaluronidase (Sigma). Eggs are washed once in hyaluronidase, and twice in Whitten's W640 medium (described, for example, by Menino and O'Claray, Biol. Reprod. 77:159 (1986), and Dienhart and Downs, Zygote 4:129 (1996)) that has been incubated with 5% CO 2 , 5% O 2 , and 90% N 2 at 37° C. The eggs are then stored in a 37° C./5% CO 2 incubator until microinjection.
[0278] Ten to twenty micrograms of plasmid DNA containing a Zserp11 encoding sequence is linearized, gel-purified, and resuspended in 10 mM Tris-HCl (pH 7.4), 0.25 mM EDTA (pH 8.0), at a final concentration of 5-10 nanograms per microliter for microinjection. For example, the Zserp11 encoding sequences can encode the amino acid residues of SEQ ID NO:2.
[0279] Plasmid DNA is microinjected into harvested eggs contained in a drop of W640 medium overlaid by warm, CO 2 -equilibrated mineral oil. The DNA is drawn into an injection needle (pulled from a 0.75 mm ID, 1 mm OD borosilicate glass capillary), and injected into individual eggs. Each egg is penetrated with the injection needle, into one or both of the haploid pronuclei.
[0280] Picoliters of DNA are injected into the pronuclei, and the injection needle withdrawn without coming into contact with the nucleoli. The procedure is repeated until all the eggs are injected. Successfully microinjected eggs are transferred into an organ tissue-culture dish with pre-gassed W640 medium for storage overnight in a 37° C./5% CO 2 incubator.
[0281] The following day, two-cell embryos are transferred into pseudopregnant recipients. The recipients are identified by the presence of copulation plugs, after copulating with vasectomized duds. Recipients are anesthetized and shaved on the dorsal left side and transferred to a surgical microscope. A small incision is made in the skin and through the muscle wall in the middle of the abdominal area outlined by the ribcage, the saddle, and the hind leg, midway between knee and spleen. The reproductive organs are exteriorized onto a small surgical drape. The fat pad is stretched out over the surgical drape, and a baby serrefine (Roboz, Rockville, Md.) is attached to the fat pad and left hanging over the back of the mouse, preventing the organs from sliding back in.
[0282] With a fine transfer pipette containing mineral oil followed by alternating W640 and air bubbles, 12-17 healthy two-cell embryos from the previous day's injection are transferred into the recipient. The swollen ampulla is located and holding the oviduct between the ampulla and the bursa, a nick in the oviduct is made with a 28 g needle close to the bursa, making sure not to tear the ampulla or the bursa.
[0283] The pipette is transferred into the nick in the oviduct, and the embryos are blown in, allowing the first air bubble to escape the pipette. The fat pad is gently pushed into the peritoneum, and the reproductive organs allowed to slide in. The peritoneal wall is closed with one suture and the skin closed with a wound clip. The mice recuperate on a 37° C. slide warmer for a minimum of four hours.
[0284] The recipients are returned to cages in pairs, and allowed 19-21 days gestation. After birth, 19-21 days postpartum is allowed before weaning. The weanlings are sexed and placed into separate sex cages, and a 0.5 cm biopsy (used for genotyping) is snipped off the tail with clean scissors.
[0285] Genomic DNA is prepared from the tail snips using, for example, a QIAGEN DNEASY kit following the manufacturer's instructions. Genomic DNA is analyzed by PCR using primers designed to amplify a Zserp11 gene or a selectable marker gene that was introduced in the same plasmid. After animals are confirmed to be transgenic, they are back-crossed into an inbred strain by placing a transgenic female with a wild-type male, or a transgenic male with one or two wild-type female(s). As pups are born and weaned, the sexes are separated, and their tails snipped for genotyping.
[0286] To check for expression of a transgene in a live animal, a partial hepatectomy is performed. A surgical prep is made of the upper abdomen directly below the zyphoid process. Using sterile technique, a small 1.5-2 cm incision is made below the sternum and the left lateral lobe of the liver exteriorized. Using 4-0 silk, a tie is made around the lower lobe securing it outside the body cavity. An atraumatic clamp is used to hold the tie while a second loop of absorbable Dexon (American Cyanamid; Wayne, N.J.) is placed proximal to the first tie. A distal cut is made from the Dexon tie and approximately 100 mg of the excised liver tissue is placed in a sterile petri dish. The excised liver section is transferred to a 14 ml polypropylene round bottom tube and snap frozen in liquid nitrogen and then stored on dry ice. The surgical site is closed with suture and wound clips, and the animal's cage placed on a 37° C. heating pad for 24 hours post operatively. The animal is checked daily post operatively and the wound clips removed 7-10 days after surgery. The expression level of Zserp11 mRNA is examined for each transgenic mouse using an RNA solution hybridization assay or polymerase chain reaction.
[0287] In addition to producing transgenic mice that over-express Zserp11, it is useful to engineer transgenic mice with either abnormally low or no expression of the gene. Such transgenic mice provide useful models for diseases associated with a lack of Zserp11. As discussed above, Zserp11 gene expression can be inhibited using anti-sense genes, ribozyme genes, or external guide sequence genes. To produce transgenic mice that under-express the Zserp11 gene, such inhibitory sequences are targeted to Zserp11 mRNA. Methods for producing transgenic mice that have abnormally low expression of a particular gene are known to those in the art (see, for example, Wu et al., “Gene Underexpression in Cultured Cells and Animals by Antisense DNA and RNA Strategies,” in Methods in Gene Biotechnology , pages 205-224 (CRC Press 1997)).
[0288] An alternative approach to producing transgenic mice that have little or no Zserp11 gene expression is to generate mice having at least one normal Zserp11 allele replaced by a nonfunctional Zserp11 gene. One method of designing a nonfunctional Zserp11 gene is to insert another gene, such as a selectable marker gene, within a nucleic acid molecule that encodes Zserp11. Standard methods for producing these so-called “knockout mice” are known to those skilled in the art (see, for example, Jacob, “Expression and Knockout of Interferons in Transgenic Mice,” in Overexpression and Knockout of Cytokines in Transgenic Mice , Jacob (ed.), pages 111-124 (Academic Press, Ltd. 1994), and Wu et al., “New Strategies for Gene Knockout,” in Methods in Gene Biotechnology , pages 339-365 (CRC Press 1997)).
[0289] From the foregoing, it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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Members of the serine protease family play a role in carefully controlled processes, such as blood coagulation, fibrinolysis, complement activation, fertilization, and hormone production. The enzymatic activity of the serine proteases is regulated in part by serpins, serine protease inhibitors. Serpin dysfunction is associated with various disorders, including emphysema, blood clotting disorders, cirrhosis, Alzheimer disease, and Parkinson disease. Zserp11 is a new member of the serine protease inhibitor family.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a method for injecting electrical energy and a device, in particular a wind power installation, for injecting the electrical energy.
[0003] 2. Description of the Related Art
[0004] Nowadays, electric grids, which may be hereinafter also simply referred to as electric nets or electric networks, are increasingly supplied by regenerative sources of energy, such as wind power installations or wind farms exhibiting a different electrical behavior than common large-scale power plants, which employ at least one large-scale generator for injecting current. This means that such large-scale generators are being increasingly replaced with other injection units, such as cyclo-inverters. This is also referred to by experts as substitution. Countries like Germany, in particular, have a comparatively high degree of substitution, which means that comparatively many generators are replaced with other injection units. This may also have fundamental effects on the grid. The main concerns are that the possible balancing effects of the former injecting generators might be lost or at least weakened with an increasing degree of substitution.
[0005] This is why the proposed European Network Directive ENTSO-E provides for network operators to be able to demand an asymmetrical current injection. Here, the notion of symmetry or asymmetry relates to the correlation of the three phases of a three-phase grid to each other. Especially in the case of an asymmetrical disturbance in the grid, for example a short circuit between two phases or a short circuit of one phase to ground, it is provided to inject the electrical energy in as compensatory a manner as possible. A disturbance is to be assumed, in particular, if the actual voltage in the grid of at least one phase departs by more than 10% from its set point value and/or its rated value.
[0006] Initial objectives do exist, but they may not be reaching far enough.
[0007] The German Patent and Trademark Office has researched the following prior art in the priority application: DE 10 2006 054 870 A1; U.S. Pat. No. 7,423,412 B2; ANDERSSON, G.: Elektrische Energiesysteme—Vorlesungsteil EnergieUbertragung, p. 127-147, EEH—Power Systems Laboratory, ETH Zurich, September 2009; Symmetrische Komponenten, in Wikipedia, Die freie Enzyklopadie (Wikipedia, the free encyclopedia), Version of 23 Apr. 2012, URL: http:de.wikipedia.org/w/index.php?title=Symmetrische_Komponenten&oldid=102361863 [called up on 29 Jul. 2012].
BRIEF SUMMARY
[0008] One or more embodiments of the present invention are directed to improving grid quality or, at least, for making a contribution so that the grid quality does not become worse or significantly worse. It shall at least propose one alternative solution to already known concepts.
[0009] Hence, electrical current is injected into the three-phase grid by means of an injection unit at a grid connection point. In addition, an asymmetry is recorded in the grid, which can be done, in particular, by recording a negative sequence component. An asymmetrical current portion is injected into the grid in answer thereto, in order to compensate for at least part of the recorded asymmetry. In this context, it is proposed to inject this asymmetrical current portion such that the injection unit behaves like a consumer in the area of the so-called negative sequence. The targeted injection of the asymmetrical current portion, i.e. the targeted asymmetrical injection, takes place by means of a corresponding definition of such consumer. This type of solution is based on the idea of seeing the injection unit's behavior as part of the grid and considering it in the overall behavior of the grid.
[0010] The consumer is preferably referred to as impedance Z − and defined by means of the following equation:
[0000]
Z
_
-
=
Z
n
jϕ
-
k
-
.
[0011] Impedance Z − is thus defined by the value of rated impedance Z n , adjustment phase angle φ − and scalar adjustment factor k − .
[0012] The value of rated impedance Z n can be defined through the following equation:
[0000]
Z
n
=
V
n
2
S
n
.
[0013] This value of impedance Z n is thus calculated from line voltage V n , which here goes quadratically into the numerator, and from the injected apparent power S n , which here goes in the denominator of the quotient. Solely by way of precaution, it is pointed out that Z n is referred to as the value of the rated impedance for the purpose of better illustration. For, in fact, the value of impedance Z − does also depend on the adjustment factor k − and on the adjustment phase angle φ − .
[0014] The value of the negative impedance can thus be adjusted via the adjustment factor k − and the adjustment phase angle φ − , and is hence presettable as needed. It is moreover proposed to preset the adjustment phase angle as needed. The idea is thus to go further and to not merely provide, for example, a reactance, i.e., an impedance with an adjustment phase angle of 90° or, respectively, −90°, whereby the angle—like the amplitude—is also set as needed.
[0015] According to one embodiment, it is proposed to set the adjustment factor k − and the adjustment phase angle φ − of the impedance based on at least one net property. Thus, the specification or setting of such impedance is not only geared to current conditions within the grid, which is basically also referred to as a net to simplify matters, but it also takes into account net properties, i.e., properties of the grid. The voltage level in the grid, an existing asymmetry, or even a disturbance in the grid are examples of grid conditions. The grid reactance to resistance ratio, which is also referred to as the XR ratio, is an example of a grid property. This and other net properties must be seen in particular in relation to the grid connection point. Therefore, such grid properties regularly also depend on the geographical position of the grid connection point, at any rate in relation to the grid concerned.
[0016] It is thus proposed to not only look at the current grid conditions but also at the grid properties.
[0017] The adjustment phase angle φ is preferably set within a range of 0°-90°. The bigger the grid reactance to resistance ratio at the grid connection point—i.e., the bigger the XR ratio—the bigger such angle will be set. In the case of a large XR ratio, for example in a range of 10-15, the adjustment phase angle may be set close to 90°. If that ratio is smaller, for example having a value of 2, the aforementioned angle may be proposed to be set in a range of 50°-60°. Hence, this grid property, which may be also a net feature, can be considered in addition to the conditions within the grid.
[0018] Preferably, an equivalent circuit diagram of the grid will be prepared for the injection point to serve as a basis for adjusting the consumer, in particular the impedance. In particular, the adjustment phase angle φ − and/or the adjustment factor k − will be adjusted based on the identified equivalent circuit diagram. Such equivalent circuit diagram, which in particular is supposed to reflect relevant grid properties, may even be prepared once or at least rarely at the grid connection point or in relation to the grid connection point. Such equivalent circuit diagram reflecting the grid properties thus is not subject to any, or is subject only to minor changes, like the described grid properties. In any event, the grid properties will basically change more rarely or slowly than the grid conditions.
[0019] The asymmetry of the grid is preferably identified by identifying or determining a grid negative sequence component of the voltage within the grid. This means that the voltages of the three phases are identified and broken down into a positive and negative sequence according to the method of symmetrical components. For the sake of completeness, it is pointed out that the zero sequence, which is also included in the theory of the method of symmetrical components, is to be regularly disregarded. Asymmetry thus can be easily considered by looking at the negative sequence component. According to one embodiment, it is moreover or additionally proposed that the asymmetrical current portion be specified or injected as a negative sequence component. A negative sequence component is thus not only used for measuring, but also for concrete injection or at least preset for injection.
[0020] An inverter is preferably used as an injection unit. At any rate, the injection unit comprises such an inverter and uses it to a significant degree for injecting the electrical energy. The use of such an injection unit allows for the injection of regeneratively generated electrical energy into the grid under consideration of grid requirements. By means of such an inverter, the current to be injected may be basically also adjusted dynamically according to value, frequency and phase. In this way, the inverter that is used as an injection unit may be set to exhibit the behavior of a consumer or to show impedance as a property, as desired.
[0021] Preferably, the proposed method also includes checking the grid for an asymmetrical system incident. Asymmetrical injection, as described in at least one of the above embodiments, is proposed in the case that no asymmetrical system incident has been detected. This means that the injection unit is to behave like a consumer, in particular impedance, if there is no asymmetrical system incident. These methods, as described, are hence provided in particular to consider—and especially enhance—grid quality during normal operation of the electric grid.
[0022] According to one embodiment, current is injected into a medium-voltage grid, and to this end the adjustment phase angle φ − is set to a value in the range of 40°-70°, in particular 50°-60°. When it comes to medium-voltage grids, one must reckon with a comparatively small XR ratio, for example in the range of 2. It is thus proposed to set a corresponding impedance that, due to the aforementioned adjustment phase angle, is better adapted to the nature of such a medium-voltage grid than when using a different adjustment phase angle, especially a larger adjustment phase angle.
[0023] What is further proposed is a wind power installation for injecting electrical energy generated from wind energy, which is prepared for the application of a method pursuant to at least one of the above-described embodiments. Such wind power installation for injecting current will, in particular, feature an inverter as an injection unit.
[0024] With such inverter or other injection unit, a counter current component is injected and thus the impedance of the negative sequence is specified.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025] The invention is described in more detail below based on embodiments with reference to the accompanying figures.
[0026] FIG. 1 shows a wind power installation in a perspective view.
[0027] FIGS. 2 a to 2 c explain the concept of asymmetrical current injection.
[0028] FIG. 3 explains the proposed injection method according to one embodiment.
DETAILED DESCRIPTION
[0029] FIG. 1 shows a wind power installation 100 with a tower 102 and a nacelle 104 . A rotor 106 with three rotor blades 108 and a spinner 110 is located on the nacelle 104 . When in operation, the rotor 106 is set into rotation by the wind and thereby drives a generator in the nacelle 104 .
[0030] The following is explained with reference to FIGS. 2 a , 2 b and 2 c.
[0031] The fundamental frequency content of voltages (and currents) is represented via phasors in symmetrical components
[0000] v a =√{square root over (2)} V a cos(2π ft+φV a ) V a =V a e jφV a
[0000] v b =√{square root over (2)} V b cos(2π ft+φV b ) V b =V b e jφV b
[0000] v c =√{square root over (2)} V c cos(2π ft+φV c ) V c =V c e jφV c
[0000] and transformed as usual:
[0000]
V
_
0
V
_
+
V
_
-
=
1
3
1
1
1
1
j
2
3
π
j
4
3
π
1
j
4
3
π
j
2
3
π
V
_
a
V
_
b
V
_
c
[0032] The unbalancing level used as a metric for unbalancing is given by the ratio of the magnitudes of the negative respective zero and positive sequence phasor:
[0000] V — /V + respectively V 0 /V +
[0033] Grid connected inverters can be interpreted by typical (time and state dependent) equivalents with respect to fundamental frequency and (quasi-) steady state operation conditions. One option applicable for non-isolated operation conditions of the inverter is an impedance equivalent ( FIG. 2 a ). Due to the vector group of the transformer in the test power system a zero sequence equivalent is not of relevance for the inverter operated. The positive sequence impedance is determined by the standard power control layer of the inverter FACTS-control architecture, the negative sequence impedance is controlled by additional ACI-control ( FIG. 2 c ).
[0034] Both sequence impedances influence the physical behavior simultaneously. They depend on actual terminal sequence voltages and the actual magnitude and reference of the currents of the inverters which are independently controlled for positive and negative sequence ( FIG. 2 b ). Negative real parts of the impedances indicate injection of active power in the grid, for reactive power negative imaginary parts respectively. Interpretation of this representation is limited to non-isolated operation conditions of the inverter.
[0035] With respect to the magnitudes of the sequence-voltages the power exchange between inverter and grid during normal operation condition will be absolutely dominated by the positive sequence. Positive sequence impedance during normal operation condition therefore can be interpreted as consequence from actual total inverter-power and actual positive sequence terminal voltage.
[0036] Negative sequence impedance specified from independent ACI-considerations will be achieved via negative sequence inverter-currents depend on actual negative sequence terminal voltage. This functionality provides an additional ACI control-module which belongs therefore to the power control layer of the architecture of inverter-control applied ( FIG. 2 right). Vector control generates the input signal for PWMcontrol as usual.
[0037] The abbreviation ACI stands for “Asymmetrical Current Injection”. Solely by way of precaution, it is pointed out that FACTS stands for “Flexible AC Transmission System,” a term also commonly used in German language professional circles.
[0038] FIG. 2 a hence illustrates the layout of the control unit of an inverter 2 according to one embodiment such that it is broken down into the control and injection of portion 4 in the positive sequence and the control and thus injection of portion 6 in the negative sequence. This means that, for the positive sequence, an impedance Z + is controlled, which has a real portion that is negative and which can be defined by the values I + V + . Accordingly, the negative sequence uses the impedance Z − and thus the electrical values I − V − .
[0039] The meaning of these two impedances Z + and Z − is shown on a complex level in the diagram of FIG. 2 b.
[0040] FIG. 2 c shows by means of a wiring diagram, part of which is shown as a block diagram, how injection takes place according to one embodiment.
[0041] At the three-phase grid 8 , which has phases marked with letters a, b and c, the voltage v(t) of all three phases is recorded at measuring point 10 and supplied to breakdown block 12 . Breakdown block 12 breaks down the thus recorded three-phase system into the positive sequence component of voltage v + and the negative sequence component of voltage v − . The result, along with the positive and negative sequence components of the voltage, is delivered to injection default block 16 via yet another calculation block 14 , which determines required values, such as the reactive power Q. Injection default block 16 then determines the positive and negative sequence portions that are to be injected of the current that is to be injected, and to this end determines a d-portion and a q-portion each for the positive sequence current and for the negative sequence current. This may be also indicated in abbreviated form as d−, q−, d+ and q+. Information on the DC link voltage Vdc may also be delivered to injection default block 16 . Calculation block 14 and, in particular, injection default block 16 thus form power control block 18 .
[0042] The values gathered from power control block 18 , in particular from injection default block 16 , are supplied to vector control block 20 , which in negative sequence block 22 or, respectively, in positive sequence block 24 determines the corresponding vectors for controlling the respective phase to be injected. In addition, negative sequence block 22 and positive sequence block 24 exchange information with breakdown block 12 . To this end, conversion block 26 converts the two vectors of the positive and negative sequence of the current to be injected into the concrete parameters of the phase currents to be injected and supplies this information to phase blocks 28 a , 28 b or, respectively, 28 c . To this end, block 26 determines the individual currents i aref , i bref or, respectively, i cref pursuant to the following calculation: i aref =i− aref +i+ aref +; i bref =i− bref +i+ bref or, respectively, i cref =i− cref +i+ cref . These values are then delivered to tolerance band control blocks 30 a , 30 b or, respectively, 30 c in inverter block 32 . Tolerance band control blocks 30 a , 30 b or, respectively, 30 c then perform concrete actuation of the inverter bridges of inverter 34 via a known tolerance band control and may, in the process, consider the actual current i(t).
[0043] FIG. 3 shows grid 15 as the starting point of control according to one embodiment. Grid 50 acts in particular through measurements onto a very general control, which is marked as grid control block 52 . In order to adjust an impedance Z − , such general grid control may specify values for the adjustment factor k − or, respectively, k AB − and for the adjustment phase angle φ − or, respectively, φ AB − . Here, index AB means normal operation of grid 50 , i.e., operation without any system incidents. But there may be certain asymmetries.
[0044] FIG. 3 also suggests that in the case of an asymmetrical disturbance, a constant value, such as 2, is set for adjustment factor k − or, respectively, k VNSR − . In such case, an absolute value of 90° is specified for adjustment phase angle φ − or, respectively, φ VNSR − . VNSR here means “Voltage Negative Sequence Reactance,” whereby for the negative sequence a reactance is specified in the case of a disturbance. In such case of an asymmetrical disturbance in the grid, no variable adjustment phase angle φ − is used; instead, a pure reactance is applied as a consumer.
[0045] Inverter control block 54 controls inverter 2 accordingly. Here, inverter 2 corresponds to that in FIG. 2 a , and reference sign 54 for an inverter control block 54 has also been used in FIG. 2 a . However, FIG. 2 a and FIG. 3 are schematic illustrations and may differ in terms of their details.
[0046] The controlling of inverter 2 by inverter control block 54 , as shown in
[0047] FIG. 3 , comprises various control processes, and reference is therefore again made to the control process explained in FIG. 2 c . However, when it comes to illustrating the aspect of how the impedance is specified, FIG. 3 illustrates only the delivery or rather action of adjustment factor k − and adjustment phase angle φ − onto inverter 2 . But inverter control is not limited to only specifying such values.
[0048] The dashed arrow also indicates a possible reaction of inverter 2 or of factors existing at inverter outlet 56 onto inverter control block 54 and thus onto the inverter control. Finally, inverter 2 releases a three-phase, asymmetrical current for injection at its inverter outlet 56 and injects it into grid 50 at grid connection point 60 via the illustrated transformer 58 .
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The present invention relates to a method for injecting electrical energy into an electrical, three-phase grid, comprising the steps of: injecting current by means of an injection unit at a grid connection point, detecting an asymmetry in the grid, in particular a negative sequence component in the grid, injecting an asymmetrical current portion into the grid for, at least, partial compensation of the detected asymmetry, with injection of the asymmetrical current portion taking place such that the injection unit behaves like a consumer.
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INCORPORATION BY REFERENCE
The following documents are incorporated herein by reference as if fully set forth: International Application No. PCT/DE2012/000390, filed Apr. 16, 2012; German Patent Application No. 102011100842.3, filed May 6, 2011; and German Patent Application No. 102011102814.9, filed May 30, 2011.
BACKGROUND
The invention relates to a hydraulic section for actuating a vehicle clutch.
During the actuation of a clutch pedal and therefore the pressure loading of a hydraulic fluid within a hydraulic section for clutch actuation, including essentially of a master cylinder which is connected to a clutch pedal, a slave cylinder, and a hydraulic line which connects said cylinders, it is known that air can accumulate in the end region of said hydraulic section, at the slave cylinder. Although this quantity is low, it has a negative effect on the disengagement travel at the slave cylinder in order to actuate the clutch. For this reason, as is known, the hydraulic line is laid so as to rise between the master cylinder and the slave cylinder, in a direction of the master cylinder, with the result that the introduced air is transported in the direction of the master cylinder in the form of one or more bubbles during the operation of the vehicle as a result of the buoyancy forces, and said air can escape into the reservoir via the snifting bore of said master cylinder.
It can occur, however, that the installation space does not allow a continuously rising course of the hydraulic line in the direction of the master cylinder to be realized.
SUMMARY
It is therefore the object of the invention to provide a hydraulic section for actuating a vehicle clutch, the ventilation of which is ensured via the master cylinder during operation, without the use of an additional component and without a continuously rising pathway of the hydraulic line in the direction of the master cylinder.
This object is achieved by way of a hydraulic section for actuating a vehicle clutch having one or more features of the invention.
According to one aspect of the invention, a hydraulic section for actuating a vehicle clutch having a master cylinder, a slave cylinder, and a hydraulic line which connects both cylinders is divided by a ventilating device into two line sections, said line sections of the hydraulic line which act as siphon and riser being guided together to said ventilating device, such that they are spaced apart from one another, in a chamber which is formed from at least one of these ends to said ventilating device.
In one advantageous refinement of the invention, the end of the siphon is configured as a connector of the ventilating device and the end of the riser is configured as a housing. However, it is also possible to configure the end of the siphon as a housing and the end of the riser as a siphon.
It is advantageous here that the end of that line section of the hydraulic line which acts as siphon opens with its hole laterally at the top into the chamber, and the lower inner wall of the end of the hole of that line section of the hydraulic line which acts as riser forms the lower boundary of the chamber in the radial direction.
It is advantageous here that there is a height difference between both holes, in order to make air buoyancy possible.
A further advantageous embodiment of the invention provides that the hole is routed further with a length in the housing and the internal diameter of the housing is widened radially at least over a region of said length. However, it is also possible that the hole is not routed further in the housing which is formed, but rather ends at the latter if it is, for example, a separate component with a housing, which separate component is incorporated into the hydraulic section.
Furthermore, it is advantageous that the radial widening of the internal diameter of the housing forms the chamber in the housing in the axial direction at least over said region. A further advantageous embodiment of the invention provides that the ventilating device is arranged in the hydraulic line at the highest point of the line section which comes from the slave cylinder.
The boundary of the chamber in the axial direction in the interior of the housing is formed advantageously by the end face of the connector which is introduced into the housing.
It is likewise advantageous to insert a ventilating device which is provided with connections as a separate component into the hydraulic section.
A further advantageous refinement of the invention provides that the hydraulic section is provided with a plurality of ventilating devices.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following text, the invention will be explained in greater detail using one exemplary embodiment and associated drawings, in which:
FIG. 1 is a diagrammatic illustration of one embodiment of a hydraulic section according to the invention for clutch actuation during a disengaging operation,
FIG. 2 shows the hydraulic section from FIG. 1 during an engaging operation,
FIG. 3 is a diagrammatic illustration of a further embodiment of a hydraulic section according to the invention, and
FIG. 4 shows an enlarged ventilating device in section, which ventilating device is introduced into the hydraulic section according to FIGS. 1 to 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a hydraulic section 1 for clutch actuation in two different operating positions. The hydraulic section 1 is formed essentially of a master cylinder 3 and a slave cylinder 2 . These cylinders are connected to one another via a hydraulic line 4 . As is apparent from FIGS. 1 and 2 , the hydraulic line 4 is laid so as to rise in the direction of the slave cylinder 2 , it being possible for the air 6 which is present in the hydraulic line 4 to be transported to the master cylinder 3 via a line section which falls in the direction of the master cylinder 3 , and acts as a siphon 4 a and is therefore called siphon 4 a , in which master cylinder 3 a ventilating device 5 which is introduced into the hydraulic line 4 at the highest point of the line section which comes from the slave cylinder 2 therefore prevents, at the start of the siphon 4 a , the air 6 which is situated in the hydraulic section 1 from moving back in the direction of the slave cylinder 2 during the disengaging operation.
Here, the line section which is situated upstream of the siphon 4 a is called riser 4 b.
After the disengaging operation according to FIG. 1 , the air 6 in the riser 4 b upstream of the siphon 4 a is displaced in the direction of the slave cylinder 2 . Since the time between the disengaging operation and the engaging operation is usually small and the air 6 is compressed greatly by the system pressure and therefore has considerably lower buoyancy forces, the air 6 in the riser 4 b before the engaging operation ( FIG. 2 ) virtually does not rise in the riser 4 b upstream of the siphon 4 a , as a result of which the following applies to the permissible volume in the region of the siphon 4 a:
V siphon <V swept,standard −V riser , where
V swept,standard is the swept volume which the slave cylinder 2 displaces during the disengaging operation, and
V riser is the volume in the riser 4 b between the siphon 4 a and the air bubble 6 after the disengaging operation.
In this hydraulic section 1 according to the invention with an integrated ventilating device 5 , furthermore, V riser is relatively small, that is to say the volume of the siphon 4 a can be selected to be large.
FIG. 3 shows a further embodiment of a hydraulic section 1 according to the invention, in which any desired siphon heights and therefore components in the engine compartment can be overcome as a result of a plurality of siphons 4 a with a respectively incorporated ventilating device 5 being connected behind one another.
FIG. 4 shows a sectional illustration of the ventilating device 5 which is incorporated into the hydraulic section 1 . This ventilating device 5 is formed essentially of a housing 10 which is configured as a bush which is molded or welded, for example, to the line section which acts as siphon 4 a , in order to ensure that it is seated in a positionally correct manner and a further anti-rotation safeguard can therefore be dispensed with.
A connector to the slave cylinder 2 can also be provided on the housing 10 . The housing 10 can then be attached directly to the slave cylinder 2 , by way of an anti-rotation safeguard with respect to the slave cylinder 2 .
The basic concept of the construction of said ventilating device 5 is to radially enlarge the region of the hydraulic line 4 at its end over a predefined region to such an extent that the hydraulic fluid flows through completely or partially below the air bubble 6 in the direction of the slave cylinder 2 when flowing through this space which is formed. This region of the hydraulic line therefore forms the actual ventilating device 5 , without the use of an additional housing or component.
However, the ventilating device 5 can also be configured as a separate component which is inserted between the two line sections.
As can be seen from FIG. 4 , the housing 10 is constructed as follows:
On the end side of the housing 10 , that end of the hydraulic line 4 which is configured in the form of a connector 11 is inserted sealingly into said housing 10 to such an extent that a chamber 14 which is preferably of cylindrical configuration, just like the housing 10 , remains upstream of the connector 11 which is penetrated by a hole 12 . The inlet, in the form of a hole 13 , which comes from the slave cylinder 2 is situated at the opposite lower end of the chamber 14 . This is arranged in the housing 10 and dimensioned in such a way that the hole 12 of the connector 11 lies as high as possible above the hole 13 of the inlet of the slave cylinder 2 , that is to say the axis of symmetry of the hole 12 of the connector 11 and therefore of the inlet of the master cylinder 3 lies parallel to and spaced apart from the axis of symmetry of the hole of the inlet of the slave cylinder 2 .
Due to both holes 12 , 13 , which are spaced apart from one another, of the inlets being guided together from the side and from below into the chamber 14 , the flow speed of the hydraulic fluid which flows from the master cylinder 3 to the slave cylinder 2 which is enriched with air is reduced.
At the same time, during this slowing of the flow speed, the air rises in the form of an air bubble 6 into an upper region of the chamber 14 and remains on the vertical wall there. As a result, the hydraulic fluid is displaced and “falls” below said air bubble 6 , as a result of which it passes via the hole 13 into the connector of the slave cylinder 2 .
If the fluid flows from the slave cylinder 2 to the master cylinder 3 , the moving hydraulic fluid column moves the air bubble 6 through the hole 12 of the connector 11 , or of the inlet of the master cylinder 3 , as a result of which said air bubble 6 can be transported further away from the slave cylinder 2 via the siphon 4 a out of the hydraulic section 1 in a customary way.
LIST OF ELEMENTS
1 Hydraulic section
2 Slave cylinder
3 Master cylinder
4 Hydraulic line
4 a Line section/siphon
4 b Line section/riser
5 Ventilating device
6 Air bubble
10 Housing
11 Connector
12 Hole
13 Hole
13 a Inner wall
14 Chamber
15 Region
A Region
L Length
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A hydraulic section ( 1 ) for actuating a vehicle clutch having a master cylinder ( 3 ), a slave cylinder ( 2 ) and a hydraulic line ( 4 ) which connects both cylinders and is divided into two line sections by a ventilating device ( 5 ). The line sections of the hydraulic line which act as a siphon ( 4 a ) and a riser ( 4 b ) are guided together to said ventilating device ( 5 ), such that they are spaced apart from one another, in a chamber which is formed from at least one of these ends.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to low voltage digital to analog converters. Specifically, the present invention relates to current summing converters implemented in MOS technologies.
2. Discussion of the Related Art
One of the most important aspects in the design and manufacturing of data acquisition products is the availability of high precision components. For example, video displays often are controlled by R, G, and B signals (Red, Green, and Blue Signals) which are analog voltages produced by digital to analog converters. The inputs to the digital to analog converters are the digitally encoded display data. In order to display image data with the precision at which it is encoded with minimum power, it is important for the digital to analog converter to be as accurate as possible. Virtually all data conversion products are therefore based on some type of binary weighted precision element or precisely controlled time.
In the case of digital to analog converters, transistors themselves can be used as the binary weighted component. Numerous designs using both bipolar as well as MOS technologies have used transistors as the weighted components. However, without some form of error correction, the use of MOS transistors as binary weighted current sources provides an analog output only accurate to at most eight bits of precision. In other words, the output voltage is only accurate to within one two-hundred-fifty-sixth of the overall output voltage swing.
Current summing digital to analog converters are popular due to their high speed characteristics and simplicity which make them ideal for video applications. A current summing digital to analog converter is essentially the reverse of the popular "flash" approach used in analog to digital converters. Both the current summing and flash architectures are limited to the propagation delay of the logic and settling time at the output. The conventional current summing and flash configurations are asynchronous, thus there are no clocks and the noise is primarily due to the logic switching. The logic in these architectures is usually straightforward because the conversions are performed in one step. Because the architecture is asynchronous, the noise is dependent on the input code. This contrasts with synchronous type converters (successive approximation register, constant slope, etc.) in which output noise is correlated with the system clock.
In conventional current summing topology, the precision in the matching of the currents becomes the limiting factor in the resolution of the converter. Unfortunately, the matching of currents is primarily dependent on two factors: the W/L ratio and drain-to-source voltage (V ds ). The practical limitation for conventional current summing techniques allows at most eight bit digital numbers to be accurately converted into analog.
In contrast, in charge redistribution type converters, the precision of the matching is only dependent on the area of the capacitor. Therefore, charge redistribution types of converters can achieve accuracy to within twelve bits of resolution without any error correction. However, the primary disadvantage of the charge redistribution algorithm is that the maximum speed is limited to only several MHz. Therefore, the charge redistribution converters are not practical for many video applications.
For high speed applications, the more conventional current summing approach is favored as illustrated in FIG. 1. In the circuit of FIG. 1, the unit current is given the value I and is increased in a binary weighted fashion. Depending on the binary code, the binary weighted currents are then switched either to the current outputs V OUT 111 or V OUT 112 which are then summed at the output and forced through resistors to produce an output analog voltage.
FIG. 1 illustrates a conventional MOS current summing digital to analog converter 100. A reference current I REF 101 is generated and draws current through a reference current transistor 102. The reference current transistor 102 is connected such that the drain and gate are connected. Thus, the reference current transistor 102 acts as the master of several current mirrors. This allows the gate of the reference current transistor 102 to settle to whatever voltage is necessary to bias the reference current transistor 102 in saturation such that a current of I REF flows through it. The gate of the reference current transistor 102 is a reference voltage 117 which is distributed to several slave transistors. In FIG. 1, two slave transistors 103 and 104 are illustrated. If the slave transistor 103 has the same channel width divided by channel length ratio (W/L) as the master transistor 102, then the drain current I of the slave transistor 103 equals I REF from the current source 101.
The digital to analog converter 100 illustrated in FIG. 1 is designed to convert an n+1 bit binary number having most significant binary digit bn and least significant binary digit b0 into an analog voltage V OUT 111 and its analog compliment V OUT 112. Thus, the n+1 bit binary input code assumes a value of any integer between zero and 2 n+1 -1, inclusive. By construction, the least significant input bit is subscripted with zero rather than one, resulting in an n+1 bit (rather than n bit) binary input number. The most significant digital input bit is bn 115 and its compliment is bn 116. The least significant digital input bit is b0 113 and its compliment b0 114. A variable number of intermediate digital input bits which are not illustrated in FIG. 1, but whose existence is alluded to by the dashed lines connecting the least significant and most significant current stages. Because the binary digital input codes are weighted by various powers of two, the most significant current stage which is controlled by the binary digital input bn and is supplied by the slave current through transistor 104, the drain current through the most significant weighted current slave transistor 104 is I*2 n .
Each weighted current slave transistor 103 and 104 illustrated in FIG. 1 is biased with a constant current. For example, the current I through the weighted current slave transistor 103 is conducted either through the non-inverting differential transistor 105 which is controlled by b0, or through the inverting differential transistor 106 which is controlled by b0. The drains of all of the non-inverting differential transistors 105 and 107 are connected such that the non-inverting currents are summed together and forced through the resistor 109 to create the output voltage V OUT 111. Similarly, all of the inverting differential transistor drains 106 and 108 are connected such that their output currents are summed and are forced across the resistor 110 to create the inverted output voltage V OUT 112. Because the total amount of current carried through all of the weighted current slave transistors 103 and 104 is constant, the sum of the voltages V OUT 111 and V OUT 112 is a constant.
If the current characteristic of a saturated MOS transistor were not dependent upon the source to drain voltage, then the configuration shown in FIG. 1 would be adequate and would be highly accurate and precise. However, saturated MOS transistors are non-ideal current sources and are more accurately characterized with the Shichman-Hodges model given by the following equation. ##EQU1##
If it is assumed that the variations in mobility (μ o ), gate-to-source voltage (V gs ), threshold voltage (V t ), and capacitance per unit area (C ox ) effects are negligible compared to the other parameters, then the above equation demonstrates that the current is primarily dependent on the W/L ratio of the transistor. For precise current matching, equally important is the incremental change in the output current to an incremental change to the drain-to-source voltage, which is more commonly referred to as the output resistance r o . The output resistance of a MOS transistor in its forward active region is much less than the output resistance of the same transistor in its linear region. In the above equation, λ is the channel length modulation factor.
In the conventional configuration illustrated in FIG. 1, the reference current transistor and the transistors carrying the binary weighted currents can experience V ds variations of several volts thus compromising the digital to analog converter accuracy to no better than 8 bits because the binary-weighted currents are no longer properly matched. The V ds variations will vary with different values of R1 and R2, Vdd, and I REF . Although an ideal value for the load resistors is 75 Ω, in practice, these resistances can vary from 50-125 Ω. Variations in the output resistances R1 and R2 nearly proportionally change the induced voltage at the outputs 111 and 112. Thus, drain voltage changes for transistors 103 and 104 are caused as explained below.
Because V ds of the differential transistors is less than V gs -V t for these transistors, the selected differential transistors are operating in the linear region, while the non-selected differential transistors are operating in cutoff. In the linear region, the behavior of a MOS transistor is controlled by the following equation. ##EQU2##
Typically, V ds for the selected differential transistors is approximately a constant and is relatively small. V ds for the selected differential transistor assumes a level appropriate to satisfy the above equation so that the drain current equals the binary weighted current for the relevant current switching stage. Because the selected differential transistors are in the linear region and V ds for the selected differential transistor is approximately constant, variations in the output voltages 111 and 112 are directly reflected as changes in the voltage at the drains of the saturated binary weighted current slave transistors 103 and 104. Because the saturated binary weighted current slave transistors 103 and 104 have a V ds dependency as described by the Schichman-Hodges model, the variations in the induced output voltages at 111 and 112 alter the magnitudes of the precisely matched binary weighted current slave transistors 103 and 104. These variations in the binary weighted current slave transistors results in gain errors because the binary weighted current slave transistors are no longer in the proper proportions to the reference current I REF .
Furthermore, the accuracy of the outputs of the circuit illustrated in the basic topology shown in FIG. 1 is compromised severely with variations in the supply voltage Vdd. This power supply variation induced output error is due to the changes in V ds of the binary weighted current slave transistors 103 and 104. Moreover, variations in I REF 101 compromise the accuracy of the outputs 111 and 112 beyond 6-8 bits of precision due to the fact that as I REF varies, so does the output current being summed by R1 109 and R2 110. The resulting error in the induced output voltages 111 and 112 are then reflected as errors in V ds of the binary-weighted current slave transistors 103 and 104.
As is apparent from the above discussion, a need exists for a high-precision, high speed, low power digital to analog converter which is immune to output errors created by non-ideal output resistances and fluctuations in power supply or reference currents.
SUMMARY OF THE INVENTION
In conventional current summing digital to analog conversion, the precise matching of the currents is the limiting factor in the accuracy of the converter. In practice, this configuration offers a maximum of 8 bits of resolution. Charge redistribution type converters achieve accuracy up to 12 bits, but are limited to only several megahertz and are, therefore, not practical for video applications.
One object of the present invention is providing a high precision digital to analog converter compatible with low voltage operation. In the presently preferred embodiment using modern process parameters, the resolution is 10 bits using a 3 volt supply. Another object of the present invention is to provide a high speed digital to analog converter suitable for video applications.
According to the present invention, an operational amplifier in a bias voltage generator of a MOS current summing digital to analog converter corrects deviations in output current due to variations in drain to source voltages in current slaves caused by differing output resistances and supply voltages. Matching of MOS current sources uses an operational amplifier feedback circuit to create a controlled turn-on reference voltage used for biasing selected differential current paths so as to eliminate drain to source voltage variations in precisely ratioed current slave MOS transistors.
One transistor of each differential current pair is enabled by a corresponding switch coupled to the turn-on reference voltage produced by the operational amplifier. In the preferred embodiment of the differential current switching stage, the switches are CMOS transmission gates enabled by the binary digital input and its complement. In an alternative embodiment of the differential current switching stage, the switches are simpler single transistor pass gates.
Low voltage (3 volts) operation is achieved by having minimum number of stacked transistors between power supply voltages. Reliable current matching allows converter resolution of 10 bits. Due to cascode switching action controlling alternative differential current paths, output current is independent of the load resistance at the output. The precisely ratioed current slave transistors are maintained in a saturated state, independently of load, so that the dependency of the output current to the drain to source voltage is minimized.
The operational amplifier samples the current bias reference used to bias the binary ratioed slaves and the drain of a current mirror and drives a feedback transistor gate and the enabled differential current paths with the turn-on reference voltage so that the precisely ratioed current slaves have the same drain to source voltage as the reference current transistor. The reference voltages produced are thereby independent of supply voltages and process.
These and other features and advantages of the present invention will be apparent from Detailed Description of the Invention in conjunction with the Figures, in which like reference numerals indicate like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
In FIGS. 1 through 6, like numerals label like parts.
FIG. 1 illustrates a conventional MOS current summing digital to analog converter.
FIG. 2 illustrates a five-bit current summing digital to analog converter according to the present invention.
FIG. 3 illustrates a MOS current summing digital to analog bias voltage generator according to the presently preferred embodiment of an aspect of the present invention.
FIG. 4 illustrates a MOS current summing digital to analog converter stage according to the preferred embodiment of another aspect of the present invention.
FIG. 5 illustrates an operational amplifier used in the presently preferred embodiment of the MOS current summing digital to analog bias voltage generator according to an aspect of the present invention.
FIG. 6 illustrates an n-bit MOS current summing digital to analog converter circuit according to the present invention.
The Detailed Description of the Invention fully describes the Figures in the context of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The digital to analog converter circuits according to the present invention are relatively immune to variations in supply voltage Vdd and reference current I REF . The matching of the binary-weighted MOS current sources to the current reference source I REF is greatly improved over the prior art. The present invention uses a feedback circuit having an operational amplifier to force the drain voltages of the binary weighted current sources to equal that of the reference current transistor.
FIG. 2 illustrates the architecture 200 of a MOS current summing digital to analog converter circuit according to the present invention. A bias voltage generator 201 produces a current bias reference output 202 and a turn on reference output 203 which are each routed to each of the current switching stages 204, 205, 206, 207 and 208. The bias voltage generator has power supply voltages of positive Vdd and ground. A reference voltage V REF is input into the bias voltage generator 201 to create the reference current used to generate the output reference voltages 202 and 203. Each converter current switching stage 204, 205, 206, 207 and 208 has only a Vdd positive power supply input. The primary architectural difference between the MOS current summing digital to analog converter 200 according to the present invention and the conventional converter 100 depicted in FIG. 1 is the inclusion of the second reference voltage 203 routed to each current switching stage. Specifically, the turn on reference output 203 of the bias voltage generator is unique to the architecture 200 of the MOS current summing digital to analog converter 200 according to the present invention.
FIG. 3 illustrates the presently preferred embodiment of the bias voltage generator 201 illustrated in FIG. 2 according to the present invention. The bias voltage generator includes a reference current transistor 301 which is driven by a reference current I REF that is produced by applying a reference voltage V REF to the gate of a generator bias transistor 302. A current mirror transistor 303 is biased by the current bias reference voltage 202. The current mirror transistor 303 drives the source of a feedback transistor 304 which drives the emitter of a diode-connected PNP bipolar current mirror sink transistor 305. An operational amplifier 306 drives the gate of the feedback transistor 304 and supplies the turn on reference voltage 203. The plus input of the operational amplifier 306 is connected to the current bias reference 202 while the minus input is connected to the drain of the current mirror transistor 303.
According to ideal operational amplifier theory, because the current into the operational amplifier plus input 307 and the current through the operational amplifier minus input 308 are approximately zero, the drain current through the current mirror transistor 303 and the drain current through the feedback transistor 304 are equal and are independent of circumstances outside the bias voltage generator 201. For example, referring to FIG. 2, regardless of the size of the resistances 209 and 210 or the magnitudes of the currents i0 through i4 or their complements, the drain currents through the current mirror transistor 303, the feedback transistor 304, and the current mirror sink transistor 305 are constant regardless of the circuit conditions in the current switching stages 204 through 208.
FIG. 4 illustrates a MOS current summing digital to analog converter stage 400 according to the presently preferred embodiment of the present invention. The non-inverting differential transistor 402 and the inverting differential transistor 403 have gate terminals which are carefully controlled. When the non-inverting differential transistor 402 is not selected to conduct the bias current carried through the current slave transistor 401, a non-inverting turn off transistor 404 pulls up the gate of the non-inverting differential transistor 402. Similarly, when the inverting differential transistor 403 is not selected, an inverting turn off transistor 405 turns off the inverting differential transistor 403. The non-inverting 404 and inverting 405 turn off transistors are controlled at their respective gates by the binary digital input bn and its logical compliment bn.
The terms "non-inverting" and "inverting" as used herein are merely to distinguish between two circuit elements which while otherwise similar to one another are nonetheless distinct from one another inasmuch as they are associated with, process or are controlled by, the non-inverted binary digital input bn and its logical complement (i.e., the inverted binary digital input) bn, respectively. Hence, for example, transistors 402 and 403, which are interconnected in a differential configuration, are identified as "non-inverting differential transistor 402" and "inverting differential transistor 403," respectively, and transistors 404 and 405, which are used to turn off transistors 402 and 403, are identified as "non-inverting turn off transistor 404" and "inverting turn off transistor 405," respectively.
Because the binary digital input and its compliment are used to enable the non-inverting 404 and inverting 405 turn off transistors, one of the non-inverting and inverting 405 turn off transistors is always enabled so as to pull up the gate of one of the differential transistors 402 and 403 so that one of the differential transistors 402 and 403 is disabled. It is desirable to enable the selected differential transistor 402 or 403 so that the entire current 2 n *I flowing throughout the weighted current slave transistor 401 is switched to the proper output node 409 or 410. To this end, a non-inverting turn on switch 406 is used to enable the non-inverting differential transistor 402 by connecting the turn on reference voltage 203 to the gate of the non-inverting differential transistor 402. Similarly, an inverting turn on switch 407 is used to selectively connect the turn on reference voltage 203 generated by the operational amplifier 306 to the gate of the inverting differential transistor 403.
In the preferred embodiment, the turn on switches 406 and 407 are implemented with CMOS transmission gates. The complementary control necessary for the CMOS transmission gates 406 and 407 is easily facilitated by the fact that both the inverting bn and non-inverting bn binary digital inputs are supplied to each current switching stage 400. However, there is no requirement that a transmission gate be used as the turn on switches 406 or 407. For example, as illustrated in FIG. 6, the turn on switches can be implemented as simple single-transistors pass gates 601 rather than transmission gates. In either case, the gate voltage of the selected differential transistor 402 or 403 is equal to the turn on reference voltage 203. When one of the differential transistors 402 or 403 is enabled, one of the turn on switches 406 and 407 is enabled such that the gate of the selected differential transistor 402 or 403 is controlled with the turn on reference voltage 203 while the other differential transistor 402 or 403 is turned off.
The result is that the current reference transistor 303 in the FIG. 3 is biased under the same circuit conditions as the weighted current slave transistor 401 in FIG. 4. In other words, the voltages at the gates, drains, and sources of the current reference transistor 301 and the weighted current slave transistors 401 are equal.
Similarly, the feedback transistor 304 in FIG. 3 is biased in the same way as the selected differential transistor 402 or 403. Because the current mirror transistor 303 and feedback transistor 304 in FIG. 3 are under identical conditions as the weighted current slave transistor 401 and the selected differential transistor 402 or 403 in FIG. 4, the drain 408 of the weighted current slave transistor 401 is at the exact same voltage as the drain of the current mirror transistor 303 in FIG. 3 which is connected to the operational amplifier minus input 308. Furthermore, ideal operational amplifier theory requires that the plus input and minus input to the operational amplifier are approximately equal for operational amplifier output voltages within the operational amplifier's forward active region.
Thus, in FIG. 3, the voltage at the minus input 308 is approximately the same as the voltage at the plus input 307 of the operational amplifier 306. In order to drive the drain of the current mirror transistor 303 shown in FIG. 3 such that the minus input 308 of the operational amplifier 306 is the same as the plus input 307, the operational amplifier 306 must produce a turn on reference voltage 203 which is just the right voltage to bias the feedback transistor 304 enough such that the gate and drain of the current mirror transistor 303 are exactly equal.
Since the selected differential transistor 402 or 403 is also controlled by the turn on reference voltage 203, the drain 408 of the weighted current slave transistor 401 equals the voltage of the minus input 308 of the operational amplifier 306. Therefore, the biasing of the weighted current slave transistors is independent of the resistances to which the outputs 409 and 410 in FIG. 4 are connected.
FIG. 5 illustrates the operational amplifier 306 as it is implemented in the presently preferred embodiment of the present invention. In FIG. 5, the presently preferred transistor W/L ratios are listed beside each of the transistors. The power supplies for the operational amplifier 306 are Vdd and ground similar to the rest of the circuit as shown, for example, in FIG. 2; therefore, no supply voltage higher than Vdd or lower than ground is required by the operational amplifier 306. The operational amplifier 306 is controlled by a voltage V BIAS which provides bias current to the rest of the circuit 306. The operational amplifier 306 illustrated in FIG. 5 is carefully implemented such that there are as few stacked transistors as is practical, so that the same low power supply voltages are used to power the operational amplifier 306 as are used to power the rest of the digital to analog converter circuit. A power supply voltage of 3 volts is compatible with the circuits of the present invention.
FIG. 6 illustrates an embodiment of the present invention which contrasts with the prior art circuit 100 as shown in FIG. 1. In FIG. 6 the turn on switches 601 are implemented with n-channel pass transistors 601 rather than CMOS transmission gates 406 and 407 as illustrated in FIG. 4. FIG. 6 also illustrates that the current mirror sink transistor 602 can be implemented with a diode-connected n-channel MOS transistor 602 rather than a diode connected PNP bipolar transistor 305 as illustrated in FIG. 3. The reference current I REF 602 can be generated outside the digital to analog converter circuit and connected to an input pin rather than being generated internally as illustrated by the transistor 302 in FIG. 3. In FIG. 6, the reference current I REF 602 is generated outside the digital to analog converter circuit and is connected to an input terminal 603 designed for providing the bias current.
The reference current, I REF 602, flows through M1 establishing the current bias reference line 202. This reference line 202 is fed to all the binary-weighted current slave transistors. In the diagram, M5 is only one of many currents which are summed to form the digital to analog converter as shown. In order to keep the drain voltage of M5 constant, the gates of M8 or M9 must be driven with controlled voltages. If standard logic voltages are used, the drain voltage of M5 will vary by several volts and result in uncontrollable current variations in M5 as discussed above. The resulting uncontrolled current results in matching degradation of the binary weighted slave currents which lead to resolution error in the digital to analog converter.
The primary purpose of this invention is to present a circuit which keeps the drain of M5 tracking the drain of M1. Once this is accomplished, the precise ratioing of the weighted currents is primarily dependent on the gate areas of the binary weighted devices and not on the drain to source voltages V ds of the weighted current slave transistors as in the prior art approach. In the following explanation on the operations of the proposed circuit, it is assumed that the ratioing of the channel W/L contributes no errors to the output. The circuit shown in FIG. 6 then works in the following manner. Transistors M1 and M2 are matched, and the W/L parameter of transistor M5 is ratioed to the W/L parameter of transistor M2. Transistors M1, M2, and M5 all have equal gate, source, and drain voltages. Transistor M3 and one of transistors M8 and M9 (the enabled one) have equal gate, source, and drain voltages. Transistors M2, M3, and M4 form a current path which simulates the voltage drops along each of the current switching stages.
The goal is to establish a turnon reference voltage which is independent of the power supply voltage Vdd and the process parameters, which is used to bias the current switches M8 and M9. To establish this voltage, a feedback loop utilizing an operational amplifier is incorporated. The operational amplifier samples both the current bias reference node 202 and the drain of M2 and uses M3 as its feedback path to control the voltage at the drain of M2 since the feedback transistor M3 serves as a source follower. When the operational amplifier is operating in its forward active region, V+ and V- of the operational amplifier are equal according to the ideal operational amplifier theory. The output of the operational amplifier settles to the correct voltage that forces V ds1 of transistor M1 and V ds2 of transistor M2 to be equal. This operational amplifier output 203 is then used to enable the selected differential transistors in the various binary-weighted current branches of the digital to analog converter array. Because the turnon reference signal 203 is controlled and is less than the positive supply voltage Vdd, the selected differential transistor (either M8 or M9) remains in the saturation region rather than the being permitted to drift into the linear region; therefore, its drain current dependency on V ds is minimized.
The circuit operates independent of supply voltage and process and is fully compatible with 3 volts operation. Because M5 and M12 stay in the saturation region due to the cascode switching action of M8 and M9, the binary weighted currents (I, 2 n *I, etc.) are not dependent on the output load resistors R1 and R2. The gain error with respect to I REF , which occurs due to V ds variations in M5, M12, etc. is also eliminated.
In order for the circuits according to the present invention to function properly, the operational amplifier's gain must be high enough to correct the mismatch in the bias voltage developed at the output of the operational amplifier. In other words, the operational amplifier's gain must be high enough to force v- of the operational amplifier to the same voltage as v+ within a given precision. As a general rule, the gain of the operational amplifier should be as high as the number of bits of precision desired from the digital to analog converter. For example, a 10 bit system should have at least 60 dBs of open loop gain. This is based on the assumption that each input bit provides about 6 dBs of dynamic range. The output of the operational amplifier labelled node 203 then is the correct voltage that when presented to the gates of M3, M8, M9, etc. will set the voltage properly at the drain of M5 (and other related devices) as the same voltage which is on the drain of M1, the reference transistor.
The present invention virtually eliminates the V ds mismatch problem. Because of its low number of stacked transistors, it is 3 volt compatible. This is primarily due to the combined multifunction cascode-switch which is formed by M8 and M9.
Those of ordinary skill in the art would be enabled by this disclosure to add to or modify the embodiment of the present invention in various ways as needed and still be within the scope and spirit of various aspects of the present invention. Accordingly, various changes and modifications which are obvious to a person skilled in the art to which the invention pertains are deemed to lie within the spirit and scope of the invention.
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An operational amplifier in a bias voltage generator of a MOS current summing digital to analog converter corrects deviations in output current due to variations in drain to source voltages in current slaves caused by differing output resistances and supply voltages. Matching of MOS current sources uses an operational amplifier feedback circuit to create a controlled turn-on reference voltage used for biasing selected differential current paths so as to eliminate drain to source voltage variations in precisely ratioed current slave MOS transistors. One transistor of each differential current pair is enabled by a corresponding switch coupled to the turn-on reference voltage produced by the operational amplifier. In the preferred embodiment, the switches are CMOS transmission gates enabled by the binary digital input and its complement. Low voltage (3 volts) operation is achieved by having minimum number of stacked transistors between power supply voltages. Reliable current matching allows converter resolution of 10 bits. Due to cascode switching action controlling alternative differential current paths, output current is independent of output resistance. The operational amplifier samples the current bias reference used to bias the binary ratioed slaves and the drain of a current mirror and drives a feedback transistor gate and the enabled differential current paths with the turn-on reference voltage so that the precisely ratioed current slaves have the same drain to source voltage as the reference current transistor. The reference voltages produced are thereby independent of supply voltages and process.
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BACKGROUND OF THE INVENTION
This invention relates to apparatus and a method for supporting, without marring an article such as an ophthalmic frame, which softens while being heated and which is subject to being marred while being heated.
The heating device this subject matter is concerned with, is radiant type heating or convectional hot air heating or both.
Particularly in radiant type heating are we concerned with the distance the object or article is from the radiation source. Since the temperature varies inversely to the square of the distance we want to be at a certain place relatively to the infrared generator so as not to be too cool or get too hot. Too close might mean scorching at a certain temperature setting of the machine while too far away would mean slower heating. Small variations in position when heating by convection makes little temperature difference and is not critical.
In radiant heating to keep the article close also means that physical contact with the heater parts is likely. This can mean heat dents, scratching and marring of the article, thus damaging it to some degree. The operator then tends to keep the article too far away or he sets the machine to a low setting thus taking longer to heat and at times underheating the article.
The present invention can accomplish the close positioning of the article to the radiator in the heater and at the same time eliminate any marring or damage to the article.
A prime object is to support a heat softened article while being exposed to heat without deformation or marring of its surface.
Another object is to provide tens of thousands of upwardly projecting but resilient filaments in carpet like arrangement which individually in supporting never press upwardly hard enough to impress their shape into the soft article and yet in their multitude effort are able to support the whole article.
Another important object is to provide a support which is transparent to infrared rays to allow their transmission past and through the support to the article.
Still another object is to take advantage of the phenomenon of fiber optics to transmit infrared rays to the article being supported through the carpet itself.
A further object is to provide a grid structure which allows free flow of air while serving as a support.
Another object is to support an article at a fixed distance from its radiant heat source to establish uniformity of heating of subsequent articles placed there, with the machine heating at a particular heat setting.
SUMMARY
This invention relates to carpet supports for articles composed of heat softening material whose surfaces are easily subject to deformation or other deleterious effects by reason of the weight of the article bearing down upon the supports when the article reaches its softening temperature. Fine filaments of glass fibers, vertically set, on end, in line with the direction of radiation and air flow serve to support an article set upon them. These pliant upstanding fibers in great multitude adapt to whatever conformity is needed to bear the object or article, each bearing upwardly with a pressure insufficient to indent its own form into the soft surface of the article while at the same time being greatly transparent to infrared rays but also transmitting the infrared rays from their bottom end to their top end, to the article by fiber optics effect.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan of an article heater showing a pair of eyeglass frames in dotted lines, being heated.
FIG. 2 is a front elevation of FIG. 1.
FIG. 3 is a vertical sectional view taken along line 3--3 in FIG. 1.
FIG. 4 is another vertical sectional view taken at 90° to FIG. 3 along line 4--4 in FIG. 1.
FIG. 5 is a greatly enlarged fragmentary section of the article support similiar to FIG. 3.
FIG. 6 is a fragmentary vertical cross section of a modified form of the invention.
FIG. 7 is a vertical section of another modified form. FIG. 8 is a plan view of a form jig.
FIG. 9 is a side elevation of FIG. 8.
FIG. 10 is a vertical section on line 10--10 of FIG. 8.
FIG. 11 is a vertical section of impregnated tapes.
FIG. 12 is another vertical section of a tape.
DETAILED DESCRIPTION
A heater housing 10 is shown in FIGS. 1 and 2 as having a flat top 11 provided with an opening 12 and is fastened upon a heater housing 13 by screws 14.
The housing contains regulated heating means 20 which may be electrical or otherwise, operable through a switch 21 to turn it on or off and controlled in temperature by a setting level 22 rotatable over a dial 23 to read the setting.
Legs 24 lift the housing 10 above the surface it is placed upon for entrance of air into the housing interior 25 through an opening (not shown) in its bottom 15. Air pressurizing means (not shown) is provided in the housing to cause an out flow of heated air past and through the heating means 20. The arrows 27 indicate this out flow of heated air as shown in FIGS. 3 and 4 as well as the direction of infrared radiation, which may be supplied by the heating means 20. The heater and housing may be of hot air type shown in U.S. Pat. No. 2,789,200 or of the radiant type shown in U.S. Pat. No. 3,816,705.
A frame member 30 is held to the top 11 by screws 31 and has an opening 32 which is larger than the opening 12 in the top 11. This frame member 30 provides a holding means for a grid carpet generally indicated at 40.
The grid 40 is the foundation for the subject matter of this application and in this form comprises a glass fiber fabric 41 having the usual woof yarns 42 interwoven with the warp yarns 43. The lower portion as seen in FIG. 5 has the woof and warp yarns impregnated with a thermosetting or other suitable resin or cementitious binder 45 thus fixing this lower portion in a rigid monolithic structure. The upper warp yarns 43 are removed as seen in FIG. 5 to provide the woof yarns 42 with an individual freedom characteristic of the hairs of a tuft of a camel hair brush and is indicated as 46.
Since an individual glass fiber has an outside diameter of about 0.0005 inch (five ten thousandths of an inch) it has great tensile strength, resiliency, great softness and is a carrier of infrared radiation.
A successful carpet support illustrated and described herewith was made, starting with a 2 inch wide fiberglass tape doubled upon itself to be one inch wide. The warp yarns numbered 18 to the inch while the woof yarns numbered 34 to the inch. Each of the warp and woof strands were comprised of three twisted threads and each thread was comprised of approximately 150 continuous monofilaments, thus giving each strand about 450 individual fibers five ten thousandths of an inch in diameter.
After manufacture and assembly into the grid 40 the rigid bound portion equalled three eights of an inch high and the tuft portion equalled three eights of an inch, giving a total of three quarters of an inch finished height. In making such a carpet support the density or number of vertically disposed fibers per square inch determine its support capability, thus it can be designed for supporting heavier or lighter articles.
As seen in FIG. 1 this grid 40 is the form of many lateral bars 50 across the narrow span of the frame 30 and opening 12. These bars 50 meet and join at their ends to a perimeter band 51 totally surrounding all of the bar ends. A cross section through the perimeter band would look just like that in FIG. 5.
FIG. 3 shows the perimeter band 51 fitting inside the opening 32 of the frame member 30 while the bars 50 cross over and span the opening 12 in the top 11 of the housing 10. In FIG. 4 it is clearly seen how a lateral bar 50 spans across the opening 12. These bars 50 provide the rigid support necessary to carry an opthalmic frame F shown in dotted lines in FIG. 1 and FIG. 2.
The grid 40 is fitted into the opening 32 of the frame 30 in any suitable way, is possibly cemented in place or the frame 30 might be molded around and with the grid 40.
It will be seen in FIG. 1 that the frame assembly 30 with grid 40 with the bars 50 and perimeter 51 are held in place by the screws 31.
The manner in which the just described grid was made will now be described.
METHOD OF MANUFACTURE
In FIG. 8 can be seen a form jig 300 which essentially comprises a base 301 and a plurality of dowels or pegs 302. These dowels might be placed in various locations and spacing other than those shown to get many other contours or grid configurations.
Shown in FIGS. 8 and 10 are a tape 41 wound about the jig 300 in the following manner. Starting at 310 the tape 41 is wound downwardly and around the lowermost dowel 302a and up and around dowel 302b, then down to 302c around and up and down over the pegs 302 as the dotted, arrowed, lines 350 illustrate until the dowel 302d in the lower right hand corner is reached. The tape 41 is then wrapped up and around dowel 302e and then over to the left, around dowel 302b and down to 302a, then over to the right to dowel 302d and then up to 302e where it is fastened to hold its end in place.
In FIG. 8 the up and down lines 350 would represent the lateral bars 50 while the dotted lines 351 represent the perimeter band 51 previously described.
The windings may be made of tapes of heavy or light, double or single, whatever density is required to support those particular articles, the carpet is to be used for.
The completely wound tape 41 on the form 300 is now inverted and dipped, as shown in FIG. 10 into an impregnating and hardening liquid 345. Of course instead of being dipped the liquid 345 could be painted on. This liquid may be an epoxy resin, other thermosetting compound or other cementitious material which will impregnate the fibers to bind them together mechanically. The form 300 with the wound and impregnated tape 41 is now removed from the liquid and the cement is allowed to harden or set. A rigid grid 40 has now been formed and it can be removed from the form 300 because it now is self supporting.
A cross section of a portion of the grid 40 is shown in FIG. 11 and would be typical of the locale of the section line 10--10 in FIG. 8. A section through the perimeter 51 and a looped portion of one of the bars 50 would look like FIG. 4, the loop portion now being joined to the perimeter 51 by the cement to make all of the runs 50 and 51 integral.
The lower edges 349, FIG. 11, of the grid 40 are next ground off and polished to form the optically receptive faces 47, shown in FIG. 5 and the upper ends of the woof strands 42 are cut at 348, FIG. 11, to form the upper terminal ends 46, in FIG. 5. These ends 46 may be trimmed flush with each other or may be cut to give a textured surface.
Upper warp strands 43 are now stripped off from their inter-weaving with the woof strands 43, down to the upper limit of the cemented and impregnated portion 45, FIG. 5.
Since the lower ends of all of the individual fibers are ground and polished they are now receptive to receiving of infrared radiation from the heating means 20 and will readily transmit these rays to their upper tips 46 contacting the article such as the frames F to deliver the energy rays to the article by the principles of fiber optics.
The arrows 60 in FIG. 6 indicate the entrance and exit of rays transmitted through the fibers 42 and 142.
A modified form of the invention is disclosed in FIG. 6 wherein the vertical fiber strands 142 are set on end and then have their lower ends impregnated with a suitable binding agent 145 such as an epoxy resin and with a slight change in procedure the just described steps of manufacture are used to make this form of the invention. Again a form jig 300 and a woven tape 41 are used. The tape 41 is wound on the jig as previously described to form the runs 350, 351 in FIG. 8 with the tape end then fastened in place. The extending edges 349 of the tape are cut at the selvage through the bends of the woof strands 142 at 449, FIG. 12. Several weaves of warp strands 143 are then stripped off to expose the woof strands 142 alone. This stripped portion is then impregnated with a hardening cement and left until hardened. Again an integral grid 40 has been made, the bars 50 being integral with the perimeter 51. The upper selvage bends of the woof strands 142 are now cut and the warp strands 143, see FIG. 12, that remain are removed to leave just woof strands 142 bound together at 145 and as shown in FIG. 6. The bottom 147 is then ground and polished and the top 146 may be trimmed or textured. Thus the warp strands 143 that are removed completely have served to position and hold the woof strands 142 in position until formed as described in the grid 40.
Another modified form is illustrated in FIG. 7 wherein the vertically disposed strands 242 are gripped in a channel member 245 which is then fabricated into a suitable grid.
From the foregoing it can be realized that even with careless handling of an article on the carpet support, the article will not be marred. Also, that it is now possible to lay the article on the carpet while being heated instead of hand holding it and that the article will not be harmed even when softened. This carpet will also aid in heating the article since it is transparent to the infrared rays, even transmits the rays and allows for convectional air heating at the same time.
Also it has been demonstrated in what manner a carpet of this type and use can be easily and economically produced and varied in texture to be adapted to fit a product need.
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention, in that 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 claimed.
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A soft non marring carpet type support for articles while being heated into a softened condition consisting of either an intermittent or a continuous line of fine fiberglass fibers to accommodate either a flat or uneven surface in contact with the flexible tips, the support being so gentle and so distributed so as not to leave any impression on the articles softened surface. The support transmits a minimum of heat or cold by conduction, is transparent to infrared radiation across its thickness and also at the same time transmits infrared radiation through the length of its optical fibers.
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BACKGROUND OF THE INVENTION
The field effect transistor (FET) is a three terminal device in which the current through two terminals is controlled by the voltage at the third terminal. FETs are used in many electronic devices, from computer systems to communications systems. FETs can be divided into two main classes, n-type and p-type. n-type or p-type refers to the doping type of the channel region. Thus, a p-type FET or pFET comprises p-type source region, drain region, and channel, and n-type gate regions.
In some applications, the drain signal will originate from a chip that is different from the origination of the source and gate signals. For example, the FET may be located on a receiver chip, and is the intended termination of signals from a driving chip. Thus, it will sink a certain amount of current, depending on the voltage of the incoming signal VM. Since the signals may be on different chips, the FET power signal may be off, while the driving signal may be on. This can cause problems for both the FET resident, receiving chip and the driving chip.
An schematic example of a pFET is shown in FIG. 4A. A physical arrangement of a PFET is shown in FIG. 4B. FET 40 includes source 41 connected to VDL, drain 42 connected to VM, control gate 45 which is connected to a control signal, here GND, and substrate gate 43 which is tied to VDL. Substrate gate 43 could be an n-well in a p-type substrate, or it could be a portion of a n-type substrate. In operation, FET 40 uses a p-type channel 44, which is controlled by control gate 45. When control gate 45 is at ground, channel 44 is open and allows current to flow. When gate 45 has voltage greater than source 41 minus the pFET threshold voltage, then channel 44 is pinched off and current flow from source 41 to drain 42 is prevented. Thus, gate 45 controls the flow of current by application of the voltage in the gate signal.
A problem occurs when the resident chip of FET 40 loses power, and VDL at source 41 drops to ground. When this occurs, a pn diode is formed between drain 42, which is p-type, and n-type substrate gate 43. Drain 42 receives VM which is the signal from the driving chip. If VM is a positive voltage of greater than approximately 0.7volts, or the threshold activation voltage of the pn diode, then the pn diode turns on and sinks a large amount of current from source 42 to substrate gate 43. This occurs because the substrate is no longer biased at the power supply voltage, it is now held at ground.
Note that the diode provides a very low resistance path to ground, thus this appears to be a short circuit to the driving chip from a transmission perspective. If the VM signal is not terminated with the correct impedance, it will cause a reflection wave back to the driving chip, at nearly full value of voltage. Since the diode appears as a short circuit, the reflection signal will reflect back with a negative or inverse wave (an open circuit would reflect a positive wave). The negative wave could cause interference, either constructive or destructive, depending upon the phases of the signals. Constructive interference may result in a signal that exceeds the capabilities of the driving chip and damage the chip, whereas destructive interference may result in degradation of the signal sent to the receiving chip.
The large amount of current flow causes the driving chip to have to supply a lot of current. Moreover, the large current generates a large amount of heat in both the driving chip and the receiving chip. The current flow to the receiving chip could also charge up the substrate of the receiving chip, as if the receiving chip were a capacitor. During power up of the receiving chip, or otherwise grounding the charged substrate, the stored current would discharge and may damage the receiving chip.
Current also flows from VM to VDL. When VDL is at power off ground, and gate 45 is also at ground, then FET 40 is still in the saturation region and current flows through the source to ground from the drain, as channel 44 is still open. So this is another current flowing through the FET when the power is down on the receiving chip. Moreover, this additional current must also be provided by the driving chip. Note that this current flow will also cause signal reflection, as the current flow will result in improper impedance matching, and hence reflection.
Both current sinking mechanisms, i.e. the draining from the pn diode and the drain through the channel, together draw approximately 1.6 amps. This is much larger than the normal power up driving current of 72 ma. Thus, a power off condition of the receiving chip places a very tough current demand for the driving chip power supplies to meet.
Note that the problems described herein only occur with a pFET, and not a nFET. With a nFET, a np diode would be formed, which will not turn on from a voltage at the drain. Moreover, the gate of the nFET would have to be connected to VDL in order for the nFET channel to be open, and upon power loss would go to ground, and thus pinch off the channel.
Therefore, there is a need in the art for a mechanism which will prevent current flow from the drain to the source and substrate, in a power off condition of a p-type FET.
SUMMARY OF THE INVENTION
These and other objects, features and technical advantages are achieved by a system and method which prevents current flow from the drain to the source and substrate, in a power off condition of a p-type FET. The inventive mechanism has three aspects, one aspect to control the current drain to the substrate, another aspect to control the current drain to the source, and third to prevent driving signal reflection.
The first aspect raises the voltage required to turn on the diode. If the threshold voltage exceeds the maximum VM voltage, then the diode will never turn on, and no current will be sinked from the drain through the substrate. This is accomplished by having the substrate gate connected to a series of diodes formed from other pFET devices, instead of tied to the VDL power supply. The other pFET devices are connected to VDL such during the power on condition, the substrate gate is connected to VDL. In a power off condition, the substrate gate is then connected to ground via a series of pn diodes, whose combined threshold voltage exceeds the maximum expected VM voltage.
The second aspect shuts off the receiving FET and pinches off the channel. If the channel is pinched off, then no current can flow through the channel and no current will be sinked from the drain to the source through the channel. This is accomplished by pulling up the gate voltage of the FET from ground. Note that p-type FETs require the gate to be grounded to operate. The gate of the FET is connected to voltage provided by another circuit, instead of being tied to ground. The circuit would provide a ground signal during a normal power on condition. In a power off condition, the circuit provides the signal of VM to the gate, thus the gate will be at a voltage equal to the drain and greater than ground, and thus pinch off the channel and prevent current from flowing to the source through the channel.
If the first two aspects are implemented, and thus no current flows to the receiving chip, then the receiving chip appears as open circuit to the driving chip. This will cause a reflection wave back to the driving chip, at nearly full value of voltage. Since the chip appears as an open circuit, the reflection signal will reflect back with a positive wave. The positive wave could cause interference, either constructive or destructive, depending upon the phases of the signals. Constructive interference may result in a signal that exceeds the capabilities of the driving chip and damage the chip, whereas destructive interference may result in degradation of the signal sent to the receiving chip.
Thus, the third aspect of the inventive mechanism provides the proper impedance to prevent reflection upon a power off condition. If the driving chip sees the proper impedance, then no reflections of the signal will be sent back to the driving chip. This is accomplished by providing an pFET which is turned off during a normal power on condition. In a power off condition, the pFET provides sink for the current of the VM signal. The pFET is preselected so as to provide an approximate impedance match for an expected voltage range of VM. Thus, the pFET greatly reduces the amount of reflection of the VM signal.
A technical advantage of the present invention is undesired current is prevented from flowing into the FET device.
Another technical advantage of the present invention is that current flowing through the drain into the substrate of a p-type FET is prevented from flowing during a power off condition of the FET.
A further technical advantage of the present invention is that current flowing through the channel into the source of a p-type FET is prevented during a power off condition of the FET.
A further technical advantage of the present invention is that reflections from impedance mismatch during a power off condition of a receiving chip are reduced.
A further technical advantage of the present invention provides a reliable signal termination in a communications link on a signal receiving chip using a p-type FET.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a simplified view of the inventive circuit for preventing current from flowing from the drain into the substrate of a p-type FET;
FIG. 2 depicts the inventive circuit for preventing current from flowing from the drain to the source of a p-type FET;
FIG. 3 depicts an expanded circuit of FIG. 1 operating in combination with the circuit of FIG. 2 to prevent undesired current from flowing in a p-type FET;
FIGS. 4A and 4B depict a prior art arrangement of a p-type FET.
FIGS. 5A, 5B, 5C, and 5D depict the performance aspects of the circuits of FIGS. 1, 2, and 3; and
FIGS. 6A and 6B depict the performance aspects of the circuit of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 depicts a simplified version of the inventive circuit mechanism 15 that prevents current from flowing from drain 12 into the substrate 13 of a p-type FET 10. As shown in FIG. 1, mechanism 15 comprises a single FET, however additional FETs could be used as needed. For example, if the maximum expected voltage of VM 12 is less than 1.4 volts then a total of two pn diode are needed (assuming each diode has a threshold voltage of 0.7v), and thus only the two pFETs as shown in FIG. 1 are required to provide the pn diodes in a power off condition. A higher voltage would require additional diodes, and hence additional pFETs, this arrangement is shown in FIG. 3.
In FIG. 1 the n well or substrate gate 13 of pFET 10 is connected to the drain of pFET 15, and is not directly connected to the power supply VDL. In a power on condition, substrate gate 13 is connected to VDL via pFET 15. pFET 15, has its control gate tied to ground and is always turned on, and thus passes the VDL signal from source 17 to its drain, which is connected to substrate gate 13 or pFET 10. In a power off condition, substrate gate 13 is then connected to ground via a pn diode formed from the drain and substrate gate 16 of pFET 15. Thus, the diode formed of drain 12 and substrate gate 13 of pFET 10 is connected in series with the diode formed in pFET 15. In order for any current to be sinked through substrate gate 13, the VM must exceed the threshold voltage for the two diodes, which is approximately 0.7v for each in series, for a total of 1.4v. More diodes could be used as needed, depending upon the voltage of VM.
FIG. 5A depicts the voltages at VM 51 and VDL 52 at different times. The y-axis is the voltage axis, expressed in volts. The x-axis is the time axis, expressed in picoseconds. FIG. 5C depicts the effects of the pFET 15 on pFET 10. The y-axis is the current axis, expressed in milliamps. The x-axis is the time axis, expressed in picoseconds. The time section prior to 50 picoseconds represents the normal power on operation, i.e. with VDL 52 at approximately 1.8v, and source 54 and drain 53 currents at approximately +72 ma and approximately -72 ma, respectively. At 50 picoseconds, the chip is powered down and VDL begins to go to zero. The source and drain currents also begin to move to zero. At 150 picoseconds, VM increases from zero while VDL remains at zero. At approximately 200 picoseconds, substrate gate current 55 is approximately -200 ma. Substrate gate current 55 represents the current flowing through the pn diode formed in pFET 10, from drain 12 and substrate gate 13. Thus, by adding a single pFET, the current has dropped from approximately -1.6 a to approximately -200 ma, because of the resistances of the two pn diodes. The current of approximately -1.6 a can be seen in FIG. 5D, which depicts the effects of circuit of FIG. 2, which lacks the diode from pFET 15 in FIG. 1. Since the substrate gate current 55 has not been reduced to zero, additional pn diodes need to be included in the circuit of FIG. 1.
FIG. 5C also depicts source current 54 at approximately -155 ma at 200 picoseconds. This current represents the current that flows into source 11 through channel 14 of pFET 10. The circuit of FIG. 1 cannot reduce this current as pFET 10 is in the saturation region. Note that this current is approximated twice the normal operating current of 72 ma. Drain current 53 represents the total current flowing into pFET 10, i.e. the sum of source current 54 and substrate gate current 55.
FIG. 2 depicts the inventive circuit mechanism 25 that prevents current from flowing from drain 22 to source 21 via channel 23 of p-type FET 20. As shown in FIG. 2, mechanism 25 comprises two FETs 26, 27 connected to pFET 20. The two FETs 26,27 provide a ground voltage to control gate 24 of pFET 20 during normal power on conditions, and during a power off condition, provide the signal VM voltage to the control gate 24. This will pinch off channel 23 of pFET 20, so that no current can flow through the channel, and thus, no current can be sinked from drain 22 to source 21.
In FIG. 2, control gate 24 of pFET 20 is connected to the sources of FETs 26,27, and is not connected directly to ground. In a power on condition, control gate 24 must be at ground. This is accomplished by FET 25, which is a n-type FET. The gate control of FET 27 is tied to the power supply VDL, and thus FET 27 is turned on when power is on, and passes the ground signal from the drain to the source, and thus to gate control 24 of pFET 20. FET 26 is a p-type FET, with its control gate tied to VDL, and thus is turned off when the power supply is on. So in normal operating conditions VDL is high, which turns on FET 27, which pulls control gate 24 down to ground. In a power off condition, control gate 24 must be at a voltage higher than the drain voltage minus the pFET threshold voltage. Since the receiving chip is in a powered down condition, an off chip voltage signal must be used. As the VM signal is from the driving chip, then this voltage can be used to turn off pFET 20. This is facilitated by FET 26, which is a p-type FET. The gate control of FET 26 also is tied to the power supply VDL, and thus FET 26 is turned on when power is off and VDL is at ground. Note that the substrate gate or n-well 28 of FET 26 is tied to VM. In a power off condition, VM will be the highest voltage, and thus for FET 26 to operate normally, the substrate gate must be connected to the power supply, which by default is VM. FET 26 then passes the VM signal from the drain to the source, and thus to gate control 24 of pFET 20. FET 27 is a n-type FET, with its control gate tied to VDL, and thus is turned off when the power supply is off. So in power off operating conditions VDL is low, which turns on FET 26, which pulls control gate 24 up to VM, and turns pFET 20 off, thus preventing any current from flowing through channel 23.
As described above, FIG. 5A depicts the voltages at VM 51 and VDL 52 at different times. FIG. 5D depicts the effects of the FETs 26, 27 on pFET 20. The y-axis is the current axis, expressed in amps. The x-axis is the time axis, expressed in picoseconds. The time section prior to 50 picoseconds represents the normal power on operation, i.e. with VDL 52 at approximately 1.8v, and source 54 and drain 53 currents at approximately +72 ma and approximately -72 ma, respectively. Note that this portion is the same for FIGS. 5B, 5C, and 5D, but looks different because the y-axis scaling is different. Again, at 50 picoseconds, the chip is powered down and VDL begins to go to zero. At 150 picoseconds, VM increases from zero while VDL remains at zero. At approximately 200 picoseconds, source current 54 is at approximately zero amps. This current represents the current that flows into source 21 through channel 23 of pFET 20. As compared to FIG. 5C, which represents the circuit of FIG. 1 which lacks the circuit of FIG. 2, this current has been reduced from -155 ma to zero.
FIG. 5D also depicts substrate gate current 55 at approximately -1.6 a. Substrate gate current 55 represents the current flowing through the pn diode formed in pFET 20, from drain 22 and substrate gate. Thus, by not including the circuit of FIG. 1, the current is approximately 1.6 a as compared with approximately -200 ma. Drain current 53 represents the total current flowing into pFET 20, i.e. the sum of source current 54 and substrate gate current 55.
FIG. 3 depicts the inventive circuit mechanisms 15, 25 of FIGS. 1 and 2, preventing current from flowing into pFET 30. The mechanism 15 prevents current from flowing from drain 32 into the substrate 33 of a p-type FET 30. The mechanism 25 prevents current from flowing from drain 32 into source 31 of pFET 30.
As shown in FIG. 3, mechanism 15 comprises a plurality of p-type FETs, each forming a diode from there respective drains and substrates in a power off condition. The drains and substrates of the FETs are connected such that the formed diodes are connected in series. The drain of the first FET 35 is connected to substrate 33 of pFET 30. The substrate 37 of the last FET 37 is connected to VDL. The sources of each of the FETs are connected to VDL. Note that control gate 30, as well as the control gates of the FETs 15 are connected to VG, which is provided by FETs 26,27. In a normal, power on condition, substrate gate 33 is pulled up to VDL. With VDL high, FET 26 is off, and FET 27 is on. Thus, FET 27 connects VG to ground. This turns on pFET 30, and FETs 15. First FET 35 pulls substrate gate 33 to VDL. Therefore, pFET 30 will operate normally.
In a power off condition, substrate gate 33 is then connected to VDL which is now at ground, via a series of pn diodes are formed from respective drains and substrate gates of each of FETs 15. In a power off condition, VDL is low, FET 27 is off and FET 26 is on. Thus, FET 27 connects VG to VM. This turns off pFET 30, and FETs 15. Thus the current path is from drain 32 to substrate gate 33, to the drain of the first FET 35 to the substrate gate of FET 35, to the drain of the next FET, and so on, until substrate gate 37 of the last FET 36, which is connected to VDL now at ground. This chain forms a series of pn diodes. Thus, for any current to be sinked through substrate gate 33, the VM must exceed the threshold voltage for the diode series, which is approximately 0.7v for each diode in the series. In FIG. 3, there are a total of 5 diodes for a total threshold voltage of 3.5v. Thus, VM must exceed 3.5v for any current to flow.
More diodes could be used as needed, depending upon the voltage of VM. Furthermore, a circuit could be included which will switch additional FETs into the series connection as needed. Thus, the precise quantity of voltage of VM does not have to be predetermined in building the receiving chip. The receiving chip could be made flexible in the amount of voltage that it can receive from the driving chip.
In a power off condition, VDL is low, FET 27 is off and FET 26 is on. Thus, FET 26 connects VG to VM. This turns off pFET 30, and FETs 15. Note that FETs 15 are turned off in addition to pFET 30. This prevents any current from flowing through their channels to their sources, and on to VDL at ground.
As described above, FIG. 5A depicts the voltages at VM 51 and VDL 52 at different times. FIG. 5B depicts the effects of the FETs 15, 26, 27 on pFET 30. The y-axis is the current axis, expressed in milliamps. The x-axis is the time axis, expressed in picoseconds. The time section prior to 50 picoseconds represents the normal power on operation, i.e. with VDL 52 at approximately 1.8v, and source 54 and drain 53 currents at approximately +72 ma and approximately -72 ma, respectively. Note that this portion is the same for FIGS. 5B, 5C, and 5D, but looks different because the y-axis scaling is different. Again, at 50 picoseconds, the chip is powered down and VDL begins to go to zero. At 150 picoseconds, VM increases from zero while VDL remains at zero. At approximately 200 picoseconds, source current 54 is at approximately zero milliamps. This current represents the current that flows into source 21 through channel 33 of pFET 30. Also substrate gate current 55 at approximately zero milliamps. Substrate gate current 55 represents the current flowing through the pn diode formed in pFET 30, from drain 32 and substrate gate 33. Consequently, drain current 53, which represents the total current flowing into pFET 30 or the sum of source current 54 and substrate gate current 55, is approximately zero milliamps.
FIG. 3 also includes resistor FET 38. This p-type FET provides an approximate impedance match for the VM signal. If no current is flowing into pFET 30, then the connection to the pFET appears as an open to the driving chip, and signal reflection will occur. FET 38 provides a sink for the current with a suitable impedance. The impedance of the FET 38 is preselected to provide an approximate impedance match for an expected voltage range of the VM signal from the driving chip. The control gate of FET 38 is connected to VDL so that in normal power on conditions, this FET is turned off. In a power off condition, VDL goes to ground, and FET 38 turns on, and provides a path for VM to ground. The signals are terminated at FET 38 and not reflected back to the driving chip. Note that the FET 38 will provide a linear current for a particular voltage. Thus, FET 38 can be selected to sink a particular amount of current, however, it will not track over the complete range of VM. This will greatly reduce the amount of reflection.
FIG. 5B includes a measure of source current 56 of FET 38. Note that the source current 56 is substantially linear with respect to VM 51. A period of non-linearity is present between 150 and 155 picoseconds. The non-linearity is due to a threshold voltage that VM must overcome, before FET 38 begins to operate.
FIG. 6A is similar to FIG. 5A. FIG. 6B is similar to FIG. 5B, but includes reference line 60 which defines the normal operating current of pFET 30. The intersection 61 of reference line 60 and rFET source current 56, marks the point at which the current through rFET 38 matches the normal operating current of pFET 30. The current of the rFET 38 is from the VM signal, and thus the corresponding point 62 (in time) on VM voltage 51 is at approximately 1.8 volts which matches the normal operating voltage VDL 52. Therefore, the impedance of rFET 38, when rFET 38 is operating at points 61 and 62, is the same as pFET under normal power on conditions.
Note that the characteristics depicted in FIGS. 5A-5D and 6A-6B are for purposes of illustration only, as the precise operating conditions and characteristics depend on the specific devices being used.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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The inventive mechanism prevents current flow from the drain to the source and substrate, in a power off condition of a p-type FET. The current flow from the drain to the substrate is prevented by raising the voltage required to turn on the diodes that are formed when the power is off. This is accomplished by having the substrate gate connected to a series of diodes formed from other pFET devices. The combined threshold voltage of the series exceeds a voltage associated with the current. The current flow from the drain to the source is prevented by pinching off the channel of the pFET during a power off condition. Since a high signal is required to turn off a pFET device and the power to the pFET is off, an off chip voltage associated with the current is used to turn off the pFET. A current sink FET is used to prevent reflections by supplying the proper impedance to receive the off chip signal associated with the current.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of, and claims a benefit of priority under 35 U.S.C. 120 of the filing date of U.S. patent application Ser. No. 12/566,364, by inventor Brian Reistad et al., entitled “METHOD AND SYSTEM FOR MESSAGE PACING” filed Sep. 24, 2009 now U.S. Pat. No. 8,065,375; which is a continuation of, and claims a benefit of priority under 35 U.S.C. 120 of the filing date of U.S. patent application Ser. No. 11/818,192 by inventors Brian Reistad et al., entitled “METHOD AND SYSTEM FOR FACILITATING MARKETING DIALOGUES” filed Jun. 13, 2007, issued as U.S. Pat. No. 7,647,372; which is a continuation of, and claims a benefit of priority under 35 U.S.C. 120 of the filing date of U.S. patent application Ser. No. 11/353,792 entitled “METHOD AND SYSTEM FOR FACILITATING MARKETING DIALOGUES” filed on Feb. 14, 2006, issued as U.S. Pat. No. 7,389,320; which is a continuation of, and claims a benefit of priority under 35 U.S.C. 120 of the filing date of U.S. patent application Ser. No. 09/621,913 by inventors Brian Reistad et al., entitled “METHOD AND SYSTEM FOR FACILITATING MARKETING DIALOGUES” filed on Jul. 24, 2000, issued as U.S. Pat. No. 7,127,486, all of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to methods and systems for managing online and other communications.
BACKGROUND OF THE INVENTION
With the growth of use of the Internet, more and more people have access to e-mail, and more and more entities use e-mail to communicate with customers, potential customers, or other people of interest. In, for example, a marketing context, companies periodically send e-mails to customers with new product information, special offers, company news, or other information.
As a result, recipients find themselves receiving more e-mails than they want to read. Recipients may get angry at the sender, may “opt-out” of further mailings (if that option is available), or may simply stop reading the mailings. Thus, the benefits from sending mailings are reduced and recipients may not get information they otherwise would have found useful.
SUMMARY OF THE INVENTION
According to the present invention, message volume and timing is managed, preferably for both messages from a single message source and messages from multiple, independent message sources. In one embodiment, a centralized message pacing system is used, which regulates when messages are sent to recipients. In another embodiment, each message source uses a commonly-accessible data repository to determine when it sends messages, so that the timing of messages from each message source is coordinated.
The invention permits messages to be spaced at regular or other periods, depending on the type of message, its priority, or other factors. In addition, the invention permits messages to be combined in accordance with a set of rules, so as to reduce the number of separate messages that each recipient receives. Also, the invention permits the pacing of messages to be monitored, so that if a message is not sent to a recipient within a specified time period, one or more message sources are notified. Either the sender or the recipient can have control over the message pacing, both with respect to the timing of messages and the types of messages.
The invention is applicable generally to various types of communications channels. In a preferred embodiment, the invention is used in conjunction with a marketing system, such as the system described in commonly-assigned patent application Ser. No. 09/621,913, entitled “Method and System for Facilitating Marketing Dialogues,” which is incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system according to an embodiment of the present invention.
FIG. 2 is a representation of a structure for use with an embodiment of the present invention.
FIG. 3 is a block diagram of a system according to an embodiment of the present invention.
FIG. 4 is a flow diagram of steps performed according to an embodiment of the present invention.
FIG. 5 is a flow diagram of steps performed according to an embodiment of the present invention.
FIG. 6 is a flow diagram of steps performed according to an embodiment of the present invention.
FIG. 7 is a representation of a structure for use with an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 , a network includes various message sources 12 , a pacing system 14 , and a recipient 16 . Although only a single recipient is shown, for clarity, it is understood that the pacing system may be applied to multiple recipients. Pacing system 14 includes a data storage system 18 , such as a database system, that is used to store pacing and message information. Messages 20 intended for recipient 16 (and possibly for other recipients as well) are sent from message sources 12 over communication paths 22 , 24 , and 26 to pacing system 14 . Although shown as separate communication paths, paths 22 , 24 , and 26 could all be part of a single network, such as the Internet. The communication paths also could involve wide area networks (WANs), local area networks (LANs), dedicated communication paths, or any other communication channel. Or, the message sources 12 and pacing system 14 could be components on the same system, using direct procedure calls or inter-process communications.
Pacing system 14 forwards messages 20 on to recipient 16 over one or more channels 28 according to a pacing algorithm. For example, messages may be delivered no more than once every n time units (such as once every 7 days). The value of n can be different for each recipient, and can vary for different types of messages or different delivery channels. In a preferred embodiment, one channel 28 is an e-mail channel and a second channel is a phone channel. Facsimiles, pagers, regular mail, and any other communication channel could also be included.
Preferably, as shown in FIG. 2 , each message 20 that pacing system 14 receives has, in addition to its content 120 (including the identity of the recipient, the recipient's address, and the message to be delivered), a set of delivery properties, including: an expiration date 102 and a priority 104 . After the expiration date, the message will be discarded if it has not yet been delivered. Optionally, some messages can have no expiration date. In a preferred embodiment, there are three levels of priority, high, normal, and low, with normal being the default value. Generally, higher priority messages are delivered before lower priority messages. However, the priority can be treated as one factor, along with the expiration date, in determining which message to deliver. Some messages also may be marked as “always deliver,” (field 106 in FIG. 2 ) indicating that it should be delivered before its expiration date, even if that would be sooner than provided by the pacing algorithm. For example, if messages are to be delivered no more than once every 7 days, and an “always deliver” message would expire 4 days after the last message was delivered, then it would be delivered after 4 days. Preferably, the 7 day period would be restarted after the “always deliver” message is sent. Optionally, messages can be marked as “urgent” (field 108 ) and delivered immediately, regardless of when the last message was delivered. An “urgent” message may or may not re-set the delivery timer.
According to one embodiment, pacing system 14 will accept each message it receives from each message source 12 . Other than with “always deliver” or “urgent” messages, pacing system 14 then waits until n time units after it sent the last message to recipient 16 . Pacing system 14 then considers all messages that have not been delivered and have not expired. The message properties are then used to select a message to deliver, For example, pacing system 14 could select the message with the shortest expiration date, using priority as a tie-breaker. Or, pacing system 14 could select the message with the highest priority, using expiration date as a tie-breaker.
Also, combinations of these and other properties of the message can be considered. For example, the recipient could designate certain senders as higher priority than other senders. In addition, pacing system 14 can treat message channels individually or in combinations. Thus, messages sent by e-mail may have no effect on the timing of telephone calls (and vice versa), messages sent by e-mail and telephone calls could be treated together for timing (that is, no call is made or e-mail sent until n days after the last call or e-mail), or some combination of these extremes could be used. For example, calls could be separated by at least 14 days and e-mails could be separated by at least 7 days, with the added requirements that an e-mail cannot be sent for at least 3 days after a call and a call cannot be made for at least 4 days after an e-mail. As another example, message timing can be based at least in part on categorized message types.
Instead of a centralized pacing system, a central pacing storage system 214 can be used, as shown in FIG. 3 . In this embodiment, each message source 212 sends messages directly to recipient 216 , through channel 222 or channel 224 . For example, channel 222 could be an e-mail channel and channel 224 a phone channel. Although only two channels are shown, it is understood that more channels could be used. In addition, each message source 212 is connected to pacing storage system 214 over network 226 . Of course, it is understood that network 226 and one of the channels (such as e-mail channel 222 ) could overlap (if, for example, both use the Internet). Pacing storage system 214 maintains for each recipient 216 message managing information, such as a record with the value of n (the timing between messages) and the date the last message was sent to that recipient. If the value of n is global for all recipients (or a group of recipients), then it is understood that its value may be maintained for each recipient without storing separate instances of the value for each recipient. Where appropriate, pacing storage system 214 may maintain records of the date the last message was sent on each channel or in each category.
When a message source 212 is ready to send a message to a particular recipient, the message source checks with pacing storage system 214 to determine when the last message was sent and the timing interval n. Or, message source 212 may make a request for whether a message can be sent to the recipient, in which case pacing storage system 214 would calculate whether the current date is greater than the date the last message was sent plus the timing interval, and respond to message source 212 . If the new message can be-sent, message source 212 sends the message and informs pacing storage system 214 , so that the date of the last message can be updated. If the current time is less than the timing interval since the last message was sent, then message source implements a pacing algorithm to determine when to try again. For example, the message source could wait until the end of the interval and then check again. Or, if this is an “always deliver” message, the message source would wait until the message is about to expire and then send the message.
The message gap can vary based on the priority of the message. For example, the message gap for a high priority message could be 3 days (that is, 3 days since the last contact of any priority), with the message gap for a normal priority message 7 days, and the message for a low priority message 14 days. Also, the message gap can vary based on the prior message. So, for example, a low priority message can be sent 7 days after a high or normal priority message, but not for 14 days after a low priority message.
In a preferred embodiment, pacing system 14 uses storage system 18 to keep track of the message gap or gaps (which can be a global value, or personalized for each recipient), and the following information for each recipient: T last (the date of the last contact, which could be never); T next (the earliest date at which the recipient can be contacted); and S msgs (the set of messages to be sent to the recipient). For each message, pacing system 14 records the arrival date, so that messages with the same priority and expiration date can be processed according to a “first-come, first-served” algorithm.
One way for the pacing system to decide, as each new message arrives, whether it should be sent immediately or placed in the data store, is shown in FIG. 4 . A message arrives at step 310 . Pacing system 14 then determines (step 312 ) whether the message is marked “urgent.” If so, the message is sent (step 314 ) and the process ends (step 316 ). It is assumed, with this example, that urgent messages do not cause the timer gap to be reset. If the message had not been marked urgent, the pacing system looks up the last contacted date (T last ), at step 318 , and determines if the recipient had previously been contacted (step 320 ). If the recipient had not previously been contacted, the message is sent (step 322 ). The pacing system then updates the last contacted date (step 324 ), looks up the message gap (step 326 ), and updates the next contact date (T next ) at step 328 . The process then ends (step 330 ). However, if the pacing system determines at step 320 that the recipient had been contacted, then the message is inserted into the database by updating S msgs (step 332 ). The process then ends (step 334 ). Alternatively, the lookup message gap and update next contact date steps (steps 326 and 328 ) can be performed if the recipient previously had been contacted. In this case, those steps preferably would be performed after inserting the message in the database at step 332 . With this alternative, the pacing system would not “wake up” (as discussed below) unless a message is waiting in the database.
This process also can be implemented in a number of other ways. For example, the system could let the next contact date have a value of “immediately” when the last message gap has expired (or no messages previously have been sent), and use that value at step 318 (instead of the last contacted date) to determine whether a message should be sent. Similarly, the system could check whether the next contact date is prior to the current time. Or, a separate flag (such as a “window open” flag) could be tested at step 320 to determine whether a message can be sent immediately.
Using timers or periodic queries, pacing system 14 “wakes up” when the next contact date arrives. The pacing system then determines which message to send, then resets the message dates.
One way to implement this process is shown in FIG. 5 . At step 410 the process begins. The pacing system first deletes expired messages, at step 412 . Then, the pacing determines whether any active messages remain (step 414 ). If not, then the system deletes the last contacted date (step 416 ), so that when a new message arrives it will be sent immediately. The process then ends (step 418 ). If, at step 414 , the system determined that one or more active messages remained, the messages preferably are sorted by priority, expiration date, and arrival date (step 420 ). Alternatively, other selection processes can be used. After sorting the messages, the system sends the highest priority message (step 422 ). The system then updates the last contacted date T last (step 424 ), deletes the sent message from the set S msgs (step 426 ), and updates the next contact date (T next ) at step 428 . The process then ends (step 430 ). If, instead of checking (at step 320 of FIG. 4 ) the last contacted date, the system checks for whether the window is open, then step 416 could be omitted. Or, if at step 320 the system checks the next contact date for an “immediate” value or value in the past, then step 416 would be replaced with updating the next contact date to the immediate value, or omitted.
Alternatively, with either of the above systems, to select which message is sent (and when the message is sent) the system (the pacing system, where a centralized pacing system is used, or each message source where a centralized storage system is used) could assign delay times based on the message properties and a random number. In this alternative, the system sends messages during an open window period. The window is open if the last message was sent at least n time units previously, where n is the message gap. The message gap can be the same for all recipients or can vary by recipient. Otherwise, the window is closed and the message is delayed until a point in time shortly after the window is expected to open. If the window is still closed after the delay, the process repeats.
With the use of an open window period, because each message is processed individually, the length of each message delay is staggered, so that messages with a higher priority “wake up” before messages of lower priority. For messages with equal priority, the delay is adjusted so that those with shorter expiration dates wake up before messages with longer expiration dates. For messages with the same priority and expiration date, a random factor is used to ensure they do not wake up at the same time. In a system with a single engine or processor executing the programs for sending messages, it may also be the case that only one message is processed at a time, which will lead to one message being processed first, and the other message then waiting until the window re-opens. Preferably, the wake up time (T wake ) determined using the following algorithm:
T wake =T open +[priority weight]+5min*(20,num_weeks[T exp −T open ])+ran(0-5min),
where T open is the time that the window opens, calculated as:
T open =(last contacted date+message gap).
and where T exp is the expiration time (that is, the expiration date of the message) and where [priority weight] is 0 hours for high priority messages, 2 hours for normal priority messages, and 4 hours for low priority messages. Alternatively, a simpler algorithm employing only some of these factors, could be used, or a different algorithm could be used. Also, the algorithm can consider the message channel as well (as discussed above), so that messages in one channel (such as e-mail) are considered independently of messages in another channel (such as phone calls or facsimiles), or so that prior messages in one channel affect when messages can be sent through another channel.
One way to implement this selection process is shown in FIG. 6 . The process begins at step 510 , when a message arrives or a message wakes up. At step 512 , the system determines if a message is marked “urgent.” If it is, the message is sent (step 514 ) and the process ends (step 516 ). If, at step 512 , the message had not been marked urgent, the system determines (step 518 ) if the message has expired. If so, the process ends (step 520 ). If not, the system looks up the last contacted date (step 522 ) and the message gap for this recipient (step 524 ). The system then checks (step 526 ) whether the current date is greater than the sum of the last contacted date plus the message gap. If so (or if the recipient had not previously been contacted), then the message is sent (step 528 ). The system then updates the last contacted date (step 530 ) and ends (step 532 ). If the current date was not greater than the sum of the last contacted date plus the message gap (that is, the window is closed), then the system waits (step 534 ) until the window opens, then returns to step 518 . This ensures that the current message will be processed before another message that wakes up while the system waits. The window could be closed, for example, because another message had been sent since the wake-up time for that message had been calculated. Alternatively, if the window was closed, the message could go back to sleep for a specified time period and the process could end, which could mean that another message will be processed before it if the other message wakes up first.
In addition to determining the timing of messages, in a preferred embodiment the pacing system can be used to manage message volume. Message volume management mechanisms include aggregating messages, discarding similar messages, and stimulating messages. Thus, volume management can be used both to reduce and to increase the number of messages, depending on the message volume.
For aggregating messages, as shown in FIG. 7 , messages can be assigned the additional properties of type 610 and topics 612 . A message type indicates the kind of content contained in the message, such as informational, advertisement, or cross-sell. The message topics indicate the subjects that the message contains, such as the type of product to which an offer relates. The message topics also can refer to the source of a product or offer, where information or products from different sources may be offered.
The pacing system, in this example, still accepts messages from the message sources. Given a pool of messages, pacing system 14 can select a subset of the undelivered messages and combine them into a single message to be delivered at one time. To do this, pacing system 14 is configured with a set of rules and templates for combining messages. The rules could be, for example, “no more than two advertisements in a message,” “at least one informational item in a message,” and rules preventing certain message topics from being combined in a single message. For example, a rule might ensure that information about a new humidifier is not sent along with information about a new dehumidifier. These rules would work with the selection rule to determine which messages are combined into the single message. The templates describe how to format the messages. For example, informational items are placed on the left side and advertisements are placed on the right side, or two advertisements must be separated by some other type.
In addition, messages can be identified as carriers or tag-alongs (field 614 in FIG. 7 ). Tag-along messages are placed in a priority queue or queues. When a carrier message is about to be sent, the message source checks the tag-along queue(s) and selects one or more items to add to the carrier message in accordance with a set of rules. The rules could, for example, limit the number of tag-alongs per message or the types of tag-alongs that can be combined in a single message, and could prevent tag-along messages with certain topics from being combined with certain carrier messages or tag-along messages of specified types or topics. The templates, in this case, may describe how to format the carrier message relative to the tag-along messages, and the tag-along messages relative to each other.
Optionally, messages also can identify the channel or channels (field 616 ) over which a message can be sent. The channel identifier 616 may be used, for example, to determine which messages to aggregate, so that the pacing system will aggregate messages being sent over the same channel. Also, the channel identifier 616 can be used so that the pacing system can choose one of several channels to use for message delivery. This may apply, for example, to optimize aggregation or to minimize the delay before a message is sent to a particular recipient. In one embodiment, channel identifier 616 is used to determine the channel by which to send a message when the delay periods over different channels are different. Optionally, where multiple channels are identified, other fields (such as priority field 604 ) can have an entry for each channel.
Where recipients have the ability to “opt-out” of receiving certain messages or it may otherwise be determined that a message should not be sent to a recipient during the delay period before a message is forwarded to the recipient, messages also may be assigned a permission check property 618 . Permission check property 618 can be used, similarly to expiration date property 602 , to determine when a message should not be sent. For example, in a centralized pacing system, if permission check property 618 is true, the pacing system checks whether a participant has opted out of a message before sending the message on to the recipient.
For discarding similar messages, the pacing system can apply a set of precedence rules. For example, the pacing system can have a rule that a message is discarded if another message of the same or a similar type (or on the same or a similar topic) was delivered within a particular time period. Alternatively, this type of rule could be used to delay a message, so that two messages of the same or similar types (or topics) are not sent within a specified time period.
While the preceding volume management functions reduce the volume of messages (or the volume of similar messages), it may also be desirable to stimulate the sending of messages when a specified time frame has elapsed without any messages being sent. Thus, in addition to storing a minimum period between messages, the pacing system—can store an upper threshold period. If the upper threshold period is exceeded without a message being sent, the pacing system can notify the message sources.
Although some of the message volume management functions have been described in terms of a central pacing system and some in terms of a pacing storage system, it should be understood that the functions could be implemented with either type of system or a combination of the two.
While there have been shown and described examples of the present invention, it will be readily apparent to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the following claims. For example, the invention can be implemented with a push system, a pull system, an inbox or outbox system, or any other message delivery system. Also, timing periods could be adjusted so that, for example, all e-mails are sent on a particular day of the week or month, or low priority messages are sent only on a particular day. Furthermore, some functions of a central pacing system can be combined with some functions of a pacing storage system (allowing, for example, some messages to be sent directly from the message sources to the recipients) as part of an overall pacing system. Moreover, while some message delivery functions or properties have been described in terms of global properties and some in terms of personal properties, the delivery algorithms can apply the rules globally, at an individual level, or at a group level as desired. Accordingly, the invention is limited only by the following claims and equivalents thereto.
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A system for managing message volume and timing, which permits messages from multiple sources to be spaced apart over time, with the pacing controlled in part by the type or priority of the message. The system permits the volume of messages to be reduced by aggregating messages according to a set of rules and by discarding or delaying messages that are sufficiently similar and sent too close together. In addition, the system allows message sources to be notified when a recipient has not received a message within a designated time period. The system can be implemented as a centralized pacing system or through use of a data storage system accessible by the message sources.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a technique for plotting a variable-width signal in a fixed-width plot area of a monitor screen. More particularly, the present invention relates to an apparatus and associated method for plotting a variable-width waveform signal of one or more consecutive cylinder firing cycles of an internal combustion engine in a fixed-width plot area of a screen using a constant sample rate.
2. Description of the Prior Art
Engine analyzers sense, measure, store and then display engine data, in some form or another, to an attached monitor. Monitors have a fixed plot width, predefined by each monitor's maximum pixel width. A typical monitor has a fixed pixel-dot, horizontal graphical width, usually 640 pixels wide, a portion of which--typically 560 pixels--is allocated for plotting waveforms. For internal combustion engine analysis, the plotting of cylinder firing information--including both primary and secondary voltage signals, over a range of engine speeds (varying frequency)--is useful to an automotive technician. However, when sampling a variable-frequency analog signal of an engine cylinder firing that will ultimately be plotted, the maximum number of points that can be sampled, during a varying-interval waveform, necessarily varies as a function of engine RPM. Assuming a fixed sample rate, a cylinder firing signal from a fast-revving (high RPM) engine is sampled fewer times than it would be at low RPM (low frequency). In fact, the lower the RPM (long time between cylinder firings), the greater the number of points sampled per cylinder cycle.
Because the sampled data points must be stored in memory, at very low RPM available memory limitations pose a problem. Thus, unless a large enough buffer is dedicated for this purpose, and it usually is not, the complete waveform cannot be captured. Also, since a partial-plot of a cylinder firing is generally less useful than a plot of the entire waveform on the monitor screen, it is a waste of memory resources to assign large memory space for sampled waveform information, when a significant portion of that information will ultimately be discarded before display of the cylinder firing waveforms because of the limited width of the display.
As a way to overcome these problems, some prior art techniques vary the sampling rate as a function of engine RPM. The drawback to this, however, is that an external RPM or period measuring source is necessary in order to reset the sample rate. There is also the further drawback that when RPM changes during a cylinder firing, waveform jitter results on the display.
With varying sample rate techniques, well-known routines are provided which permit sampling at those intervals of time for which useful pixel information is produced. Thus, when a 560 pixel waveform is to be displayed, data is sampled at predetermined intervals calculated on the basis of the known RPM rate.
With non-varying (constant) sample rate techniques, all of the points captured during a complete cylinder firing by sampling the analog-input, variable-frequency signal at a fixed sampling rate, are stored in large memory buffers. For full-screen display on a conventional 560-pixel monitor, only the 560 most relevant sampling points are then isolated to generate a displayable cylinder-firing waveform. This is accomplished by any of a number of well-known waveform point-compression routines. Typically, such compression routines--associated with constant sample rate sampling of variable-frequency signals --identify and discard the non-relevant or redundant sample points of a variable width signal. Where a number of previously-sampled cylinder firing signals are to be plotted, point-compression typically is performed at the end of a series of consecutive cylinder firing cycles, typically at the end of a complete engine cycle. Thus, where a fixed sampling rate is used, a large enough buffer memory must be available for all the points sampled for an entire engine cycle. The memory capacity must be quite high to accommodate low engine speeds. Accordingly, if data compression is to occur at the end of multiple consecutively sampled cylinder firing cycles, for example at the end of an engine cycle, the problem with insufficient memory space to store all the sampled points is particularly significant.
Compression routines of the type described above are quite conventional and are of either the floating-point or scaled-integer type as described generally in U.S. Pat. No. 5,150,461 to Reynolds, which patent is owned by the assignee of the present invention. Floating-point compression routines, while more accurate, consume a significant portion of available processor time and are only now--with the increased processing speed of modern computers--becoming more popular.
The major overall distinction between constant sample rate techniques and variable sample rate techniques is that the latter require an additional resource that provides for direct measurement of RPM or signal period, such as with an external RPM measuring source. Constant rate sampling techniques, on the other hand, do not rely on a direct measurement of RPM or frequency, but require a large memory capacity to store all sampled points.
U.S. Pat. No. 5,397,981 to Wiggers describes a constant sample rate technique as employed in a digital storage oscilloscope. In this regard, a stream of digital samples derived by sampling, at a constant rate, a variable-frequency, input-repetitive signal, are stored by an acquisition unit in a fast-acquisition memory (FAM). When the acquisition unit receives a trigger (interrupt) from an associated trigger circuit, acquisition is terminated and the stored samples are transferred to a main acquisition memory (MAM). The acquisition unit processes the digital samples in accordance with a calculated time base reduction factor (TBRF) provided by a system CPU to provide a waveform display memory resolution of a predetermined number of samples per division. The acquisition unit also measures the time period of one cycle of the input repetitive signal for each completed acquisition, and adjusts the number of digitized samples per display division to update each display following acquisition, so that the width of the display remains constant despite changes in frequency of the input repetitive signal. Additionally, the oscilloscope horizontal display (sweep pattern) may be selectively changed by an oscilloscope user to select one or more cycles, or portions of cycles, of a waveform of the input repetitive signal for viewing, and the oscilloscope will automatically establish the desired display. Data compression involves first calculating the period of each cycle of an input repetitive signal and then, on the basis of the number of cycles to be displayed at a given sweep rate, a TBRF value is determined. The TBRF value is then used to discard non-relevant or redundant points from the total points acquired by the acquisition unit, the rest being stored in the display memory. The number of points stored for each cycle to be plotted is therefore a function of the sweep rate at the time of data acquisition. Consequently, when the sweep pattern consists of several displayable cycles at one time, in order to use the Wiggers system to display only one of those cycles across the full screen width of the monitor, would obviously require some duplication of the points collected for that cycle.
The Wiggers technique eliminates the need for a large buffer, since only a predefined number of sample points are actually ever stored during a given cycle. The disadvantage of this scheme, however, is that a sudden, dramatic change in RPM during data acquisition--quite common when plotting engine cylinder-firing waveforms--will result in jitter. This is particularly true at low RPM, where a proportionately greater number of consecutive points are discarded.
With regard to plotting of cylinder-firing waveforms, it is very important that very dramatic, high-amplitude spikes, occurring in the beginning of each cylinder-firing cycle, are properly plotted. Because the Wiggers algorithm arbitrarily collects every (n)th point sampled by the acquisition unit, it will recurringly fail to detect--and therefore be unable to plot--such sharp spikes.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide a unique constant-sample-rate data reduction technique, which discards superfluous captured sample points several times during each cycle of an input repetitive signal, for displaying variable-width waveforms in a fixed-width area on a screen, in a manner which overcomes the memory limitation problem of conventional techniques regarding sampling of a low-frequency input repetitive signal.
It is another object of the present invention to provide a unique data reduction technique, which discards superfluous captured sample points several times during each cycle of an input repetitive signal, for producing a set of sample data points representative of the amplitude of an input repetitive signal at temporally equidistant time intervals over one waveform cycle, whereby the numbers of sample points are equal to a predetermined fixed number regardless of signal frequency and are selected without prior knowledge of the period of any given cycle.
It is another object of the invention to provide a data reduction technique, which discards superfluous captured sample points several times during a cylinder firing cycle, for use in selectively plotting an entire engine firing cycle, individual cylinder firing cycles, or consecutive cylinder firing cycles of a user-selected cylinder of an internal combustion engine, over a fixed-width area of an analyzer screen.
It is another object of the present invention to provide a data reduction technique for plotting, in substantially real-time, multiple consecutive frames--each representative of a single engine cycle of an internal combustion engine--and storing them in fixed size buffers, to provide a retrievable collection of frames for later inspection in non-real time (review mode).
These and other features of the invention are provided by a data acquisition device for plotting at least one cycle of a repetitive analog input signal of varying-frequency on a fixed-plot area of a display device having a horizontal plot axis defined by a fixed number of pixels. The data acquisition device includes a sampling unit for sampling, at a constant sample rate, each cycle of the repetitive input signal to generate and collect, during each cycle, consecutive sets of sample points each containing a fixed number of sample points. In turn, a final set of sample points is generated, equal in number to the fixed number of pixels, and containing a portion of each of the consecutive sets.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 shows a functional block diagram of a system for plotting an input repetitive waveform signal representative of consecutive engine cylinder-firing cycles of an internal combustion engine, on the basis of a constant sample rate technique for capturing, compressing, and displaying the signal in accordance with the present invention;
FIG. 2 is a flowchart of the initial setup routine for capturing of cylinder waveform data;
FIG. 3 is a flowchart of the DMA interrupt service routine executed when the DMA controller reached terminal count; and
FIG. 4 is a flowchart of the cylinder interrupt service routine executed when a cylinder initially fires.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings, and more particularly FIG. 1 thereof, there is depicted a data processing system, incorporating the features of the invention, for executing a data reduction technique, described in greater detail below in connection with FIGS. 2-4, to display cylinder waveforms--captured from a running internal combustion engine 10--in a fixed-width area on a color CRT display module (screen) 15.
The major system components utilized in the data reduction system are shown in FIG. 1. Electrical signals are obtained from the engine 10 by means of signal pickup leads 11 and 12 and trigger pickup lead 13 which feed into the signal conditioning and trigger detection module 20. Module 20 converts the "raw" analog signals sensed by pickup leads 11 and 12--corresponding respectively to the primary and secondary ignition signals of the engine 10--to a form suitable for processing by a data acquisition system (DAS) 30. The conditioned signal is communicated to the DAS over line 31. Module 20 also generates two digital signals, including a cylinder clock signal 32 indicative of cylinder firings and an engine sync signal 33 indicative of the firing of cylinder number one.
The DAS 30 includes an onboard analog-to-digital converter (ADC) 34 that performs analog-to-digital conversion of the input waveform signal(s), based on instructions received from an MPU 40. The digital sampled output of the DAS 30 is piped into an onboard first-in-first-out memory (FIFO) 35 and from there the data are stored in the main MPU memory 50 by means of a direct memory access (DMA) controller 60. An Initial Setup routine, to be discussed below in connection with FIG. 2, is initially entered at start-up, which allows the MPU 40 to provide overall system initialization and to control DMA and DAS functions via control lines 65.
In addition to performing ADC conversions, the DAS 30 generates two types of interrupts to the MPU 40. A DMA interrupt 70 occurs whenever the DMA controller 60 completes the requested number of data point transfers. DMA interrupt 70 is processed by a DMA interrupt service routine (DMA ISR), in a manner to be described below in connection with FIG. 3. A cylinder interrupt 80 occurs whenever a cylinder firing is detected and is processed by a cylinder interrupt service routine (Cylinder ISR), described in FIG. 4. Occurrence of either interrupt causes the DAS 30 to temporarily stop DMA 60 operation, which is later restarted under MPU 40 control. DAS 30 continues, however, to sample digital sample points of the analog input waveform data, while DMA operation is halted, and to store the data in the FIFO 35 until DMA operation resumes, which will occur before the FIFO 35 is full.
After initialization, the MPU 40 instructs the DAS 30 to begin data sampling and storing of cylinder firing information from engine 10, in accordance with the data reduction algorithm of the present invention. The purpose of this algorithm is to produce a set of data points representing the amplitude of the signal at spaced time intervals over one cylinder period. The number of data points is equal to a fixed number (PLOT -- WIDTH) regardless of the engine speed. PLOT -- WIDTH is the width of the waveform-plotting portion of the scope screen in pixels and is equal to 560 in the monitor module 15 of the illustrative embodiment.
The data reduction algorithm will now be described with reference to the flowcharts shown in FIGS. 2-4. Initially, the software allocates two data buffers in the MPU memory 50, each having a size of PLOT -- WIDTH*2 data points. The first is the DMA buffer which receives data from the DMA controller 60. The second buffer is the reduction buffer, which is used to store data from the DMA buffer, after being processed by the reduction algorithm. As will be explained below, data reduction occurs several times during a cylinder firing. This presumes that the rate at which the DAS performs data sampling (ADC conversions), which is at a predetermined, constant sample rate, is faster by at least a factor of PLOT -- WIDTH than the rate (frequency) of the incoming cylinder firing signals, which rate is a proportional to engine RPM. The algorithm maintains a parameter called REDUCTION -- FACTOR, which is used to determine how much data to discard as new data is copied from the DMA buffer to the reduction buffer. For every data point retained, REDUCTION -- FACTOR-1 data points are discarded. For example, if REDUCTION -- FACTOR is 4, 3 out of 4 data points are discarded. REDUCTION -- FACTOR is initially set to 2 at the start of a cylinder capture cycle, and is repeatedly doubled. Thus, the value of REDUCTION -- FACTOR will always be a power of 2.
The data reduction algorithm works as follows. The DAS is set up to perform ADC conversions (digital sampling) at a fixed, predetermined rate. At the start of a cylinder capture cycle (triggered by a cylinder firing--trigger pickup lead 13), the DMA controller 60 is programmed to transfer PLOT -- WIDTH*2 ADC conversions into the DMA buffer. When the DMA controller 60 completes the transfer, a DMA interrupt activates the DMA ISR which processes the data in the DMA buffer and starts another round of DMA transfers. This process is repeated until the next cylinder fires, activating the Cylinder ISR, which saves the captured data in a cylinder storage buffer and starts another cylinder capture cycle. Details of the ISR are discussed below.
Referring to FIG. 2, the following initialization routine is executed before cylinder waveform capture and data acquisition begins (110-140). First, an appropriate memory size is allocated for each of the DMA and reduction buffers (105). The REDUCTION -- FACTOR is then set to two and the reduction buffer declared empty (110). Immediately after, the DMA controller 60 is programmed to transfer PLOT -- WIDTH*2 ADC conversions to the DMA buffer (120). Thereafter, some initialization takes place again at the end of the Cylinder ISR, as explained below in connection with FIG. 4.
The DMA ISR (see FIG. 3) performs data reduction as it processes newly captured data. Each time a DMA interrupt occurs (whenever the DMA buffer is full), the data in the DMA buffer are reduced by the current REDUCTION -- FACTOR and added to the contents of the reduction buffer (210). The program then asks (220) if the reduction buffer is full and, if it is not, restarts DMA operation (250) and exits the DMA ISR (260). This process is repeated (250) until the reduction buffer is full (220), at which time the contents of the reduction buffer are reduced in half (230), and at the same time the REDUCTION -- FACTOR is doubled (240). Because the size of the reduction buffer is PLOT -- WIDTH*2, reducing the full buffer in half results in PLOT -- WIDTH data points. In this manner, after occurrence of the first DMA interrupt in a cylinder capture cycle, the data count in the reduction buffer will be PLOT -- WIDTH and after succeeding DMA interrupts the count will vary between PLOT -- WIDTH and PLOT -- WIDTH*2.
Eventually the next cylinder will fire and activate the Cylinder ISR, which is shown in FIG. 4. At this point the DMA buffer will typically contain some data but the reduction buffer may or may not contain any data. If the reduction buffer is empty (no DMA interrupt has occurred), PLOT -- WIDTH data points are selected from the DMA buffer and copied to a cylinder storage buffer (310, 315). If PLOT -- WIDTH data points have not been accumulated in the DMA buffer, selective duplication of some of the sample points, in a conventional manner, will be necessary. If the reduction buffer is not empty, the data in the DMA buffer is reduced by REDUCTION -- FACTOR and added to the existing data in the reduction buffer (310,320). PLOT -- WIDTH data points are then selected from the reduction buffer and copied to the cylinder storage buffer (330). Then another cylinder capture cycle is reinitiated (340, 350) and the cylinder ISR is exited (360). The process of selecting PLOT -- WIDTH data points from the reduction buffer is similar to the method described in U.S. Pat. No. 5,150,461, discussed in the Description of the Prior Art.
The workings of this algorithm can best be illustrated by an example. Table 1 shows the state of the data reduction algorithm at successive DMA interrupts during the course of a cylinder capture cycle. In this example, the time between cylinder firings is 100 milliseconds. Column (1) is the DMA interrupt number. Columns (2) and (3) show the value of REDUCTION -- FACTOR and the reduction buffer data count at the start of each DMA ISR. Column (4) shows the reduction buffer data count after addition of new data from the DMA buffer. Columns (5) and (6) show the reduction buffer data count and the REDUCTION -- FACTOR, respectively, at the end of each DMA ISR. The data aquisition rate is eight microseconds per sample and PLOT -- WIDTH is 560. Thus, the time between DMA interrupts is 8.960 milliseconds (8*10 -6 *PLOT -- WIDTH*2).
TABLE 1______________________________________(1) (2) (3) (5) (6)DMA Initial (4) FinalInterrupt Conditions Intermediate ConditionsNumber RF RB Count RB Count RB Count RF______________________________________1 2 0 560 560 22 2 560 560 + 560* 560 43 4 560 560 + 280 560 + 280 44 4 560 + 280 560 + 560* 560 85 8 560 560 + 140 560 + 140 86 8 560 + 140 560 + 280 560 + 280 87 8 560 + 280 560 + 420 560 + 420 88 8 560 + 420 560 + 560* 560 169 16 560 560 + 70 560 + 70 1610 16 560 + 70 560 + 140 560 + 140 1611 16 560 + 140 560 + 210 560 + 210 16______________________________________ RF = REDUCTION.sub.-- FACTOR, RB = Reduction Buffer, *indicates that Reduction Buffer is full.
As shown in Table 1, each time the reduction buffer is full (indicated by * in column 4), the data therein is reduced by half and the REDUCTION -- FACTOR is doubled. DMA Interrupt #11 occurs 98.560 ms after the cylinder fires. The next interrupt will be a cylinder interrupt, which will occur 1.440 ms later. When the cylinder interrupt occurs the DMA buffer will contain 180 data points, which will yield 11 points when reduced by the current REDUCTION -- FACTOR of 16. These 11 data points will be added to the 770 data points already in the reduction buffer, for a total of 781 points. Out of these 781 points, 560 will be selected and transferred to the cylinder storage buffer.
These first 560 points selected for display may be, for example, representative of the cylinder firing waveform fully plottable over a 560-pixel horizontal axis of screen 15. If the MPU is initialized for real-time (live) mode processing, the stored cylinder firing data is displayed. In the meantime, the DAS 30 continues to receive and process waveform data corresponding to the next-to-fire cylinder, which cylinder firing data also undergoes data reduction in accordance with the present invention technique, at the end of which, the new 560 points of data of the next-to-fire cylinder is determined and stored in MPU memory 50. This process goes on indefinitely or until MPU operation is terminated. At the end of each engine cycle, which is equal to a predetermined number of cylinder firing cycles, a complete frame of information is available for simultaneous display at the screen 15. Since a complete frame consists of more than one cylinder firing cycle, each of which is represented by 560-points--which also corresponds in the instant case to the maximum pixel length of the screen 15--it necessarily follows that each cylinder firing waveform must be further sized down by a factor equal to the number of cylinder firing cycles in an engine cycle. For example if the operator wishes to look at the plot of a complete engine cycle of a four-cylinder engine (total of four cylinder firings), each 560-point cylinder firing waveform must be reduced by a factor of four to allow all four cylinder firings to be simultaneously displayed.
In the preferred embodiment, the MPU memory 50 is of sufficient memory capacity to store a dozen or more consecutive frames of information for display in non-real-time. This allows an automotive technician to stop data acquisition at any time and review a number of stored frames to aid in engine analysis.
It should be apparent that, since utility is made for data acquisition of a set of consecutive frames, provision can be made so that the information available in memory is plottable in a variety of ways, including display of multiple waveform data in superimposed or vertically spaced relationship. For example, it is possible that data acquisition occurs over separate channels, one for primary signals and another for secondary signals. In such case, a separate set of frames is stored in MPU memory 50 and available for plotting, in either real-time or non-real-time, along vertically-spaced axes on the screen 15.
It is further envisioned that a technician may elect that only the first (or one of the other) cylinder firings for a predetermined number of consecutive frames be plotted along a particular axis on the screen 15.
It should further be apparent that because each cylinder firing waveform includes very sharp transitions in voltage, particularly during the beginning of the cylinder firing, it is important that provision be made that such peaks, not be deleted during data reduction. This could be accomplished using any one of a number of conventional peak-search routines, and easily incorporated in the algorithm of the present invention.
While particular embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A data acquisition device permits plotting of cylinder firing cycles, of varying-frequency, on a fixed-plot area of a CRT screen. Each cylinder firing cycle is sampled, at a constant sample rate, and consecutive sets of sample points, each containing a fixed number of sample points, is generated. On the basis of a unique data reduction technique triggered after the collection of each consecutive sample-point set, certain of the sample points considered superfluous are deleted from the set and the remaining appended to a temporary buffer. The sample-points in the temporary buffer further undergo reduction of the sample points when certain conditions occur, such as buffer full, at which time certain ones are discarded and others are kept. At the end of a cylinder firing cycle, the remaining points are further reduced and a final-set is generated, representative of a full cylinder firing waveform, consisting of sample points equal in number to the plot-width of the CRT screen.
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FIELD OF THE INVENTION
[0001] The invention relates to a folding shutter arrangement having the features of the preambles of claim 1 , 13 or 14 . According thereto, a first folding shutter element is fastened or is fastenable indirectly or directly to a building so as to be pivotable about a first axis, which is positionally fixed or is virtually positionally fixed with respect to the building, in the vicinity of a non-buckling (first) element edge. A second folding shutter element is held pivotably about a second axis, which is shiftable transversely with respect to itself, in the vicinity of a non-buckling second element edge and is shiftable along guides arranged in pairs perpendicularly to the second element edge. The folding shutter elements which are adjacent in pairs are connected pivotably to one another in pairs at their buckling, third element edges, which are opposite and parallel to the first and second element edges, by means of a buckling joint. Pairs of further folding shutter elements on the first two folding shutter elements can adjoin the preceding pair of folding shutter elements. Furthermore, a final folding shutter element which projects freely on the end side can adjoin the pair(s) of folding shutter elements.
TECHNOLOGICAL BACKGROUND
[0002] WO 2008/125343 A1 by the same applicant discloses a folding shutter arrangement, in which a locking/unlocking device and optionally a deployment and pulling-up device are provided in the vicinity of the buckling pairs of element edges such that the folding shutter arrangement is moveable from a closing arrangement, which is extended flat per se, into any opening position. In principle, said folding shutter arrangement is also usable for a plurality of pairs of folding shutter elements.
[0003] FR 2600892 A1 discloses a folding shutter arrangement for obliquely inclined veranda roofs, in which the folding shutter elements do not adopt an extended position with one another even in the closure position, but rather the adjacent folding shutter elements have already adopted an angular position with one another at the connecting edges thereof, and therefore buckling aids are not required for lack of an extended position. On the contrary, because of the predetermined, slightly buckled basic position of the pairs of folding shutters, a successive, complete buckling of the adjacent pairs of folding shutters occurs during the opening.
[0004] DE 20 2004 010 622 U1 discloses a folding shutter arrangement as a door system, i.e. in a vertical orientation, which, in the closed position thereof, permits an extended position of the folding shutter elements aligned with one another. Here, the final (third) folding shutter element, as seen from the fastening edge, can be opened and closed like a door without the adjacent pair of folding shutter elements being moved. All of the opening and closing movements are undertaken manually.
SUMMARY OF THE INVENTION
[0005] Proceeding therefrom, the invention is based on the object of realizing a folding shutter arrangement which permits folding shutter arrangements having three or even more sections to move between a closed extended position and an open, buckled position of the folding shutter elements in a simple manner driven by a motor. To solve this problem, a folding shutter arrangement having the features of claim 1 is proposed. According thereto, in a folding shutter arrangement of the type in question, provision is made for at least one drive element which is moveable along the guides to drive at least one, preferably the final one, of the non-buckling element edges in the opening and closing directions. By means of at least one coupling element, the folding shutter elements, which are connected to at least one of the non-buckling element edges, are forcibly pivoted in pairs in the opening or closing direction.
[0006] By means of the invention, it is possible, inter alia, in the case of horizontally extending folding shutter elements, in particular for openings which are to be closed vertically, but in principle also for inclined or horizontal openings, to drive a lowermost, or final, freely projecting folding shutter element in the opening and closing directions by motor. This makes it possible to obtain favorable light and/or ventilation conditions and/or for relatively large solar panels to be installed in a favorable orientation in the outer side of the folding shutter arrangement. Folding shutter arrangements to be opened and to be closed by motor could hitherto be realized only with an even number of folding shutter elements because the motor-driven element edge furthest away from the coupling point of the folding shutter arrangement on a building had to be guided in the lateral guides.
[0007] The invention therefore first of all makes it possible to realize folding shutter arrangements having as many folding shutter elements as desired in an uneven number. However, it is also possible, according to the invention, to realize folding shutter arrangements having an even number of folding shutter elements, such as having two, four, six and more folding shutter elements.
[0008] The opening and closing drive, and also the buckling, pulling-up, locking and unlocking can be realized by the invention in a simple manner. The actuating elements for this purpose can be of comparatively simple design and/or accommodated unobtrusively.
[0009] Within the context of the invention, the buckling element edges are understood as meaning that region of the folding shutter arrangement at which one element edge or one pair of element edges is remote from the guides during the opening of the folding shutter arrangement transversely with respect to the direction of extension of said guides. By contrast, within the context of the invention, a “non-buckling” element edge is an element edge which, individually or in pairs, always remains in the plane of the guides or parallel thereto and is displaced along the guides or parallel thereto only in the opening direction.
[0010] It is now possible in various ways to realize the invention. At least one (first) guide carriage which is moveable along guides arranged at right angles to the second element edges can be provided as the means for the pivotable holding and, in particular pairwise, shifting of the at least one non-buckling, second element edge. Such a guide carriage is basically already known from WO 2008/125343 A1 for folding shutter arrangements having only two folding shutter elements. If, as preferred, the folding shutter arrangement comprises more than two folding shutter elements, such a guide carriage has to remove two element edges in a pivotable manner. This is preferably undertaken by the at least one guide carriage having pivot bearings, which are spaced apart from one another, for the pivoting mounting of the adjacent folding shutter elements. If the pivot bearings separated by such dimensions are located on pivot bearing arms, the desired alignment position of adjacent folding shutter elements can thereby be obtained in a simple manner and the torques occurring at the pivot bearings can be introduced into the guide carriage irrespective of the required distance from the guides. The coupling points on the folding shutter element for the forced pivoting thereof are preferably provided on or in the vicinity of the non-buckling element edge(s) and are therefore, inter alia, arranged substantially unobtrusively. The coupling elements therefore act on the folding shutter elements preferably in positions which are situated on the or in the vicinity of the non-buckling element edges.
[0011] The coupling of the moveable drive element to the folding shutter elements, said coupling permitting a forced pivoting of the folding shutter elements into a buckled position or back into an extended position, is particularly preferably undertaken by a (first) coupling element in the form of a sliding element for pivoting one of the folding shutter elements during movement of the moveable drive element. An example of a suitable sliding element is an arrangement similar to a sliding rod which, during the movement of the drive element in the opening direction, leads to a torque being produced on one of the folding shutter elements with the effect of pivoting out same.
[0012] The forced pivoting means, in particular the sliding element or in general at least one of the coupling elements, can comprise a separate angle adjustment means, for example a linear drive, for at least one of the folding shutter elements, said angle adjustment means separately increasing or reducing the effective length of the forced pivoting means. This enables the action of the drive element to be superimposed on the folding shutter element to be pivoted, specifically both with the effect of a more rapid pivoting-out movement and with the effect of a retarded or less pronounced pivoting-out movement. Said angle adjustment means can be effective both parallel in time and offset in time to the drive element.
[0013] In order to pivot a further folding shutter element during movement of the moveable drive element, at least one further (second) coupling element in the form of a sliding element can be provided. The latter can be similar to a sliding rod, as the (first) coupling element already is, and can be variable in the effective length thereof, optionally separately.
[0014] In order to reinforce the effect of the first and/or second coupling element, the moving folding shutter element can comprise a pivot arm which is connected thereto, preferably rigidly, and is actuatable by the coupling element. The coupling element can thereby be arranged comparatively unobtrusively in the direct vicinity of the guide rails and relatively large torques can be introduced into the relevant folding shutter element for pivoting out same.
[0015] Unlike in the prior art, for example according to WO 2008/125343 A1, the shifting of the folding shutter elements from an extended position into a buckled position and the pulling-up of the folding shutter elements into the closed extended position can be introduced into the folding shutter elements at a point situated in the vicinity of the non-buckling element edges. The folding shutter elements can be pulled back out of the buckling position thereof, i.e. into the extended position again, by the coupling elements. The buckling and pulling-up are undertaken in a visually very unobtrusive manner, since the previously known buckling and pulling-up elements no longer have to be mounted in the region of the buckling folding element edge.
[0016] A particularly favorable pivoting of the folding shutter elements is possible by a (third) coupling element in the form of a pairing of teeth being used. The use of the latter turns out to be particularly simple and effective if intermeshing teeth segments, or optionally gearwheels on the pivot axes of adjacent folding shutter elements, are provided on the non-buckling and/or buckling element edges.
[0017] At least some of the folding shutter elements could be equipped with solar cells. The latter can be accommodated, for example, in frames of the folding shutter elements. If at least one pair of folding shutter elements is jointly provided with a self-supporting solar panel, comparatively large solar panel surfaces can thereby be effectively oriented with respect to the sun. At the same time, a favorable shadow effect for the spatial region located therebehind can be obtained. Within the context of the invention, self-supporting solar panels are understood as meaning that there is a corresponding inherent rigidity or reinforcing means, for example a reinforcing grid or frame, are provided.
[0018] In order to keep a folding shutter arrangement securely in position in the closed extended position even under wind attack, attack by vandals or in other situations, locking and unlocking means which are known per se can be actuated by at least one drive means which is moveable along the guide, in particular the drive means for opening and closing the folding shutter arrangement, being operatively connected to an idle travel means, by means of which, inter alia, the locking and unlocking of at least one of the folding shutter elements in the, or in the vicinity of, the closed extended position of the folding shutter arrangement and in particular in the vicinity of a folding shutter element edge is permitted. An arrangement of this type is also of independent inventive significance independently of the features of claim 1 . It can also be used for driving buckling and/or pulling-up means. The idle travel means can optionally also be connected in terms of drive via at least one extension means to the locking and unlocking means and/or to the buckling and/or pulling-up means for at least one of the folding shutter elements such that the locking and unlocking and/or the buckling and/or pulling-up can optionally also be undertaken in a remotely actuated manner simultaneously at different positions along the folding shutter arrangement and preferably in the region of the buckling element edges. An arrangement of this type is also of independent inventive significance independently of the features of claim 1 .
[0019] In principle, it is already possible to use the (first) guide carriage as the moveable drive element; in particular if the distance from the pivot point of the coupling element on the guide carriage can change during the movement by telescopic rails or the like. A simple arrangement of the coupling elements is possible by the fact that at least one (second) guide carriage which is moveable along guides arranged at right angles to the element edges is provided as the moveable drive element. This simplifies the pairwise pivoting of folding shutter elements which are adjacent with respect to a non-buckling pair of element edges.
[0020] The components mentioned above and the components claimed and described in the exemplary embodiments and to be used according to the invention are not subject in their size, shaping, choice of material and technical conception to any particular exception conditions, and therefore the selection criteria known in the field of use can be used without restriction.
[0021] Further details, features and advantages of the subject matter of the invention emerge from the dependent claims, and also from the description below and the associated drawing, in which an exemplary embodiment of a folding shutter arrangement is illustrated by way of example. Individual features of the claims or of the embodiments may also be combined with other features of other claims and embodiments.
BRIEF DESCRIPTION OF THE FIGURES
[0022] In the drawing
[0023] FIG. 1A shows a side view of a folding shutter arrangement having three folding shutter elements in a closed position;
[0024] FIG. 1B shows the same folding shutter arrangement in detail;
[0025] FIG. 1C shows the same folding shutter arrangement in the approximately half-buckled state of the folding shutter elements;
[0026] FIG. 1D shows the same folding shutter arrangement in the completely buckled state of the folding shutter elements;
[0027] FIG. 2 shows the folding shutter arrangement according to FIG. 10 with an additional upper locking and unlocking element (as an excerpt);
[0028] FIGS. 3A-E show a side view of a second embodiment of a folding shutter arrangement with five folding shutter elements (partially as an excerpt) in the closed position ( FIG. 3A ), in a partially open position ( FIG. 3B ) and in a complete opening position ( FIG. 3C ) and in detail ( FIGS. 3D and 3E );
[0029] FIGS. 4A-E show a side view of a third embodiment of a folding shutter arrangement having solar panels, with five folding shutter elements (partially as an excerpt) in the closed position ( FIG. 4A ), in a partially open position ( FIG. 4B ) and in a virtually complete opening position ( FIG. 4C ) and also in detail ( FIGS. 4D and 4E );
[0030] FIGS. 5A-C show a fourth embodiment of a folding shutter arrangement, with three folding shutter elements and telescopic surface elements in a closed position ( FIG. 5A ), in a partial opening position ( FIG. 5B ) and in a virtually complete opening position ( FIG. 5C );
[0031] FIGS. 6A-C show a side view of a fifth embodiment of a folding shutter arrangement in a closed position ( FIG. 6A ), in a partially open position ( FIG. 6B ) and in a complete opening position ( FIG. 6C );
[0032] FIGS. 7A-D show a side view of a sixth embodiment of a folding arrangement with two folding shutter elements and a buckling aid and with a second lock, in a closed position ( FIG. 7A ), in a slightly buckled position ( FIG. 7B ) and in a further open position ( FIG. 7C ) and also in the form of a simplified detailed illustration ( FIG. 7D );
[0033] FIGS. 8A-E show a side view of a seventh embodiment of a folding arrangement, with three folding shutter elements and a buckling aid, in a closed position ( FIG. 8A ), in a slightly buckled position ( FIG. 8B ) and in a full opening position ( FIG. 8C ), and also in an alternative (FIGS. 8 D and 8 E)—as an excerpt;
[0034] FIGS. 9A-B show a side view of an eighth embodiment of a folding arrangement, with three folding shutter elements and a buckling aid and with a second lock, in a closed position ( FIG. 9A ), in a slightly buckled position ( FIG. 9B ), and also
[0035] FIGS. 10A-D show a side view of a ninth embodiment of a folding arrangement, with three folding shutter elements, in a closed position ( FIG. 10A ), in an approximately half-buckled position ( FIG. 10B ) and in a full opening position ( FIG. 10C ), and also in detail with regard to FIG. 10B ( FIG. 10D ).
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0036] The three-section embodiment according to FIGS. 1A to 1D shows one of two guides 16 A, 16 B, which stand vertically and are spaced apart from each other in parallel and in which a first guide carriage 17 A and a second guide carriage 17 B are vertically moveable. The uppermost of three folding shutter elements 12 A, 12 B and 12 C is indirectly fastened to a building 1 (merely indicated) so as to be pivotable about a positionally fixed axis 12 A′ in the vicinity of the first (uppermost) element edge 13 A. A second folding shutter element 12 B is held with respect to the first guide carriage 17 A so as to be pivotable about a second axis 12 B′, which is shiftable transversely with respect to itself, in the vicinity of a non-buckling, second element edge 13 B. The second, non-buckling element edge 13 B is shiftable vertically by means of the guide carriage 17 A along the guides 16 A, 16 B, which are arranged in pairs at right angles to the second element edge 13 B. The adjacent folding elements 12 A and 12 B form a (first) pair of folding shutter elements. The folding shutter elements are connected to one another pivotably in pairs by means of a buckling joint 14 A at their buckling, third element edges 15 A, 15 B, which are opposite in parallel to the first and second element edges 13 A, 13 B. A further (third) folding element 12 C adjoins the pair of folding elements 12 A, 12 B on the end side as the final folding element and has a freely projecting element edge 13 C. The third folding shutter element 12 C is mounted in a freely projecting manner in the vicinity of its upper element edge so as to be able to pivot about a pivot bearing 17 A′, which is located on the guide carriage 17 A.
[0037] The actuation of the folding shutter arrangement now proceeds in the following manner: a drive element, such as a tension strap 11 , and in particular a toothed belt running around upper and lower deflecting pulleys 11 A, 11 B, which tension strap/toothed belt is drivable in both directions in the region of an upper and/or lower deflecting pulley 11 A, 11 B, in particular by means of an electric motor, acts on the second (lower) guide carriage 17 B, which is moveable vertically along the guides 16 A and 16 B via guide rollers 17 C. The drive means and the elongate guide carriage 17 B are referred to overall as a drive element 30 . A first coupling element 32 A and a second coupling element 32 B are each fastened pivotably to the second guide carriage 17 B. A sliding rod is used as the first coupling element 32 A, said sliding rod being fastened by its lower pivotable coupling point (pivot point 19 A) to the second guide carriage 17 B and by its upper pivotable coupling point (pivot point 19 B) to the third folding shutter element 12 C at a distance and lateral offset below the pivot bearing 17 A′, thus producing a pivot arm 34 , and the first coupling element 32 A is thereby able to exert a torque on the third folding shutter element 12 C. The second coupling element 32 B is likewise designed as a sliding rod and is connected pivotably to the second guide carriage 17 B, for example at the same connecting point as the first coupling element. At its second, upper end, the second coupling element 32 B acts on a pivot arm 34 B. The latter is connected rigidly, i.e. non-pivotably, to the second folding shutter element 12 B, in the lower region thereof, and therefore the pivot arm 34 B exerts a torque on the second folding shutter element 12 B. The drive means therefore acts on the first guide carriage 17 A only indirectly, namely by means of the second coupling element 32 B and the pivot arm 34 B. The first guide carriage 17 A is therefore raised and lowered indirectly via the movement of the second guide carriage 17 B.
[0038] If the second guide carriage 17 B is now moved upward ( FIG. 1C ) out of the closed and locked extended position illustrated in FIG. 1A , during the initial movement only a lower locking and unlocking means 40 A is disengaged ( FIG. 1B ). Said locking and unlocking means 40 A comprises a short extension arm with a locking cutout 17 B″ and a locking stop 17 B″′, which extension arm protrudes laterally in the lower end region of the third folding shutter element 12 C. The extension arm has an elongated hole 19 , in which the lower pivot points 19 A of the first and second coupling elements 32 A and 32 B can be displaced by a sufficient length. During the initial opening movement of the second guide carriage 17 B, said pivot points 19 A are displaced downward with respect to the extension arm, while the locking cutout 17 B″ moves upward and finally releases the movement stop 17 B″′, as illustrated in FIG. 1A by dashed lines, and by solid lines in the detailed excerpt according to FIG. 1B . The pivot point 19 A is then located at the lower end of the elongated hole 19 . A further movement of the second guide carriage 17 B upward consequently leads to the two coupling elements 32 A and 32 B being raised. This in turn leads to the first coupling element 32 A slightly pivoting out the lower folding shutter element 12 C and to the second coupling element 32 B slightly pivoting the pivot arm 34 about the pivot part 17 A′, and hence the second folding shutter element 12 B, i.e. transferring the latter in an extended position into a buckling position, as is apparent in more detail in FIG. 2A . As soon as the second folding shutter element 12 B is buckled from the extended position thereof into a slightly buckled position, the first guide carriage 17 A can shift upward along the guides 16 A, 16 B under the lifting action of the first and second coupling elements 32 A and 32 B. In the process, the buckling movement of the folding shutter elements 12 C and 12 B continues. At the same time, however, as a consequence of the buckling movement of the second folding shutter element 12 B and indirectly by means of the second coupling element 32 B, the first folding shutter element 12 A is also pivoted outward about the first axis 12 A′. The first guide carriage 17 A and the three folding shutter elements 12 A-C then follow the lifting movement of the second guide carriage 17 B, as is apparent from FIGS. 1C and 1D . The second and third folding shutter elements 12 B and 12 C are therefore forcibly pivoted in pairs by the drive element 30 and the first folding shutter element 12 A is thereby also inevitably pivoted at the same time.
[0039] During the closing of the folding shutter arrangement, the second guide carriage 17 B is lowered and the first guide carriage 17 A follows this movement, because of its own gravitational force and assisted by the gravitational force of the three folding shutter elements 12 A to 12 C.
[0040] It is apparent from the exemplary embodiment according to FIG. 2 how an, in particular second, locking and unlocking means, the upper one in the exemplary embodiment, can likewise be actuated by the drive element 30 : two sliding rod guides 21 A, 21 B fastened to the relevant guide 16 A or 16 B guide a sliding rod 21 in a sliding manner and approximately parallel to the guides by means of an, in particular lower, stop 21 C and an, in particular upper, sliding rod extension 21 D, which is flexible per se or is connected in a slightly pivotable manner to the sliding rod 21 . At its upper end in the example, the sliding rod extension 21 D is connected pivotably in the driving direction to a locking and unlocking lever 40 B″, thus resulting overall in an upper locking and unlocking means 40 B in the example, which is remotely actuatable by an extension means, denoted overall by 42 , and can engage in a locking manner in a locking stop on one of the folding shutter elements. A compression spring 21 F loads the upper locking and unlocking means 40 B in the direction of an unlocking position, as illustrated in FIG. 2 . Locking is served by the drive element 30 , at which a stop 21 E is provided, the stop coming into contact at the end of the closing movement with the stop 21 C and, in the locking phase of the lower locking and unlocking means 40 A, simultaneously displacing the extension means 42 downward such that the upper locking and unlocking means 40 B also passes into the locking position thereof, as is realized in a similar manner which has yet to be described in the exemplary embodiments according to FIG. 7 , 8 or 9 .
[0041] The second and third exemplary embodiments according to FIGS. 3A to 3C and 4 A to 4 C differ from the first exemplary embodiment in that, firstly, five folding elements 12 A to 12 E are provided instead of three folding elements. In the third exemplary embodiment according to FIGS. 4A and 4E , the two pairs of folding elements 12 A, 12 B and 12 C, 12 D are covered in the closed state by a solar panel 38 covering the two folding shutter elements, but said solar panel is fastened in each case only to the upper of the folding elements ( 12 A and 12 C) of a pairing of folding shutter elements and therefore the lower half of said solar panel projects significantly when the folding shutter arrangement is opened, as is apparent from FIG. 4C .
[0042] The difference of the second exemplary embodiment ( FIGS. 3A to 3C ) from the first exemplary embodiment consists in that, in addition to the first coupling element 32 A, a pair of gearwheels 18 A, 18 B is provided as the (third) coupling element 32 C. Said toothed segments are connected to the folding shutter element 12 E for conjoint rotation at the upper axis of rotation thereof and are connected to the folding shutter element 12 D for conjoint rotation at the lower axis of rotation thereof in the vicinity of the lower element edge. The center points of the gearwheels 18 A and 18 B are aligned with the pivot bearings 17 A′ and 17 A″ of the first guide carriage 17 A and are in meshing engagement with each other. The same toothed segment arrangement and a further guide carriage 17 C are located on the non-buckling, second element edge 13 B at the transition between the second folding shutter element 12 B and the third folding shutter element 12 C. The function of the first coupling element 32 A is the same as in the first exemplary embodiment, i.e. raising of the second guide carriage 17 B leads to a slight buckling at the lower, free end of the lower folding shutter element 12 E. By means of this buckling movement, the gearwheel 18 B is rotated, in particular by the same angular amount, and entrains the gearwheel 18 A and the fourth folding shutter element 12 D by the same angular amount, with the effect of buckling same. As a result, in turn, the third folding shutter element 12 C is inevitably also buckled and the latter, in turn, pivots the second folding shutter element 12 B by means of a pairing of gearwheels 18 C, 18 D on the non-buckling element edge 13 B. This, in turn, leads to a forced pivoting of the uppermost folding shutter element 12 A about the positionally fixed axis 12 A′ thereof. Overall, therefore, the entire folding shutter arrangement with all five folding shutter elements is uniformly buckled, specifically as a consequence of the lifting movement of the second guide carriage 17 B. The locking and unlocking with the aid of the elongated hole 19 , which serves as the idle travel means 36 , is the same as in the first exemplary embodiment. By contrast, in the third exemplary embodiment according to FIGS. 4A-E , the pivoting coupling between the fourth and fifth folding shutter elements 12 D and 12 E takes place as in the first exemplary embodiment according to FIGS. 1A-D between the second and third folding shutter elements 12 B and 12 C. The pivoting coupling according to FIGS. 4A-E between the second and third folding shutter elements 12 B and 12 C takes place, in turn, as according to FIGS. 3A-D .
[0043] From the fourth exemplary embodiment according to FIGS. 5A to 5C , two telescopic surface elements 39 A, 39 B, which can be equipped, for example, with solar panels, are apparent. Said surface elements are preferably the same width as the folding shutter elements and, in the pushed-in state, have a length which is approximately identical to, to somewhat shorter than, the folding shutter elements between the joint regions thereof. In the pushed-in state, as in FIG. 5C at the lower surface element 39 B, the building region located therebelow is therefore not shaded. The useful surface of the multi-part, telescopic surface elements 39 A, 39 B or the surface to be shaded can be changed via telescopic guide rails, in particular arranged laterally. Different drive systems can be used for the extension and retraction thereof. When toothed belts are used, it is possible, as illustrated, for the telescopic sections to be moved in both directions by a drive 39 C, 39 D in both directions. Alternatively, a belt drive or cable drive with a winding-up mechanism can be operated. The weight of the telescopic arrangement can be used to extend the latter. Multi-part panels are particularly favorable for folding shutter elements located further below, but may advantageously also be used in folding shutter arrangements having two folding shutter elements, such as, for example, according to FIGS. 7A-C , for the upper of the two folding shutter elements. In this fourth exemplary embodiment according to FIGS. 5A to 5C , the difference with regard to the first exemplary embodiment consists in that the first coupling element 32 A is independently changeable in length and can be designed, for example, as an electric spindle drive. As is apparent from the full opening position according to FIG. 5C , such an independent adjustment drive may be used to actuate the coupled forced pivoting device for the second and third folding shutter elements 12 B and 12 C in such a manner that the pivoting angles of said two folding shutter elements differ in size.
[0044] In the exemplary embodiment according to FIGS. 6A to 6C , the buckling in a three-part folding shutter arrangement takes place in a manner known, for example, from WO 2008/125343A1, by means of a pulling-up and locking device 22 which serves at the same time as a buckling means and is actuated via a driver 22 A which acts on the pulling-up and locking device 22 in the vicinity of the closing position in the pulling-up and locking direction. During the opening, the driver 22 A brings about a force-actuated buckling of the upper folding shutter element 12 A and of the folding shutter element 12 B which is coupled thereto and is located therebelow. Owing to the coupling element 32 C in the form of intermeshing toothed segments in the region of the non-buckling, second element edge 13 B, the lower folding shutter element 12 C is also buckled and, in the subsequent movement, pivoted out, as is in principle already apparent in conjunction with the exemplary embodiment according to FIGS. 3A to 3E . In principle (differently than illustrated), the pulling-up, locking and buckling means 22 can also be provided on the central folding shutter element ( 12 B) or on the lower folding shutter element 12 C, instead of on the upper folding shutter element 12 A, and the position of said means between the upper and lower pivot joint of the associated folding shutter element is, in principle, freely selectable. The starting position of the driver 22 A, which is fixedly connected to a tension strap 11 and, like the guide carriage 17 A, is drivable upward and downward by said tension strap, is selected accordingly. Only one guide carriage 17 A is required, said guide carriage being fastened to a driven, revolving tension strap 11 , such as a toothed belt, at a fixed height distance from the driver 22 A, which is likewise fastened to the tension strap. A single drive therefore brings about the buckling and locking, on the one hand, and the opening and closing, on the other hand.
[0045] In the exemplary embodiment according to FIGS. 7A , 7 B with only two folding shutter elements 12 A and 12 B, remote locking and unlocking and also buckling of one of the folding shutter elements—the upper folding shutter element 12 A by way of example in the drawing—are likewise undertaken, as in principle already known from FIG. 2 and as also at least partially apparent from FIGS. 8 and 9 . In all of these exemplary embodiments, an extension means 42 serves remotely to actuate a locking and/or unlocking means and/or buckling means 22 or 40 B situated higher, or, if desired, lower. In this case, the locking and/or unlocking means and/or buckling means 40 B carries out a multiple function, since it can also serve as an actively driven buckling means, in the same manner as the pulling-up and locking device 22 according to the exemplary embodiment in FIGS. 6A to 6C . Also in this exemplary embodiment, the driven moving carriage 17 A is provided with a lower locking/unlocking for the extended closed position ( FIG. 7A ), which can also be designed, by way of example, approximately as per FIG. 2 , 8 or 9 . FIG. 7 illustrates locking and/or unlocking means 40 A and 40 B to the extent that they emerge in more detail from the detailed illustration according to FIG. 7D : the essential design of the locking and/or unlocking means 40 B corresponds to the likewise remotely operated version according to FIG. 2 . In addition, a double stop 25 A/B ( FIG. 7D ) is provided, the double stop permitting the locking lever 22 B or 40 B″ to be completely pivoted upward and back again by means of the driver 22 A, as is apparent from FIG. 7C . For this purpose, the locking lever 40 A″ which is pivotably connected to the lower end of the sliding rod 21 of the extension means 42 is shiftable along a positionally fixed guide slot.
[0046] The exemplary embodiment according to FIGS. 8A to 8E shows a three-winged folding shutter arrangement which differs from the embodiment according to FIGS. 1A to 1C in that an additional buckling aid 24 is provided. In the two alternatives shown in FIG. 8 , namely FIGS. 8A to 8C , on the one hand, and FIGS. 8D , 8 E, on the other hand, the buckling aid 24 comprises a toggle lever arrangement, consisting of the levers 24 A and 24 B, which are connected pivotably to each other via a toggle lever joint 24 C and, as buckling means, bear, for example, a roller 24 D which is assigned to the toggle lever joint 24 C and presses against one of the upper folding shutter elements (the folding shutter element 12 A in the drawing) as a buckling assistance, as illustrated in FIG. 8B . In order to actuate the buckling aid 24 , an extension means 42 is again provided, as already implemented in conjunction with the sliding rod arrangement 21 to 21 E in FIG. 2 in the form of the outer side of the locking lever 40 B″. Owing to the toggle lever arrangement, comparatively strong buckling forces can be produced in a simple manner without an additional drive being required. The second coupling element 32 B, which is illustrated in FIGS. 8A to 8C , can therefore generally be omitted. It is also possible to omit the first coupling element 32 A, namely if a third coupling element 32 C is used, such as intermeshing toothed segments, for example according to FIGS. 3A to 3D . It is likewise possible to provide or to combine a toggle lever arrangement according to FIGS. 8A to 8C with an upper locking and unlocking element. This in turn, enables relatively large locking forces with little use of driving force. Such a combination is found in the exemplary embodiment according to FIGS. 9A , 9 B.
[0047] Finally, the exemplary embodiment according to FIGS. 10A to 10D shows an alternative, according to which a freely projecting folding shutter element can be pivoted without a second guide carriage, and the entire folding shutter arrangement can be opened and closed with the same drive. For this purpose, the guide carriage 17 A is raisable and lowerable with a revolving drive element, such as a toothed belt 11 , and is connected thereto at the fastening point A. A coupling element 32 A, as known, for example, according to the exemplary embodiment from FIGS. 1A to 1D , is connected to the freely projecting folding shutter element 12 C in the pivoting-out direction and, at its drive-side end, is connected to the drive element, such as a toothed belt 11 , via a fastening point B. In order initially to buckle the folding shutter elements to a small extent from the extended closed position according to FIG. 10A , an elongated hole, for example, can be provided at the fastening point A of the guide carriage 17 A, along which elongated hole the fastening point A can be displaced relative to the guide carriage 17 B. In order to bring about pronounced pivoting-out of the lower folding shutter element 12 C when the guide carriage 17 A is raised, the driving speeds of the fastening points A and B may differ. For example, the driving cables 11 ′, 11 ″ can run over upper and lower deflecting pulleys 11 A, 11 B of differing size such that, at the same angular speed of the deflecting pulleys, the tension cable 11 ′, which is guided around the larger deflecting pulleys in each case, moves more rapidly than the other one.
LIST OF DESIGNATIONS
[0000]
1 Building
10 Folding shutter arrangement
11 Tension strap, such as toothed belt
11 A,B Deflecting pulleys
12 Folding shutter elements
12 A First folding shutter element
12 A′ First axis
12 B Second folding shutter element
12 B′ Second axis
12 C Third folding shutter element
12 D Fourth folding shutter element
12 E Fifth folding shutter element
13 A First element edge
13 B Second element edge
13 C Third element edge
14 A,B Buckling joint
15 A/B Third element edge
16 A/B Guides
17 A First guide carriage
17 A′,A″ Pivot bearing
17 B Second guide carriage
17 B′ Extension arm
17 B″ Locking cutout
17 B″′ Locking stop
17 C,D Guide rollers
18 A-D Pairs of gearwheels
19 Elongated hole
19 A,B Pivot points
20 Buckling element
21 Sliding rod
21 A,B Sliding rod guide
21 C,E Stop
21 D Sliding rod extension
21 F Compression spring
22 Pulling-up, locking and unlocking device
22 A Driver
22 B Locking lever
22 C Locking stop
24 Buckling aid
24 A,B Lever
24 C Toggle lever joint
24 D Roller
25 A,B Double stop
26 Guide slot
30 Drive element
32 A First coupling element
32 B Second coupling element
32 C Third coupling element
34 A,B Pivot arm
36 A,B Idle travel means
38 Solar panel
39 A,B Surface elements
39 C,D Drives
40 A,B Locking and/or unlocking means and/or buckling means
40 A′,B′ Locking stop I
40 A″, 40 B″ Locking lever
42 Extension means
A,B Fastening points
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In a folding shutter arrangement having three or more inherently rigid folding shutter elements ( 12 ) having element edges that bend out and element edges that do not bend out in alternation, a first folding shutter element ( 12 A) is or can be fastened indirectly or directly to the building ( 1 ) so as to be pivotable about a first axis ( 12 A′), which is stationary or nearly stationary with respect to a building ( 1 ), near a (first) element edge ( 13 A) that does not bend out. A second folding shutter element ( 12 B) is pivotably retained about a second axis ( 12 B′), which can be moved perpendicularly to itself, near a second element edge ( 13 B) that does not bend out, and can be moved along guides ( 16 A, 16 B) arranged perpendicular to the second element edge ( 13 B) in pairs. Adjacent folding shutter elements ( 12 A, 12 B; 12 C, 12 D; . . . ) are pivotably connected to each other in pairs at the third element edges ( 15 A, 15 B) thereof, which bend out and which are opposite from and parallel to the first and second element edges ( 13 A, 13 B; . . . ), by means of a bend-out joint ( 14 A, 14 B; . . . ). Additional folding shutter elements are connected in pairs to the preceding folding element pair and/or a last folding shutter element freely protruding at the end is pivotably connected to the folding element pair(s) near the second, fourth, or further element edge ( 13 B; . . . ) that does not bend out. At least one driving element ( 30 ) is provided, which can be moved along at least one of the guides ( 16 A, 16 B) and which drives at least one, preferably the last, of the second, fourth, or further element edge ( 13 B, . . . ) that does not bend out, in the opening or closing direction, and which forcibly pivots the folding shutter elements ( 12 B, 12 C; . . . ) connected to at least one of the element edges ( 13 B; . . . ) that do not bend out, in pairs in the opening or closing direction by means of at least one coupling element ( 32 A, 32 B, 32 C).
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BACKGROUND OF THE INVENTION
The invention relates to a seat guide device with at least one linear guide system and with a seat base being supported in a movable fashion on the carriage of the system against the force of a spring.
Such seat guide devices are known in particular from the former Bundestag [German Parliament] building in Bonn and the Reichstag [Imperial Diet] building in Berlin. The seats are arranged on and use a support pipe as the seat base, which is supported in a longitudinally movable fashion on the carriage of the linear guide system. In this manner, it is possible to move the seat away from the table, and in so doing giving the spring a tension, which returns the seat base with the seat to its initial position once the user gets up. This automatic return of the seats provides a harmonious arrangement in larger halls and keeps the exit routes behind the seat rows free in that the seats are returned automatically to the initial position; i.e., being guided towards the tables or away from them depending on the installed position.
It has been demonstrated that at greater travel distances, the developed spring tension is so great that the seat with its base is accelerated significantly and hits hard at the stop. Both the mechanical stress and, in particular the associated noise, are undesirable.
SUMMARY OF THE INVENTION
It is, therefore, the objective of the invention to return the seat base of a seat guide device of the aforementioned kind to its initial position in a controlled manner, in particular with a reduced speed compared to the known seat of this type.
This objective, as well as further objectives which will become apparent from the discussion that follows, are achieved, in accordance with the present invention, by providing a damping element, coupled to the carriage and/or the spring, and a block and tackle having at least:
one fixed end which is attached to a stationary attachment point; one loose end which is connected to the carriage; and one first loose pulley which is connected to a stationary attachment point via the spring.
Because the carriage and/or the spring are coupled with a damping element, the seat base, which is accelerated by the tension of the spring, is slowed down. By providing a block and tackle, the tensioning path of the spring is reduced at the same time such that, with the same spring constant as with seat guide device known in the art, the displacement of the spring when moving the seat base back, and thus the tensioning forces, can be reduced by half.
In particular, the arrangement of a block and tackle allows for the use of a gas pressure spring through which the spring and the damping element can be combined. Because of the block and tackle, a gas pressure spring with a short design can be employed. This allows for retrofitting of known seat guide devices without the need to change the overall length of the device. Rather, it is possible to integrate the gas pressure spring in the free space between the preferably two parallel linear guides arranged at a prescribed distance to one another underneath the travel of the carriage.
A second block and tackle that operates opposite to the first block and tackle is provided in a preferred embodiment.
This preferred embodiment designed such that, at the second block and tackle, a fixed end is attached to a stationary attachment point, which with regard to the linear guide system is on the opposite side of the stationary attachment point of the first block and tackle, wherein a loose end is connected with the carriage and wherein a second loose pulley of the second block and tackle coincides with the first loose pulley or is arranged with it on the same rotational axis, or exhibits a rotational axis that is positively connected with the rotational axis of the first loose pulley.
This arrangement in particular avoids the problem of slacking cables when the tensioned spring expands and accelerates the carriage together with the seat base and the seat. The second counter-acting block and tackle has the effect that the seat base can move only according to the movement of the first block and tackle, but that the seat base cannot run ahead of the movement of the first block and tackle, or the return pulley of the first block and tackle, respectively. This prevents the cable from coming off the preferably profiled return pulley. The loose pulleys of the first end of the second block and tackle are coupled such that the movement in the first block and tackle leads to a simultaneous counter-movement of equal length in the second block and tackle. The second block and tackle gives way in the amount that the carriage is pulled back to its initial position. Thus, the carriage is positively suspended between the two loose ends of the two block and tackles and can move only proportional to the displacement of the gas pressure spring.
Preferably both block and tackles use a common loose pulley, which is approached from opposite directions. There may also be two separate pulleys provided, which are supported by a common rotational axis. These embodiments save the most design space.
If more design space is available, the loose pulleys of both block and tackles may also be coupled in some other manner, such that the distance of their rotational axes remains unchanged.
Since a seat guide device is typically long and narrow, due to the linear travel, it is advantageous to attach the fixed ends of both block and tackles at opposite sides of the travel and then to provide several return pulleys in order to create the different force attack directions of the two block and tackles.
To affect a space-saving design, it may be provided to attach the loose pulley of the first block and tackle and possibly also of the second block and tackle directly at the tip of the piston rod of the gas spring.
To achieve simple assembly and/or maintenance, it is advantageous to arrange the return pulleys in pulley carrier units, each exhibiting a horizontal axis that stretches perpendicular to the travel. Also provided in the housing are grooves or other recesses perpendicular to the direction of travel, which stretch, when viewed in a cross-section from the side, in a slanted manner down from one top side of the housing and at the same time to the center of the housing. Thus, the pulley carrier units can be installed by simply sliding their horizontal axes into the recesses. The slant in the recesses prevents the pulley carrier units from sliding out on top of the recesses. In this manner, no additional means of attachment are required for the pulley carrier units. The cable paths determine the distance between the horizontal axes of the pulley carrier units through the slant towards the inside and the coupling of the two block and tackles via a common loose pulley and via attachment points at the carriage. Only after loosening one of the loose ends of the block and tackles can the pulley carrier units be pulled apart from each other and thus pulled out of the recesses in the housing.
One preferred embodiment also provides for the gas pressure spring to be coupled directly to one of the pulley carrier units.
For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the seat guide device according to the present invention.
FIG. 2 is a sectional side view of the seat guide device of FIG. 1 .
FIG. 3 a is a schematic presentation, viewed from above, of a first embodiment of the cable path in the seat guide device of FIG. 1 .
FIG. 3 b is a schematic presentation, viewed from above, of a second embodiment of the cable path in the seat guide device of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to FIGS. 1-3 b of the drawings. Identical elements in the various figures are designated with the same reference numerals.
FIG. 1 shows a seat guide device according to the present invention where all parts are integrated in one housing 1 . Two linear guides 3 are located parallel and at a certain distance to one another in a housing 1 . The seat base 21 is mounted to the rectangular plate 20 , which forms a common carriage for the two linear guides 3 .
Pulley carrier units 10 , 36 are located to the left and right of the linear guides 3 . They each exhibit a horizontal lateral axis 17 , 37 , which is suspended in corresponding grooves 4 , 5 in the housing 1 .
The right pulley carrier unit 36 exhibits at its lateral axis 37 an attachment point 35 from which a first cable 50 with its fixed end 51 runs to the return pulley 53 and from there leads as a loose end 52 to an attachment point 22 at the carriage 20 .
The left pulley carrier unit 10 incorporates two return pulleys 11 , 12 as well as an attachment point 13 , where the cable of a second block and tackle is attached. From the attachment point 13 runs the cable 64 to a loose return pulley 53 and continues from there as cable 63 around the return pulleys 11 , 12 and then from the left housing side into the interim space between the linear guides 3 to the return pulley 33 , which is supported in a rotating manner at the second pulley carrier unit 36 . From the pulley 33 , the cable then runs with its loose end 61 to the carriage 20 , where it is clamped to the attachment point 22 .
Through the cable 61 , 62 , 63 , 64 , the carriage 20 is held back by a return piston movement from left to right triggered by the gas pressure spring 30 according to the embodiment in FIG. 1 .
Return pulleys 2 , with a belt running around them, are provided on the face side in the housing. This belt covers the recess in a not shown cover of the housing 1 , with the seat base 21 being supported in a movable manner in the recess.
FIG. 2 shows the seat guide device with the same position of the carriage and the seat base 21 in a sectional side view.
In particular, the slanted profile of the recesses 4 , 5 for the horizontal lateral axis 17 , 37 of the pulley carrier units 10 , 36 can be recognized in this drawing. Additionally recognizable is that all cables and pulleys are arranged in one plane, resulting in a particularly flat construction.
FIG. 3 a again schematically shows the cables of the design described previously based on FIGS. 1 and 2 with the two block and tackles. Dashed lines on the left and right indicate the pulley carrier units 10 , 36 . The carriage 20 is shown in the center.
The first block and tackle is formed by a first cable 50 with its fixed end 51 being attached to the attachment point 35 at the pulley carrier unit 36 and running across the loose pulley 53 , and with its free end 52 then returning to the attachment point 22 at the carriage.
If the carriage 20 is moved from left to right, then by the pull at the free end 52 , the pulley 53 is pulled to the right causing the piston rod 31 to be pushed into the gas pressure spring cylinder 32 as well. This causes tensioning of the gas pressure spring 30 . During the movement of the carriage from left to right under the tension of the gas spring 30 , a simultaneous pull is exercised on the second cable via the loose pulley 53 . During the pull movement via the cable section 63 , the return pulleys 12 and 11 , the cable section 62 and the return pulleys 33 , the loose end 61 , which is also attached to the carriage 20 , is pulled, i.e., the second cable is being tensioned.
If the gas pressure spring 30 is now given the opportunity to expand, for example, because the user stands up from the seat, the piston rod 31 pushes into the cable 51 , 52 via the pulley 53 and pulls the carriage 20 to the left. To prevent the carriage 20 from running ahead of the cable movement at great acceleration, and to prevent the first cable 50 from coming off the return pulley 53 , the carriage 20 is connected to the second cable; i.e., the carriage 20 is held back via the sections 61 , 62 , 63 of the second cable with the return pulleys 33 , 11 , 12 , 53 .
By the fact that both cables use the same loose pulley 53 , or at least have pulleys with rotational axes that are in a fixed position to one another, only as much cable can be released on the second cable, which is functioning as the holding cable, as on the first cable due to the return pulley 53 moved by the gas pressure spring cylinder. This presupposes an essentially equal angle of contact at the loose pulley 53 . Thus, the different diameters at this pulley shown in FIG. 3 a serve only the purpose of better presentation and do not constitute a preferred embodiment, because a slip would occur due to different arc lengths of the cables in the contact area of the pulley 53 .
FIG. 3 b shows, in a schematic functional form, the cable guides of a slightly modified embodiment, where only one return pulley 11 is provided in the left pulley carrier unit 10 . For all other individual components, as well as in its function, the embodiment shown in FIG. 3 b corresponds to the embodiment shown in FIG. 3 a . By doing without an additional return pulley in the left pulley carrier unit 10 , the design and apparatus investments for the device according to the invention are reduced.
There has thus been shown and described a novel seat guide device which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is to be limited only by the claims which follow.
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A seat guide device has at least one linear guide system and a seat base supported in a movable fashion on the carriage of said system against the force of a spring. The device further comprises:
(a) damping element coupled to at least one of the carriage and the spring, and (b) a block and tackle which includes: (1) one fixed end which is attached to a stationary attachment point; (2) one loose end which is connected to the carriage; and (3) one first loose pulley which is connected to a stationary attachment point via the spring.
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This is a divisional of our co-pending application, entitled "Improved Waste Heat Recovery System", Ser. No. 641,721 filed Dec. 18, 1975, now U.S. Pat. No. 4,083,398.
BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates to the field of waste heat recovery systems, and more particularly to waste heat recovery systems for recovering waste heat contained in exhaust gases for subsequent beneficial use, such as the pre-heating inlet air in an inlet plenum.
2. Prior Art.
A substantial quantity of heat energy is generated as a by-product of many chemical and industrial processes. In many cases, this heat is exhausted into the atmosphere through exhaust stacks and flues because the cost of its recovery has been greater than could be economically justified. This heat is known in the field as "waste heat" because it is, in fact, all too often wasted energy. Perhaps, twenty (20) years ago and earlier, an industrial society could afford to wast energy on a massive scale because the cost of one million BTU's of energy was only about 8 cents. Today, however, the cost of one million BTU's of energy is about $2.00. Thus, there exists today a great economic incentive to recover the waste heat of chemical and industrial processes and to use it beneficially in the process; e.g., to preheat the inlet combustion air.
Waste heat recovery systems are known to the prior art. However, the systems of the prior art have one or more significant shortcomings and limitations. One waste heat recovery system well known and commonly used in the prior art utilizes the so-called Ljungstrom heat exchanger. The Ljungstrom heat exchanger is a regenerative heat exchanger in that it includes a regenerator drum rotatably mounted in a housing divided into separate compartments through which the hot exhaust gases and the cool gases to be heated flow. The drum, driven by an electric motor, has a capacity for heat absorption and release. As the drum rotates, it absorbs waste heat from the hot exhaust gases in one compartment and gives up the heat to the cooler gases in the other compartment.
The Ljungstrom heat exchanger imposes several severe limitations upon any waste heat recovery system in which it is utilized. In the first place, the regenerator drum must be relatively large in order for sufficient waste heat to be recovered. The large drum, in turn, requires the use of large exhaust and inlet compartments and associated ducts, the latter often 6 feet or larger in diameter. Secondly, by virtue of the use of a drum as the basic heat exchange medium, the two compartments of the housing must be located adjacent to one another. Thus, if the gases heated by the drum are to be used at a location remote from the location of the source of the waste heat gases, ducting must be provided between the exchanger and such remote point. Further, a blower of sufficient capacity must also be provided in order to force the heated gases to flow to the remote point of utilization. Thus, such regenerator drum systems suffer from the disadvantages of higher cost (due to the ducting and blower capacity required) and from the fact that they require relatively large installations which, together with the associated ducting, tie up much valuable property in a non-productive manner. For the foregoing reasons, a waste heat recovery system utilizing a Ljungstrom heat exchanger may prove to be economically unfeasible in some applications. In addition, such systems are typically more difficult to install than systems which use a fluid heat transfer medium, such as the present invention. In the latter case, 4 inch pipes are typically used in lieu of 6 foot or larger ducts. Another disadvantage of waste heat recovery systems which employ a Ljungstrom heat exchanger is that they are limited to transferring waste heat from hot exhaust gases to cooler combustion air.
Heat exchange apparatuses and methods are known in the prior art. Such apparatuses are generally used to transfer "process heat", as distinguished from waste heat, from one point in the process to another. Many such heat exchangers utilize a liquid heat transfer medium. However, the temperature and other conditions present in a waste heat recovery application are typically far more severe than those encountered in applications wherein process heat is being transferred. Thus, a reliable and economical waste heat recovery system cannot be constructed by simply utilizing the heat exchanger apparatuses and methods of the prior art, suitable for the transfer of process heat, to solve a waste heat recovery problem.
U.S. Pat. No. 3,623,549, issued to Horace L. Smith, is an example of a prior art heat exchanger utilizing a plurality of heat transfer liquids. Smith's invention transfers heat from a gas at one location to a cooler gas at a second location which may be considerably removed from the first location. Smith discloses the use of at least two independent flow circuits through which different heat transfer liquids flow. Each flow circuit comprises a pair of interconnected finned tube type heat exchangers. The first heat exchanger of each circuit is located in a duct through which the hot gas flows, while the second is located in a duct through which the cool gas flows.
While U.S. Pat. No. 3,623,549 teaches the use of a suitable heat transfer liquid in closed flow circuits for the transfer of heat from one point to a second remote point, it applies such teachings to a general and relatively simple application of hot and cool gases flowing in two separate ducts. Smith's invention does not address itself to the particular conditions typically found in waste heat recovery applications where, for example, the temperatures and pressures at various points are critical parameters which must be controlled. To illustrate this point, the following two temperature constraints on waste heat recovery systems are cited: (i) the temperature of the heat transfer liquid must not reach a level which could damage the pumping means typically used in the flow circuit; (ii) the temperature of the exhaust gases must not be permitted to drop to a temperature at which some of the gases may begin to condense onto the heat exchanger located in the exhaust stack, because such condensation would cause corrosion of the exchanger. If condensation of the exhaust gases is not prevented or substantially mitigated, the heat exchanger in the stack would have to be replaced periodically, thereby causing expense and down time in the operation of the process. Thus, the teachings of Smith are inadequate for the waste heat recovery applications for which the present invention is advantageously suited.
There have been attempts in the prior art to apply heat exchange apparatuses, utilizing a fluid as a heat transfer medium, for the recovery and transfer of waste heat. U.S. Pat. No. 2,699,758 issued to David Dalin, is an example of one such attempt. Dalin discloses an apparatus for improving combustion in the furnaces of steam boilers by preheating the combustion air, in two stages, to a relatively high temperature by using the flue gases as a source of heat for this purpose. He teaches the use of water as a first heat transfer medium in a first stage of waste heat recovery and superheated steam as the medium of heat transfer in the second stage thereof.
Unlike Smith, Dalin discloses the uses of some temperature and pressure control means; e.g., (i) an economizer 19 to insure a definite temperature differential between the two zones of the flue passage at which the heat exchangers draw their heat; (ii) a thermostatically controlled valve 34 which controls flow through a bypass pipe 33; and (iii) a thermally response control element 35 which controls the opening of the valve 34. However, the invention of Dalin suffers from one of the major shortcomings of the prior art at the time of its invention (circa 1950); namely, the unavailability of heat transfer liquids suitable for the high temperatures encountered in waste heat recovery applications. Many of the heat transfer liquids of the prior art flash off at the high temperatures typically encountered in an exhaust stack, thereby creating a fire hazard; others tend to corrode the piping means through which they flow. While water and steam, as heat transfer mediums, do not flash off or cause as much corrosion as other liquids, they have their own disadvantages. Water, since it boils at 100° C., is inherently limited with respect to the amount of heat it can absorb without changing phase. On the other hand, steam, especially superheated steam, introduces the obvious disadvantages of high pressure; for example, severe design requirements with respect to the structural strength of the heat exchange apparatus and associated piping, and (ii) maintenance problems with respect to the detection and repair of leaks.
Still another disadvantage of the Dalin system, attributable to its use of superheated steam as the heat transfer medium, is the limitation that the latter imposes with respect to the distance between the flue passage (or exhaust stack) and the place to which the waste heat is to be delivered. If the distance is great enough, the continuing loss of heat through the conducting pipes may cause the superheated steam to condense to water. As a result of the heat transfer medium being in two phases within the flow circuit (i.e., steam and condensed water), its flow becomes non-uniform and difficult to regulate. If the flow of the heat transfer medium cannot be readily regulated, the control of critical temperatures within the system becomes more difficult, if not impossible.
U.S. Pat. Nos. 3,405,509 and 3,405,769 disclose means for recovering waste heat in the exhaust stack of fired oil field equipment. The invention disclosed in U.S. Pat. No. 3,405,509 is limited in that it uses, as the heat transfer medium, the very oil well product fluids, (e.g., a mix of oil and water) which are being processed. U.S. Pat. No. 3,405,759 likewise teaches the use of the process liquid as the heat transfer medium. However, the latter patent also teaches the use of a separate heat transfer fluid contained in a source separate from the process fluids; in the latter connection, however, the patent teaches the use of water and steam as the separate heat transfer fluid, both of which have the disadvantages and limitations described above with reference to U.S. Pat. No. 2,699,758 (Dalin).
Most recently a system has been introduced which utilizes a first heat exchanger in the stack or flue, a second heat exchanger at the waste heat utilization site, such as by way of example the inlet air plenum to a set of burners, with a suitable liquid heat transfer medium carrying the waste heat therebetween. This system with its associated control apparatus provided for efficient waste heat recovery. However, installation of such systems could be time consuming, and the down time cost while the system was being installed could be on the same order as the cost of the waste heat recovery system, or higher. Aside from the fact that the first heat exchanger was actually mounted in the stack or flue, thereby requiring substantial cutting, welding and plumbing while the system is shut down, many furnace systems, particularly those fabricated since the second world war, do not have adequate structure in the stack or flue to support the heat exchanger and associated hardware, and accordingly the entire stack has to be reinforced from ground level to provide adequate structure for the required load. This is time consuming, and can lead to excessive down time, making the cost of the waste heat recovery system excessive and deterring the more immediate application of such system.
BRIEF SUMMARY OF THE INVENTION
A system for recovering the waste heat normally exhausted into the atmosphere by chemical or other processing plants. The invented system comprises a substantially self-contained apparatus for coupling to an exhaust stack and an inlet air plenum for furnaces so as to extract the waste heat from the exhaust gas for delivery to the inlet air. The system may include temperature and pressure controls which enhance the safety and efficiency of the system's operation, and further may include flow control in a multiple burner installation so that the desired fuel air ratios and heat distribution may be achieved. While the primary control is generally determined by a lower temperature limit for the exhaust gas below which condensation may occur, over-temperature and other controls are also provided. By building the present invention as a substantially self-contained and self-supporting assembly, on site installation time and the required alteration and reinforcing of pre-existing on site equipment may be minimized, thereby affecting substantially economic savings by minimizing the resulting down time of the processing plant for installation. Embodiments for a single burner nest heater, multiple nest cabins and grade level stack systems, as well as a specific embodiment of heat exchanger for use in the systems of the present invention, are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a vertical stack furnace system incorporating one embodiment of the present invention.
FIG. 2 is an illustration of the system of FIG. 1 taken on an expanded scale.
FIG. 3 is a perspective view of an alternate embodiment coupled to a cabin having multiple burner nests therein.
FIG. 4 is a still further alternate embodiment for use with grade level exhaust stack systems.
FIG. 5 is a perspective view of a heat exchanger which may be used as the exhaust gas heat exchanger in the present invention systems.
DETAILED DESCRIPTION OF THE INVENTION
The present invention comprises a waste heat recovery system which provides for the efficient and well controlled recovery of exhaust gas heat for such purposes as preheating air in an air inlet plenum of one or more burner assemblies. Three embodiments are actually disclosed and described in detail herein, each employing the general principles of the present invention, but each directed to one of the three more commonly encountered furnace and exhaust configurations. In particular, the first embodiment described is for a conventional furnace having an inlet air plenum and a single vertical exhaust stack coupled to the top of the furnace. The second embodiment is for a cabin having a bank of burner nests, with the inlet plenum being comprised of separate plenums for each nest, and the third configuration is for use in conjunction with ground level exhaust systems.
One key aspect to the present invention is its modular construction which minimizes the extent of on site construction and alteration that is required, thereby minimizing the down time required for installation. By use of the modular construction, the waste heat recovery system of the present invention is generally self-supporting so that only ducting, dampers and other relatively light-weight apparatus need be coupled to the exhaust stack, thereby generally eliminating the need to provide increased reinforcing for the entire stack. While major servicing of a furnace installation may require a down time of approximately six weeks, routine periodic maintenance normally has a turn around time on the order of two weeks. To the extent that the on site installation time required to install the present invention system may be minimized, installation may be achieved during a routine periodic maintenance without substantial increase in the down time required, thereby effecting overall savings even though the fabrication cost of certain component assemblies may be somewhat increased.
Now referring to FIG. 1, one embodiment of the present invention as it would be coupled to a typical furnace or heater of the prior art may be seen. The furnace with which this embodiment is utilized, generally indicated by the numeral 20, is comprised of a furnace chamber 22 having an air inlet plenum 24 coupled to burners within the furnace (not shown), with a single vertical exhaust stack generally indicated by the numeral 26. Typically the inlet air plenum 24 will be provided with a blower at the inlet thereof to force air past the burners at the desired velocity.
The present invention comprises the self-standing structure 30 and apparatus contained therein to provide a waste heat recovery system which may be readily coupled to existing furnace installations, as shown in FIG. 1. The key components of the waste heat recovery system 30 visible in FIG. 1, aside from its frame assembly 32, are an inlet air duct 34 containing a heat exchanger 36, with a fan 38 providing the required inlet air velocity past the heat exchanger 36 into the inlet air plenum 24, and an exhaust air duct 40 containing a heat exchanger 42 and blower 44. The exhaust air duct 40 with heat exchanger 42 is coupled through a first duct 46 to the stack 26 for directing the hot exhaust gases from the stack into the duct 40 and past the heat exchanger 42. A second exhaust gas duct 48 redirects the cooled exhaust gas delivered from blower 44 back to the stack 26, typically at an elevation above the elevation of the inlet duct 46 for subsequent flow directly out through the remaining stack structure. Preferably, a damper 50 is provided in the stack between the connections of ducts 46 and 48 to controllably block the flow of exhaust gas in this region, with a second damper 52 providing a control of the exhaust gas flow through the apparatus of the present invention. Thus with damper 50 closed and damper 52 open, the normal exhaust gas flow from the furnace will be diverted by damper 50 through duct 46, past the heat exchanger 42, and back into the exhaust stack 26 at a position above damper 50 through duct 48 for subsequent disposal through the furnace stack structure. On the other hand, should cleaning or other servicing of the apparatus of the present invention be required at times when the furnace system is otherwise preferably not to be shut down, damper 52 may be closed and damper 50 opened to temporarily operate the furnace structure in the prior art manner. Further the control of these dampers provides a convenient way of preventing an excess temperature rise in the heat exchanger 42, as the approachment of an excessive temperature in the duct 46 for the heat exchanger 42 may be used to close damper 52 and open damper 50. For this purpose a single excess temperature detection point might be used to provide an ON/OFF type control for the two dampers or if desired, a proportional control of the dampers could be used (in most instances in normal operation of the system of the present invention, damper 52 will be in the maximum OPEN position and damper 50 will be in the maximum CLOSED position).
Now referring to FIG. 2 the structure 30 of FIG. 1 may be seen on an expanded scale. In addition to those elements hereinbefore identified with respect to FIG. 1, there is provided a heat transfer fluid flow circuit and associated supply and control apparatus to provide efficient and well controlled operation of the system. A reservoir 54 provides a supply of heat transfer fluid 56 which may be pumped by pump 58 through lines 60 and 62 into the first heat exchanger 42, and therefrom through lines 64 to the second heat exchanger 36, with a return to the reservoir 54 being provided by line 66. Accordingly in operation the heat transfer fluid 56 in the reservoir circulates first through pump 58, then the heat exchanger in the exhaust gas flow stream, then to the heat exchanger in the inlet air duct and finally back to the reservoir. Thus, the temperature of the fluid in the reservoir will generally be approximately the same as the temperature of the fluid on the outlet side of the heat exchanger 36, with the outlet side of heat exchanger 42 in line 64 representing the hottest portion of the heat transfer fluid circuit. These temperature extremes may be quite severe depending upon the apparatus and the environment in which it is used, and accordingly system controls are provided to maintain the operating conditions within acceptable bounds consistent with material limitations for the heat exchanger materials and the heat transfer fluid. In that regard, heat transfer liquids capable of operating at extreme temperatures, ranging from as low as -80° F. up to as high as 900° F. are known. Such liquids include O-dichlorobenzene, diphenyl-diphenyloxide eutectic, di-aryl ethers and tri-aryl ethers sold by Dow Chemical Company under the trademark "Dowtherm" and hydrogenated terphenyls, and polychlorinated biphenyl and polyphenyl ether sold by the Monsanto Company under the trademark "Therminol". Other suitable heat transfer liquids are alkyl-aromatic petroleum oil, sold by Socony Mobil Oil Co. under the mark "Mobiltherm"; alaphatic petroleum oil sold by Exxon under the mark "Humbletherm"; and a good grade, pure lubricating oil. Any of these products would be suitable for most applications in which the present invention has utility. These preferred heat transfer liquids do not become too viscous for controllable flow at the low temperatures nor do they tend to flash at the high temperatures. In order to avoid leakage of air into the system through any possible leak which could develop, and to overcome the vapor pressure of the heat transfer fluids, particularly at the higher temperature and lower pressure regions of the flow circuit, it is preferable to pressurize the system so that the lowest pressure encountered by the heat transfer fluid is at least higher than atmospheric, and more preferably on the order of 25 psi gauge or higher. For this purpose a standard nitrogen tank 68 with a first pressure regulator 70 for providing pressurized nitrogen through line 72 to the top of the reservoir 54 is provided.
There are certain parameters within which it may be necessary to control the system of the present invention. By way of example, the exhaust stack temperatures may range from 550° F. to 900° F. or higher, so that it may be necessary to limit the maximum temperature on the outlet side of the heat exchanger 42 in line 64 to some upper boundary which is below the chemical degredation and/or boiling point of the heat transfer fluid at the established pressure in the flow circuit. Also, products of combustion normally include not only water but other compounds, some of which are extremely corrosive in the liquid form. Typically, such products of combustion will remain in the gaseous state in an exhaust stack if the temperature thereof remains in the region of 350° F. or higher, and accordingly it may be desirable in some applications, depending upon the particular requirements, to control the system so that the temperature of the heat transfer fluid in the outlet line 64 from heat exchanger 42 is at least 350° F. To accomplish this control a first temperature sensor 74 is provided in line 64 to provide a first temperature control signal on line 76 to a controller 78. This signal is used as the basic flow control by controlling valve 84, increasing the flow on temperature increases and decreasing the flow on temperature drops.
As a second temperature control parameter it will be noted that in typical applications the inlet air temperature to blower 38 is normally in the range of 30° F. to 70° F. though much colder air may be encountered depending upon the installation and environment. Accordingly it may be desirable to limit the lowest temperature of the heat transfer fluid in line 66, that is, the outlet of heat exchanger 36, and for this purpose a second temperature sensor 80 is provided in line 66 to provide another temperature control signal on line 82 to the controller 78.
In the event the temperature in the outlet line 64 of heat exchanger 42 exceeds predetermined control limits, various types of control may be implemented. The first type of control is provided by an excess heat exchanger 86 which merely dumps excess heat into the environment upon the flow of the heat transfer fluid therethrough. This flow is controlled by a valve 88 operative from a pressure switch 90 in the by-pass line 92. A set of manual valves 94 is also provided so that the flow in the by-pass line 92 may be directly returned to the reservoir 54 without flowing through the excess heat exchanger 86. In the event of a still further temperature rise in line 64, temperature sensor 74 may provide a signal to the controller 78 which may be used to open damper 50 and close damper 52 and/or to open valve 96 coupled to the nitrogen supply 68 through a regulator 98 to inject relatively high pressure nitrogen into line 62, thereby blowing the heat transfer fluid out of the heat exchanger 42 to clean the exchanger prior to its reaching temperatures which would damage the heat transfer fluid. Of course at the same time pump 58 would be turned off and the system otherwise deactivated pending the reestablishment of control.
It is also desirable to maintain the temperature in the outlet of heat exchanger 36 above some predetermined limit, and for this purpose a temperature sensor 80 is provided which may be used to provide a control signal to the valve 84 thereby determining the flow through the heat exchanger which in turn affects the outlet temperature thereof. Such a flow control allows the control of the greatest viscosity of the heat transfer fluid, thereby assuring adequate flow throughout the system by avoiding excessive flow pressure drops. A third temperature sensor 102 is provided in line 60 between the reservoir 54 and pump 58 to indicate the fluid temperature being delivered from the reservoir. This temperature sensor is thus indicative of the reservoir temperature, whether such temperature depends upon flow through the heat exchanger 36, the excess heat exchanger 86, or the by-pass system, and may be used to prevent overheating the pump. Thus, through the various temperature and pressure controls provided, heat transfer fluid flow throughout the system may be controlled by the various valves therein to control the amount of heat recovered, and to maintain the temperatures and pressures in the system within predetermined bounds.
As an additional control feature it should be noted that the reservoir 54 should never become entirely full or empty of heat transfer fluid, whether from overfilling, differential expansion or leakage of the fluid. Accordingly, for visual inspection purposes a gauge glass 104 is provided. In addition, a vertical tube is provided having float switches 106, 108 and 110 therein. Float switch 106 is used to indicate an overfill condition, with switch 108 indicating a low fluid condition and switch 110 indicating a near empty condition. In operation, switches 106 and 110 are used to shut down the system and sound an alarm, while switch 108 is used to provide a visible or audible signal, or both, to indicate the need for replenishing the reservoir. Accordingly the systems of the present invention include pressure, temperature, flow and fluid level controls to maintain operation within predetermined bounds if possible, and to shut down the system and sound an alarm if any one parameter exceeds the predetermined control limit.
Now referring to FIG. 3, an alternate embodiment of the present invention may be seen. This embodiment may be utilized with a plurality of furnaces 110, each having their exhaust ducted to a common exhaust plenum 112 and exhaust stack 114. The structure 30a of this embodiment of the invention is substantially the same as the structure 30 described in detail with respect to FIGS. 1 and 2, though in this case the single heat exchanger 36 of the earlier embodiment actually comprises multiple heat exchangers 36a, each of which is coupled to heat exchange fluid lines 64a and 66a. Valves 116 may be provided in each of the individual lines supplying these heat exchangers, if desired, to provide either manual control of the relative heat transfer fluid flow in each of the heat exchangers, or if desired, automatic flow control may be provided. Thus each of the individual furnaces may have a blower 38a supplying an inlet plenum 34a having the exchangers 36a therein, when there is insufficient draft due to the typically low pressure drop of the combustion air across the heat exchanger. By providing dampers 50a and 52a, and more particularly by closing damper 50a and opening damper 52a, the combined exhaust normally expelled through stack 114 may be redirected through the apparatus 30a of the present invention for the extraction of the heat therein and the return thereof to the stack 114.
The embodiment of FIG. 3 is highly advantageous for furnaces or furnace cabins of the type shown for a number of reasons. First it allows exceptionally good control on the heat recovery, and more particularly in the distribution of the heat added to the inlet air to each burner nest in the furnace, based on temperature sensors in each of the multiple furnace assemblies. This is particularly important, as dampers may be provided in each of the inlet air plenums, which together with control of the fuel flow in each burner nest, will allow for a more uniform temperature distribution across the length of the entire cabin. (The uncontrolled temperature distribution along a cabin tends to vary considerably, with the maximum being in the center and the minimum at the end furnaces.) This structure is also highly advantageous as it allows prefabricating at a remote location, with a minimum of onsite construction and down time required for installation. This particularly is true in those systems wherein the furnace stack does not have sufficient structure to support the weight of a heat exchanger in the stack, and which therefore otherwise would have to be structurally reinforced from the ground up to incorporate a waste heat recovery system utilizing a heat exchanger in the stack. The present invention is further highly advantageous, since any maintenance or repair of the waste heat recovery system, even with respect to the exhaust duct heat exchanger, may be accomplished without requiring the shutdown of the furnace system itself.
Now referring to FIG. 4 a still further alternate embodiment of the present invention may be seen. This embodiment is intended for use with ground level stacks such as stack 120, which typically run just below ground level to a remote vertical stack, schematically shown in the figure. The apparatus of this embodiment 30b is substantially the same as the apparatus 30a of FIG. 3, though it is generally constructed with a horizontal rather than vertical arrangement so that it may be conveniently disposed over the stack 120 and coupled to the stack through inlet and outlet ducts 122 and 124. Also by the utilization of dampers 50b and 52b the stack exhaust flow may be diverted through the apparatus of the present invention, with the recovered waste heat in the heat transfer fluid being delivered through lines 126 and 128 to the heat exchanger in the inlet air plenum 130 for furnace. As in the embodiment of FIGS. 1 and 2, pressure, temperature, flow and fluid level controls are provided in the apparatus 30b so as to provide maximum control and reliability in the operating system and to require minimum installation time.
Now referring to FIG. 5, a form of heat exchanger which has been found to be particularly useful with the present invention waste heat recovery system may be seen. In prior art systems the heat exchangers have typically been what is referred to as the finned coiled type exchanger, wherein disc like fins are disposed over a tube, such as a copper tube, which is then expanded to retain the fins in the desired position. However, particularly because of the temperatures encountered in exhaust stacks, the heat exchangers schematically represented in FIG. 5 have been found more desirable. In particular, these heat exchangers comprise inlet and outlet manifolds 140 and 142 respectively, with one or more inlets 144 and outlets 146 in communication therewith. A plurality of heat transfer fluid conducting tubes 148 are disposed in a pattern therebetween, with plates 150 pressed over the ends thereof prior to coupling the tubes 148 to the manifolds 140 and 142. Accordingly, flow restriction is minimized, as the heat transfer fluid makes multiple passes, typically at least eight, through the heat exchanger during the heat transfer cycle. This particular construction is also advantages as it allows fabrication of the heat exchangers utilizing steel plates and tubes, since it does not depend upon the expansion of the heat exchanger tubing to retain the fins as in the prior art.
There has been described herein three specific embodiments of the present invention, as well as a unique heat exchanger form particularly advantageous for use with the present invention. The present invention embodies complete waste heat recovery systems, allowing maximum fabrication at a remote location and minimum on site construction to make the systems operative. Further, the systems are so disposed and coupled to the existing furnace systems so as to allow any required servicing of the present invention systems without requiring the shut down of the furnaces. The primary temperature control as illustrated in FIG. 2 is a heat transfer fluid flow control valve 84 operative by a temperature sensor 74 indicative of the outlet temperature for the exhaust stack heat exchanger 42, thereby assuring that the exhaust gas is not cooled below the condensation temperature for the contaminates there. The primary pressure control as illustrated in FIG. 2 is the pressure sensor 90 and bypass valve 88. However, other controls are provided to provide efficient operation and to avoid damage to the system by loss of control for any reason. It should be understood, however, that while three specific embodiments of the present invention have been disclosed and described in detail herein, various changes in design and detail may be made therein without departing from the spirit and scope of the invention.
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A system for recovering the waste heat normally exhausted into the atmosphere by chemical or other processing plants. The invented system comprises a substantially self-contained apparatus for receiving hot exhaust gases and extracting the waste heat therefrom for some beneficial use, such as pre-heating inlet air in an inlet plenum. The system may include temperature and pressure controls which enhance the safety and efficiency of the system's operation, and further may include flow controls in a multiple burner installation so that the desired fuel air ratios and heat distribution may be achieved. By building the present invention as a substantially self-contained and self-supporting assembly, on site installation time and the required alteration of pre-existing on site equipment may be minimized, thereby affecting substantial economic savings by minimizing the resulting down time of the processing plant. Embodiments for a single burner nest heater, multiple nest cabins and grade level stack systems are disclosed.
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BACKGROUND
The present invention relates to boat moorings and more particularly relates to improvements in swing moorings suitable for moorings which require a 360 degree sweep thereabout. More particularly the invention relates to a simple swing mooring which enables mooring of two boats abreast but within the same area normally required by one boat.
PRIOR ART
Mooring of boats in public waterways is becoming an increasing problem due to the limitations on available space. Typically boats are moored in marinas or on swing moorings. The invention to be described herein relates to the latter type of moorings. Swing moorings which are usually found in rivers harbors, estuaries, inlets and the like are provided by maritime authorities for lease or purchase by persons such as boat owners, mariner clubs, private and commercial boat owners. A swing mooring will typically comprise a heavy weight such as a concrete block bearing on the sea or river bed a chain connected at one end to said weight and at an opposite end a float on the surface of the water. The chain may be connected directly to the float or to a length of rope which is connected to the float. The length of rope allows a crew member to more conveniently pull the float to the vessel for securing to the anchorage. When the boat is connected to a swing mooring it must have 360 degrees of clearance to swing to face the prevailing wind direction. This means that each boat moored in this way will take up a large area and in locations where hundreds of boats are to be moored this will put limitations on the number of moorings to the point where for a given water area there will be a finite number of moorings. In some waterways there are long waiting lists for swing moorings which are normally leased or bought from the local maritime authority. Moorings are a source of revenue for the government, thus it follows that if the number of moorings per unit area and thus boats per unit area could be increased, not only would there be more mooring space available for boat owners, there would also be a source of increased revenue for the government. There are a variety of mooring devices and apparatuses for mooring boats at jetties, wharves, pontoons and the like. The known systems and devices may be divided into two categories. The first relates to those devices that are used for connecting a boat to its mooring and the second relates to the mooring itself.
As an example of the first category, U.S. Pat. No. 6,213,017 discloses a device for mooring a boat has an elongate handle with proximal and distal ends. The distal end has an eyelet. A flexible mooring line with a first end is joined to the eyelet and a second end is added to join to the boat. The line extends through the eyelet and about an exterior of the handle member to the proximal end to form a loop at the distal end. The size of the loop can be adjusted by feeding more or less of the line through the eyelet. A flexible retaining line is joined to the proximal end and adapted to join to the boat.
As an example of the second category, U.S. Pat. No. 6,105,530 discloses a floating wharf or pier for boat for ship mooring, comprising a body having a hollow structure defining at least one floatation chamber, said at least one floatation chamber being accessible from outside and defining a storage compartment and an upper admittance hatch member through which said at least one storage compartment is accessible.
U.S. Pat. No. 6,273,016 discloses a portable assembly for supporting a watercraft in relation to a surface flooring of a body of water. The assembly includes a support member for supporting the watercraft and an engaging member adapted to be connected to the support member to selectively retain the watercraft in relation to the support member. A securing assembly is operably connected between the support member and the watercraft to provide a compressive loading force therebetween. Preferably, the support member is formed of a substantially rigid construction. The engaging member is adapted to receive the support member in engagement therewith and may be configured to pivotally engage the watercraft. The securing assembly is moveable between a first position and a second position, thus converting a portion of the weight of the watercraft into a compressive load on the support member. The apparatus for supporting a watercraft may also include a retaining member disposed in relation to the support member. The retaining member helps to resist slippage of the support member in relation to the surface flooring of the body of water, when the securing member is disposed in the second position.
U.S. Pat. No. 6,062,158 discloses a Vessel mooring device. The device is a simple and yet efficient device for mooring vessels that floats up and down with the tide on vertical piling which maintains both ends of a mooring line at approximately the same height from the water. This is accomplished by providing a stainless steel cage with upper and lower rings with interior diameters larger than the diameter of the piling. These rings are connected by a plurality of risers. A bail or other securing means is used to secure the end of a mooring line. A bend is provided in each of the risers near the bottom ring so that the risers project outwardly. A floating means having an interior diameter smaller than the diameter of a plane passing through the bends in the risers is slipped over the lower ring and wedges on the risers so that the mooring device can rise and fall with the tide.
U.S. Pat. No. 5,832,861 discloses a boat docking or mooring apparatus having an elongated tubular housing wherein the housing is adapted for positioning between a boat and a dock while providing positive control in two directions. Adjacent each end of the housing a pin is utilized to secure an elongated helical spring within the housing. End caps, each including a pair of spaced apart cable guiding apertures, are provided at each end of the housing. At one end of the housing, a cable, looped though the apertures in an end cap, engages the elongated spring within the housing. In a similar manner, another cable is looped through the apertures of the other end cap and engages the other spring within the housing. In use, either cable is suitable for convenient attachment to a boat cleat or to a dock cleat. During operation, the combination of spring, cables and cable guiding end caps cooperate to dampen sudden boat movements and, even under adverse conditions, to transfer loads away from the spring and cables by achieving a slow load transfer, thereby stabilizing the boat and preventing damage to boat and dock.
U.S. Pat. No. 5,988,087 discloses a pontoon for a boat including a base member and a closure member which are attached to form a U-shaped performance structure and a cylindrical support structure. A foam filled nose cone is connected to front ends of the base member and closure member, and an end cap is connected to the back end thereof to form an air tight chamber in the support structure. The pontoon is connected to a deck of the boat, so that the pontoon contacts the deck along the entire length of the pontoon. None of the prior art devices identified disclose a swing mooring capable of anchoring two vessels side by side such that the radial float area required is the same as the float area for a single vessel.
INVENTION
The present invention provides an improved swing mooring which increases the number of available moorings per unit area in a simple and efficient manner. More particularly the present invention relates to a module for a swing mooring which enables the safe mooring of two vessels in an area which would previously have accommodated only one vessel.
According to one aspect, in its simplest form, a mooring element comprises a pontoon configured to enable two vessels to be moored side by side and including an area between the vessels which allows a person to walk between the vessels.
According to another aspect the present invention provides a mooring assembly comprising a plurality of mooring pontoons each of which are capable of mooring at least two boats.
In its broadest form the present invention comprises:
a water craft mooring capable of anchoring water craft; the mooring comprising at least one mooring element; wherein each element comprises a floating body including a leading end and a trailing end; and wherein at least part of each said element provides a spacer for separating boats attached to said mooring. Preferably, each element is anchored so that each is capable of swinging responsive to wind or current direction.
Each element is subsantially T shaped wherein; a short leg of said T comprises said leading end and a long leg of said T comprises said spacer. One advantage of the T shape is that it imparts lateral and longitudinal stability to the mooring element.
Each element comprises a pontoon including at least one recess formed therein which accommodates at least part of a boat length of a boat attached to the pontoon.
The spacer allows two boats to be connected in spaced apart relationship such that as the mooring swings the boats swing without unwanted engagement with each other.
Outside splayed edges are disposed adjacent the leading end of each said element which are capable of engaging an opposing corresponding splay edge of an adjacent like pontoon. In one embodiment, a trailing edge of one pontoon is capable of engagement with a trailing end of a like pontoon to define a recess capable of accommodating a boat of predetermined length. The recesses which accommodate at least part of a boat length are defined by inside splay edges and a lateral edge of the spacer.
In another embodiment, the pontoons are disposed in alignment so that a trailing end of one pontoon engages a leading end of an adjacent pontoon. In another embodiment at least two pontoons are disposed so that outside splay edges of one pontoon engage opposing outside splay edges of adjacent pontoons such that a longitudinal axis of one pontoon is parallel to but out of alignment with a longitudinal axis of at least one other like pontoon. Pontoons may be arranged so that a trailing end of one pontoon engages a trailing end of an adjacent like pontoon. Typically, the spacer includes opposing faces each of which engage one of said boats.
In another broad form the present invention comprises;
a swing mooring for enabling the anchorage of two boats therefrom; the mooring comprising a floating element having a leading end and a trailing end,
intermediate said leading end and said trailing end a spacing element located between said boats to keep said boats spaced apart but disposed in substantially the same orientation; wherein the mooring allows both boats to rotate within the same 360 circumference subtended from said float.
According to a preferred embodiment, the spacing element includes opposing faces each of which engage one of said boats. Preferably said mooring allows both boats to face the prevailing wind direction contemporaneously.
In another broad form the present invention comprises;
a twin berth swing mooring comprising a mooring element arranged to be connected to a mooring anchorage at or near a leading end the mooring element including a spacer to separate two adjacent boats connected to said mooring; the spacer including opposing side faces which each engage one said boats so that said boats are oriented in substantially the same direction.
Preferably, said boats are connected to said mooring element in spaced apart but parallel relationship.
In another broad form the present invention comprises;
a module for use as a swing mooring for enabling the anchorage of two boats thereto; the module being adapted for floatation and including a leading end and a trailing end; and
intermediate said leading end and said trailing end a spacing element located between said boats to keep said boats spaced apart but disposed in substantially the same orientation; wherein the module allows both boats to rotate within a 360 circumference subtended from said float.
In another broad form the present invention comprises;
a swing mooring for enabling the anchorage of two boats therefrom; the mooring disposed radially of an anchorage and subtended by a sea bed weight; the mooring comprising a floating element having a leading end and a trailing end,
intermediate said leading end and said trailing end a spacing element located between said boats when said boats are connected to said mooring to keep said boats spaced apart but disposed in substantially the same orientation; wherein the mooring element is subtended from a center position defined by said weight.
In another broad form the present invention comprises:
a floating swing mooring and capable of retaining two boats at the same time; the buoy comprising a generally T shaped body including a leading end and a trailing end, wherein the leading end comprises a head which is connected to a tether such as a rope, webbing or chain and the trailing end is free to move in a 360 degrees arc; wherein intermediate said leading end and said trailing end there is provided an arm having opposing outer surfaces which are continuous with a corresponding surface on said head to define recesses either side of said arm which each receive a boat hull; wherein said boat hulls are tied to said arm via cleats located thereon and provide spacing between said boat hulls so as to prevent unwanted contact between said boat hulls and wherein said boat hulls when connected to said arm are disposed in generally the same windward direction such that both boats are able to rotate in unison in an arc 0-360 degrees.
DETAILED DESCRIPTION
The present invention will now be described in more detail according to a to a preferred but non limiting embodiment and with reference to the accompanying illustrations wherein:
FIG. 1 shows a perspective view of a swing mooring element according to one embodiment of the invention.
FIG. 2 shows a rear end underside perspective plan view of the mooring element of FIG. 1 ;
FIG. 3 shows a top perspective view of the mooring element of FIG. 1 with lateral extremities exploded.
FIG. 4 shows a perspective underside view of the mooring element of FIG. 1 with spreader plate and attachments straps to underside of swing mooring
FIG. 5 shows a typical mooring according to one embodiment with two boats attached.
FIG. 6 shows a cross sectional elevation of a mooring pontoon taken at line X-X as shown in FIG. 6 a;
FIG. 7 shows a cross sectional elevation of a mooring pontoon taken at line X-X as shown in FIG. 7 a;
FIG. 8 shows a long sectional election of a mooring pontoon taken at line X-X as shown in FIG. 8 a;
FIG. 9 shows a plan view of a mooring assembly according to one embodiment, formed by a plurality of mooring elements.
FIG. 10 shows a plan view of a mooring assembly according to an alternative embodiment in which elements are disposed end on end;
FIG. 11 shows a plan view of a mooring assembly according to an alternative embodiment, formed by a plurality of mooring elements.
FIG. 12 shows a plan view of a mooring assembly according to a further embodiment, formed by a plurality of mooring elements disposed so that a leading end engages a trailing end of an adjacent element.
FIG. 13 shows a perspective view of a spreader plate according to one embodiment.
FIG. 14 shows a perspective view of the spreader plate of FIG. 13 .
Referring to FIG. 1 there is shown a perspective plan view of a swing mooring element 1 according to one embodiment. Element 1 which is adapted for flotation includes a leading head region 2 and a trailing narrower tail region 3 . Head region 2 according to one embodiment, includes a leading edge 4 , adjacent outside splay edges 5 and 6 . Intermediate leading edge 4 and trailing end 7 are inside splay edges 8 and 9 . Narrow region 3 is defined by edges 10 and 11 and trailing end 7 . Respective edges 8 and 10 and 9 and 11 define respective recesses 12 and 13 which each receive at least part of a boat tied to mooring element 1 . Typically a mooring element will include cleats bollards or other means for securing marine vehicles. Mooring element 1 includes bollards or cleats 14 which are distributed across upper surface 15 of mooring element 1 according to particular anchorage requirements. In the case where a boat is moored in recess 12 it will preferably be connected to cleat 16 and bollards 17 and 18 . Where a boat is moored at recess 13 it may be connected via cleat 19 and 20 and bollard 21 . Selection of anchorage to cleats and/or bollards located on upper surface 15 may depend upon the size of the vessel and the prevailing weather and sea state. Tail region 3 provides a spacer to keep apart adjacent boats which will be moored in recesses 12 and 13 .
FIG. 2 shows a rear end underside perspective plan view of the mooring element of FIG. 1 with corresponding numbering. Underside surface 22 of mooring element 1 includes anchorages 23 , 24 25 and 26 which receive tethers (not shown) which are connected to a spreader plate (see FIGS. 13 and 14 ). These anchorages are spaced on underside surface 22 of mooring element 1 to ensure that the resultant anchorage force applied to the element is positioned to satisfy stability criteria. Pontoon stability criteria must be satisfied in the free state and when a vessel is moored to the pontoon. In the latter case the boat will alter applied loads to the pontoon. Provided the resultant anchorage force (see FIG. 4 ) is positioned within an optimal area, stability criteria will be satisfied in both the free state and when a vessel or vessels is/are anchored.
FIG. 3 shows an exploded top perspective view of the mooring element 1 of FIGS. 1 and 2 with corresponding numbering. In one embodiment, side elements 27 and 28 can be detachably fixed to leading end 2 . Elements 27 and 28 contain respective bollards 29 an 30 which may be replaced in the event of such events as birthing impact, wear or deterioration, by replacement of side elements 27 and 28 which may be exposed to impact damage or wear. Alternatively, removable elements 27 and 28 allow the overall width of the pontoon 1 to be reduced for road transportation. For convenient detachment of elements 27 and 28 a bracket (not shown) may be provided. Preferably elements 27 and 28 are bolted to pontoon 1 in a conventional manner. Alternatively elements 27 and 28 are permanently fixed to pontoon 1 .
FIG. 4 shows a perspective underside view of the mooring element of FIG. 1 with spreader plate 31 and attachment straps (webbing) 32 , 33 , 34 and 35 respectively attached to anchorages 23 , 24 , 25 and 26 of surface 22 . Anchorages 23 , 24 25 and 26 will preferably be disposed so that spreader plate 31 will stabilize mooring element 1 such that the resultant downward force will be applied at a location which optimizes stability in the free state and when a vessel is anchored to the pontoon to ensure the mooring element is kept level and not subject to eccentric loading. Spreader plate 31 used with webbing is intended to eliminate galvanic corrosion between the pontoon and anchor chain. This is particularly important when the pontoon is made of alloy.
As an alternative to webbing, chains, ropes or the like may be used. Throughout the specification, a reference to straps may be taken as referring to webbing, chains, rope or the like.
FIG. 5 shows a perspective view of a typical mooring element 40 according to one embodiment with two boats 41 and 42 attached. At least part of the hull of boat 41 is disposed within recess 43 defined by edges 44 and 45 . Similarly at least part of a hull of boat 42 is disposed in recess 46 defined by edges 47 and 48 . In a typical arrangement, mooring element 40 will be retained by an under pontoon mooring apparatus connected to a spreader plate in a like arrangement to the spreader plate 31 described with reference to FIG. 4 , which enables the element to move in a 360 degree circumference. Mooring element 40 will generally (where there is minor current flow) point to windward but the wind direction will dictate its compass direction particularly where vessels are attached. Known swing moorings provide for attachment of only one boat and although it might be conceivable that two boats could be connected to one mooring by rafting up, this would be entirely impractical as there are no satisfactory means for separating the craft to keep them parallel and to prevent lateral impact damage which would be occasioned by strong winds and rough waters. Mooring element 40 includes spacer 49 providing separation between boats 41 and 42 so as to minimize or eliminate the risk of engagement irrespective of the prevailing whether conditions or sea state. Mooring element 40 thus allows mooring of two boats in substantially the same water area previously taken up by single swing moorings. This allows increased boat mooring in a given area in comparison to the number of boats that could be moored in the same area suing prior art moorings.
One advantage of the swing moorings described herein is that loads and stresses normally applied to a boat hull particularly at the bow when moored, will be spread over the part of the boat most able to withstand such stresses. Mooring 40 may be constructed from a variety of materials including plastics, concrete, metal, composite, wood or any material capable of floatation but sufficiently strong to be capable of withstanding lateral impact loads and possible shock loads imposed by concurrent heaving against spacer 49 . According to one embodiment, mooring element 40 is manufactured in a mold from plastics, concrete or compound rubber or reinforced rubber. Alternatively the mooring element is manufactured by constructing a space frame of a predetermined shape and applying to the finished space frame a water tight cladding to ensure maintenance of buoyancy.
Modifications may be made to the pontoon according to required changes in buoyancy, stability displacement and strength. The size and configuration may be varied to accommodate various designs for vessels of different sizes LOA (length all over) and displacements. According to one embodiment a single mooring will accommodate vessels the majority of which fall within the 5.0 m-12 m range, but it will be appreciated that the mooring may be adapted to accommodate vessels of sizes outside that range. The mooring will typically include fendering, horn cleats, bollards, hatches mooring lines. Vessels are typically attached to pontoons via use of mooring lines to bollards and horn cleats or other attachments fixed to the deck of the pontoon.
FIG. 6 shows a cross sectional elevation of a typical mooring pontoon 50 taken at line X-X as shown in FIG. 6 a . FIG. 7 shows a cross sectional elevation of mooring pontoon 50 taken at line X-X as shown in FIG. 7 a . FIG. 8 shows a long sectional elevation of mooring pontoon 50 taken at line X-X as shown in FIG. 8 a . FIG. 9 shows a plan view of a mooring assembly according to one embodiment, formed by a plurality of like mooring elements. According to the embodiment shown, mooring element 51 engages mooring element 52 via outside opposing splay edges 53 and 54 of elements 51 and 52 respectively. This arrangement places the longitudinal axis of engaging mooring elements out of phase but parallel. Mooring elements 51 , 52 and 55 are, according to the embodiment shown arranged so as to form mooring recesses 56 - 60 . Recess 56 and 57 will combine to allow mooring of two small boats or one large boat. Similarly, recesses 58 - 60 will allow mooring of one boat. This arrangement is repeated along the length of the mooring assembly.
FIG. 10 shows a plan view of a mooring assembly according to an alternative embodiment, formed by a plurality of like mooring elements. According to the embodiment shown, mooring element 61 engages mooring element 62 via respective trailing ends 63 and 64 . Mooring elements 61 and 62 are, according to the embodiment shown arranged so as to form mooring recesses 65 and 66 . Recesses 65 and 66 will allow mooring of two small boats or one large boat. This arrangement may be repeated to enlarge the mooring assembly. In an alternative embodiment the pontoon may be tied to a wharf as a fixture or tether from a trailing end to allow swinging
FIG. 11 shows a plan view of a mooring assembly according to an alternative embodiment, formed by a plurality of like mooring elements. According to the embodiment shown, mooring elements 67 , 68 , 69 and 70 engage so that they are disposed radially. Each element engages two adjacent elements via opposing outside splay edges. For instance, mooring element 68 engages elements 67 and 69 via splay edges 71 and 72 . These edges oppose corresponding edges 73 and 74 of elements 67 and 69 respectively. This arrangement places the longitudinal axis of each engaging mooring element normal to at least two adjacent elements and in alignment with at least one other element. A further arrangement for a mooring assembly may be obtained by a combination of the assemblies of FIGS. 10 and 11 . Mooring elements 67 - 70 are, according to the embodiment shown arranged so as to form mooring recesses 75 - 82 . Recesses 75 - 82 will combine to allow mooring of one boat per recess so at least 8 boats may be accommodated in the assembly of FIG. 11 . This arrangement may be repeated to form a larger mooring assembly which engages via one of trailing ends 67 a - 70 a.
FIG. 12 shows a plan view of a mooring assembly according to a further embodiment, formed by a plurality of like mooring elements 80 , 81 and 82 joined end to end. According to the embodiment shown, mooring element 80 engages mooring element 81 via trailing end 83 of element 80 and leading end 84 of element 81 . Similarly, mooring element 81 engages mooring element 82 via trailing end 85 of element 81 and leading end 86 of element 82 .
It will be appreciated that the mooring assemblies described with reference to FIGS. 9-12 are non limiting examples and it will be appreciated that a wide variety of alternative arrangements and means of fixation are possible.
FIG. 13 shows a front perspective view of a spreader plate 87 according to a preferred embodiment. Plate 87 includes outer frame 88 including openings 89 and 90 which receive anchor ropes, webbing or chain (see FIG. 4 ). Plate 87 further comprises jaws 91 and 92 which define recess 93 . Recess 93 receives a shackle, thimble or other known fastening device (not shown) which is fastened to plate 87 via 94 and/or 95 as shown in FIG. 14 . Openings (not shown) corresponding to openings 94 and 95 are located in jaw 91 to allow for double shear connections of a fastener such as a shackle.
A mooring pontoon may be attached to a mooring chain, ropes or straps from bollards on the pontoon deck in accordance with current practice but mooring from the underside reduces the possibility of a boat hitting the under mooring pontoon apparatus
There are numerous advantages associated with the use of the swing mooring pontoon according to the invention herein described. The major advantage is that it allows two vessels to be moored in an area that currently accommodates only one vessel. This enables two vessels to be moored in half the area they would previously have required with the known swing moorings. This has the effect of reducing boat damage as the number of moorings per boat are reduced. The radius of swing which may be reduced by underwater mooring apparatus thereby provides a greater area for navigation between moorings and moored boats. The swing mooring pontoon can reduce damage to a sea bed environment such as sea grasses and other marine environments. The mooring also allows some boat maintenance to be carried out without having to move the boat to a wharf or slipway, due to walkway access provided by the mooring. The under pontoon moorings also reduce jarring in rough conditions and provide a separation for each vessel. The pontoons according to the invention also provide economic advantages
It will be recognized by persons skilled in the art that numerous variations and modifications may be made to the invention as broadly described herein without departing from the overall spirit and scope of the invention.
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A swing mooring element comprising a modular pontoon ( 40 ) configured to enable two vessels ( 41, 42 ) to be moored side by side and including an area ( 49 ) between the vessels which allows a person to walk between the vessels. The pontoons ( 67, 68, 69, 70 ) may also be interconnected to form a mooring assembly wherein each pontoon ( 67, 68, 69, 70 ) is capable of mooring at least two boats.
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FIELD OF THE INVENTION
The present invention pertains to the fabrication of three dimensional Micro-Electro-Mechanical-Systems (MEMS). In particular, the invention relates to the fabrication of three dimensional MEMS which rely on alignment to provide functionality.
BACKGROUND OF THE INVENTION
Within the field of integrated circuit (IC) fabrication, there is continuing interest in finding ways to increase the density of electronic parts such as transistors, and to shrink the interconnection of these parts. Recently, there has been great interest in miniature machines which combine electrical, optical and mechanical functional features. These micromachines are frequently referred to as Micro-Electro-Mechanical-Systems (MEMS), Bio-MEMS, and Micro-Opto-Electro-Mechanical-Systems (MOEMS).
To produce the miniature electrical devices in MEMS, those skilled in the art frequently use stacks of alternating layers of conductive material, separated by electrically insulating material, with electrical interconnects between various conductive regions in the stack. Typically, the insulating material has been glass which is anodically bonded to a conductive material such as silicon. U.S. patent application Ser. No. 09/739,078, of Harald S. Gross, filed Dec. 13, 2000, assigned to the assignee of the present invention, describes an improved method of anodic bonding of a stack of conductive and electrically insulating glass layers in a single bonding step. Also, U.S. patent application Ser. No. 10/160,215 of Harald S. Gross, filed on May 28, 2002, assigned to the assignee of the present invention, describes a method of producing electrical interconnects within such a stack of layers.
There is a clear need for a cheap and efficient method of fabricating microelectronic structures which can perform at the temperature capability of silicon, which can be machined to silicon tolerances.
One technology which is used within the MEMS and MOEMS industry is microcolumns. Microcolumns are high-aspect-ratio micromechanical structures including microlenses and deflectors. The microlenses are frequently multilayers of silicon chips (with membrane windows for the lens electrodes) or silicon membranes spaced apart by 100–500 μm thick insulating layers. The lenses have bore diameters that vary from a few to several hundred μm. For optimum performance, the structural alignment accuracy between the components should be in the few μm range. Particularly in the telecommunications industry, in order to achieve high performance, the components like glass fibers are precisely aligned and subsequently bonded.
In the past, there have been several approaches to achieve alignment accuracy. In most cases highly sophisticated tools which utilize marks on the surface of each micro-fabricated structure are used to align the components using an optical inspection tool. However such alignment equipment is very expensive. Also, a satisfying throughput rate can not be achieved with such tools if more than two components need to be aligned. Generally, the optical tool aligns just two components which are subsequently bonded. When three components are involved, the optical tool follows the same procedure; this means that the first two components are aligned and bonded and then the bonded components are then aligned with and bonded to a third component. Therefore, the process itself becomes a serial aligning and bonding method. It can be seen that efficiency of such alignment tool is low. The throughput rate is a function of the number of necessary repetitions in respect to a two component system. Moreover, there is a fast growing demand for applications that require the assembly of more than just two components, and for those applications alignment using optical system would be impractical.
U.S. Pat. No. 6,281,508 B1 issued Aug. 28, 2001 to Lee et al., and assigned to the Assignee of the present invention describes a method and the associated apparatus for alignment and assembly of microlenses and microcolumns. In the Lee et al. patent, aligning structures such as rigid fibers are used to precisely align multiple microlens components. Alignment openings are formed in the microlens components and standard optical fibers are threaded through the openings in each microlens component as they are stacked. However, the patent does not describe how the glass fibers are moved practically during the alignment procedure. Also, the patent does not mention how to achieve the necessary parallelism of the fibers. The second method described in the patent involves a “snap-mechanism” of the fiber into holes of the components, which have a smaller size than the fiber itself. In addition, the method described in this patent is a serial assembly process rather than a parallel assembly. Therefore, the method could run into the problem of throughput efficiency described above. Moreover, the assembly explained in this patent is uses an alternating layers of microlens components with glass which the present invention is trying to avoid.
There is clearly a need for a cheap and efficient method of aligning components of MEMS, bio-MEMS, and MOEMS structures to meet the precision and accuracy requirements described above.
SUMMARY OF THE INVENTION
We have developed a method of fabricating MEMS structures using silicon components which are electrically isolated by a fluid, typically gas or a vacuum. Also disclosed is a cheap and efficient device for aligning components used in the fabrication of microelectronic and/or microoptical structures of the kind fabricated using the presently described method.
One embodiment of a method disclosed herein is the fabrication of a MEMS structure using silicon components which employ gas or vacuum for electrical isolation purposes. As an example, the method includes stacking of at least two silicon components. The method includes placing at least one first spacer on a surface of a first silicon component, then stacking a second silicon component over the first silicon component, with the second silicon component resting on the at least one first spacer. At least one second spacer may be stacked over the second silicon component, followed by stacking a third silicon component over the second spacer and so on. The stacked components are then aligned and retained, fastened or bonded together to form a MEMS structure. Microcolumns of various sizes and shapes can be formed using this method.
Another embodiment of the invention is a method of fabricating the microelectronic components by etching silicon components and spacers on silicon wafers. Stacking the silicon wafers one on top of the other, using an alignment jig and then retaining, fastening, or bonding the stacked wafers together. Components and spacers may be etched on a single wafer, or components may be etched on one wafer while spacers are etched on another wafer, so that the desired structure is obtained when the wafers are stacked.
Another embodiment of the invention is a method of fabricating the microeletronic components by etching silicon-containing components and spacers on silicon-containing wafers, where the components and spacers can be stamped out of the wafer to provide individual components and spacers for a device. The components are then stacked, with the use of the spacers, to provide particular device structures. Prior to bonding, fastening or retaining components within the stacked structure, the components are aligned relative to each other using an alignment jig. The spaces between silicon-containing components may be filled with a gas or vacuum or with a liquid dielectric material which is cured in place to provide electrical isolation of the silicon and other conductive elements present in the device. The silicon-containing components may be retained relative to each other using a retainer or fastener or a built-in interlocking mechanism within the structure.
One apparatus useful in alignment of the components is a specially designed jig fixture we developed which is precise and cost effective. The alignment jig has a base plate where the silicon wafers or components to be aligned are placed. The jig also has a cantilever arm, including a leaf spring which adds flexibility to the cantilever arm. The base plate of the alignment jig has two fixed posts mounted perpendicular to the base plate. The silicon wafers or components to be aligned have grooves, indentations or other shapes which are present at the periphery of the wafer or component, in a manner such that the wafer or component can be stacked against the two fixed posts on the base plate. The alignment jig cantilever arm includes a turning head containing a tilting frame with an internal pin mounted within the tilting frame, which pin pushes against a wall of a wafer or component and generates a rotation. The wafer or component rotates around an axis comprising one of the poles on the base plate which is fitted into a shape (typically a groove) on the wafer or component, until the wafer or component motion is stopped by the second pole on the base plate, which is in contact with another shape on the periphery of the wafer or component. Typically the wafers or components are rotated until two shapes, such as grooves, on the wafers or components are in direct contact with the two poles on the base plate, and a third shape on the periphery of the wafer or component is in contact with the pin on the pusher. The process is applied to a plurality of wafers or components so that when the rotation is stopped the stacked wafers or individual components are all aligned with respect to one another.
Another embodiment of the invention involves an alignment jig which aligns at least two wafers, chips, or device components by utilizing alignment shapes located on the surface of wafers, chips, or device components. The alignment jig has a base plate with two fixed poles where the wafers, chips or device components to be aligned are placed. The jig also has a cantilever arm, which is used in combination with the base plate. The cantilever arm is attached to a stand which is placed on a slider. The slider is on rails which enables the stand to move along a line of pushing. The cantilever arm also has a first holder which is connected to the stand. A leaf spring is connected to the first holder at one end and to a second holder at the other end. The second holder is further attached to a turning head that can freely rotate around the center line of pushing. A tilting frame is rotatably mounted on the turning head so that the tilting frame can tilt freely in respect to the turning head. A pushing pin is mounted within the tilting frame. The alignment jig provides at least four degrees of freedom which include the sliding movement of the stand, movement of the leaf spring at various angles from the line of pushing (and parallel to the base plate), rotation of the turning head circumferentially around the center line of pushing and tilting of the frame in a plane perpendicular to a center line through the turning head.
Another embodiment of the invention involves fabricating a device structure by stacking a number of silicon-containing components and aligning them using a jig such as the one described above and then fastening, retaining or bonding the components together into a rigid structure. The silicon-containing components are separated from one another by spacers which may be of varying height so that the desired nominal spacing is achieved between various components. Disposed in the open spaces between the silicon-containing components may be electrically insulating components, a gas composition, or a vacuum.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other aspects of the invention will be appreciated in conjunction with the accompanying drawings, and a detailed description which follows.
FIGS. 1A–1D illustrate one embodiment of fabrication of a three dimensional MEMS structure, using spacers made of silicon to separate silicon components from one another. Vacuum or a gaseous composition or an electrically insulating component is present in the space between the silicon components.
FIG. 1A shows a schematic of a top view of a silicon-containing chip 108 having a first triangular silicon component 104 etched through it, with silicon bridges 106 holding the silicon component 104 in place within the silicon-containing chip 108 .
FIG. 1B shows a schematic of a top view of a portion of a silicon-containing chip 128 having a first set of spacers 129 etched through it, with silicon bridges 126 holding the spacers 129 in place within the silicon-containing chip 128 .
FIG. 1C shows a schematic of the top view of a portion of a silicon-containing chip 138 having a second triangular silicon component 144 etched through it. This figure further shows the second triangular component 144 rotated with respect to the frame. This figure also includes additional spacers 146 .
FIG. 1D shows a schematic top view of a portion of a silicon-containing chip 168 where a second set of spacers 150 are etched through it with silicon bridges 166 holding the spacers 150 in place within silicon-containing chip 168 .
FIG. 2A shows the top view of a stack 203 which includes a silicon component 202 stacked over a second silicon component 204 . Stack 203 is formed by stacking, bonding and removing the frame of components and spacers shown in FIGS. 1 a – 1 d.
FIG. 2B shows the side view of the stack 203 shown in FIG. 2A . This side view shows the spacial relationship between silicon first component 202 and second component 204 . A first set of spacers 208 attached to first silicon component 202 maintains a separation 206 from second silicon component 204 , which has shorter spacers 210 .
FIG. 3A shows a top view of a silicon wafer 370 , which has been etched to form a variety of microcolumn components and spacers. The etched silicon wafer components are for use in the manufacture of a MEMS structure.
FIG. 3B shows an enlargement of a portion of the etched silicon wafer of FIG. 3A .
FIGS. 4A–4D show chips 410 , 430 , 450 and 470 , which were etched out of a wafer.
FIG. 4A shows top view of a silicon chip 410 which was etched out of a wafer of the kind described in FIG. 3A with the chip 410 having silicon posts 401 – 408 which are held in place by silicon frame 400 .
FIG. 4B shows top view of a silicon chip 430 which was etched out of a wafer of the kind described in FIG. 3A with the chip 430 having silicon posts 421 – 428 and a component 438 , which are held in place by silicon frame 420 .
FIG. 4C shows top view of a silicon chip 450 which was etched out of a wafer of the kind described in FIG. 3A with the chip 450 having silicon posts 442 – 445 which are held in place by silicon frame 440 .
FIG. 4D shows top view of a silicon chip 470 which was etched out of a wafer of the kind described in FIG. 3A with the chip 470 having silicon posts 462 – 465 and a component 478 , which are held in place by silicon frame 460 .
FIG. 4E shows a top view of MEMS structure 480 . The MEMS structure 480 is fabricated by stacking chips, shown in FIGS. 4A–4D .
FIG. 4F shows a schematic of a cross section of the MEMS structure 480 shown in FIG. 4E .
FIGS. 5A–5C show various elements of an alignment jig 500 .
FIG. 5A shows a schematic of part of an alignment jig 500 ; the part of the alignment jig shown includes a base plate 502 with two fixed posts 508 and 509 with silicon-containing components 506 placed on the base plate and part of a cantilever arm 510 which is in contact with the base plate 502 .
FIG. 5B shows a schematic of the cantilever arm 510 in detail. FIG. 5B includes a stand 520 , leaf spring 524 , with the end of cantilever arm 510 attached to a turning head 528 , a tilting frame 530 , and a rotating pushing pin 514 .
FIG. 5C shows a close up view of base plate 502 having the two fixed posts 508 and 509 with the pushing pin 514 of the cantilever arm (not shown) such that the V-grooves 503 of a component 506 placed on the base plate partially align with the two poles 508 and 509 and also with a pushing pin 514 .
FIG. 6A is a schematic of the top view of a component when placed on a base plate (not shown) prior to being aligned. This figure shows the pushing pin 514 in its initial position 601 .
FIG. 6B illustrates the alignment process as the pushing pin moves from its initial position 601 (as shown in FIG. 6A ) to its final position 603 by sliding of stand 520 , on rails 521 .
FIGS. 6C–6E illustrate by way of example the steps involved in stacking two components 644 and 646 using an alignment jig of the kind described in FIGS. 5 a – 5 c.
FIG. 6C shows top view of the two components 644 and 646 placed randomly on the base plate 642 prior to being aligned.
FIG. 6D shows the alignment process where pushing pin 654 pushes on walls of V-groove 653 of the two components 644 and 646 and generates a rotation in the direction shown by the arrow 659 .
FIG. 6E shows the top view of components 644 and 646 after they are aligned and stacked on the base plate 642 using the alignment jig
FIGS. 7A–7F illustrate an embodiment where different types of components are aligned using the alignment jig of the kind described in FIGS. 5A–5C . The components illustrated in the FIGS. 7A–7F include a silicon structure mounted over an insulating glass structure.
FIG. 7A shows an extractor 720 for an electron detecting device having a silicon structure 772 mounted on a glass structure 773 with V-grooves 784 etched through the four corners of the extractor 720 .
FIG. 7B shows a spacer 730 having a silicon structure 774 mounted on a glass structure 775 with V-grooves 785 etched through at the four corners of the spacer 730 .
FIG. 7C shows a condenser 740 having a silicon structure 776 mounted on a glass structure 777 with V-grooves 786 etched through at the four corners of the condenser 740 .
FIG. 7D shows an anode 750 having a silicon structure 778 mounted on a glass structure 779 with V-grooves 787 etched through at the four corners of the anode 750 .
FIG. 7E shows a blanker 760 having a silicon structure 780 mounted on a glass structure 781 with V-grooves 788 etched through at the four corners of the blanker 760 .
FIG. 7F shows an aperture 770 having a silicon structure 782 mounted on a glass structure 783 with V-grooves 789 etched through at the four corners of the aperture 770 .
FIG. 7G shows a three-dimensional view of a stack of extractors of the kind shown in FIG. 7A which are aligned and bonded to fabricate a MEMS structure 700 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular form of “a”, “an” and the “the” include plural referents, unless the context clearly dictates otherwise. Thus, for example, the term “a semiconductor” includes a variety of different materials which are known to have the behavioral characteristics of a semiconductor, reference to “an electrical insulator” includes, for example, dielectric materials known in the art, both organic and inorganic and physical constructs which operate as an electrical insulator, such as vacuum and various gases present in spaces between conductive surfaces.
Silicon has frequently been mentioned as a material in the fabrication of MEMS. Such silicon may have sufficient impurities or doping to permit adequate charge transfer in particular applications which are electrical or optical-electrical. Other conductive materials, including but not limited to other semiconductor materials or metals may be used in place of silicon. Clearly, the number of structures used to make the MEMS may vary as desired.
MEMS structures may be fabricated using a plurality of layers which include conductive material and electrically insulating materials. In one well known embodiment, glass was used as the electrically insulating material and stacks of anodically bonded glass and silicon layers were used to form a device. However, the use of glass has been found to create problems during the fabrication process. For example, design limitations may occur due to the lower machine tolerances of glass compared to silicon; stress may be created during anodic bonding of silicon with glass, due to the differences thermal expansion coefficient; in addition, sodium compounds may be formed at the interfaces between silicon layers and the interfacing glass layers which reduce bond strength, or prevent bonding altogether.
We have developed methods of fabricating MEMS structures which avoid the kinds of problems described above. FIGS. 1A-1D illustrate how to build a three dimensional MEMS structure using silicon components, separated by spacers made of silicon, where electrical isolation is obtained using a gas or vacuum or other insulating material between the stacked silicon layers. FIGS. 1A–1D are top views of a silicon chips produced by dry anisotropic etching of a wafer (not shown) containing the chip. The wafer was subsequently diced to provide chips of the kind shown in FIGS. 1A–1D . Instead of dicing, chips may also be etched out of a wafer at the same time as the wafer is etched, provided, the wafer that is being etched is a carrier wafer. FIG. 1A shows a chip 100 including a gap 102 etched through the chip 100 leaving behind an outer chip frame 108 , a center portion 107 , which contains a first triangular chip component 104 , which is connected by silicon bridges 106 to the outer frame 108 . An aluminum layer (not shown) on the backside (not shown) of the chip 100 may be used as an etch stop. Indentations 111 , containing alignment portions 112 are etched at the periphery of the chip 100 . After etching, only aluminum holds silicon pieces 110 , 107 and 112 in place. By stripping of the aluminum etch stop film, regions 110 , 107 , and 112 drop out of the chip 100 , leaving behind the triangular component 104 connected to the outer frame 108 , by silicon bridges 106 . To minimize “loading effects” and “RIE-lag” the silicon pieces 110 , 107 and 112 were “cut out” of the wafer rather than etched out of the wafer.
FIG. 1B shows a first set of silicon spacers 129 etched within a silicon chip 120 . A piece 122 is cut out of silicon chip 120 utilizing an underlying aluminum etch stop layer (not shown), creating an outer frame 128 . Center portions 127 are also cut away, in addition to the piece 122 , to create spacers 129 . Indentations 132 , containing alignment portions 134 are also etched into the silicon chip 120 to subsequently assist in aligning the silicon triangular components 104 shown in FIG. 1 a . Once again, by stripping of the aluminum etch stop regions, piece 122 , center portions 127 , and the alignment portions 134 are removed, leaving behind spacers 129 , connected to the outer frame 128 by silicon bridges 126 , and to one another by silicon bridges 124 to provide stability.
FIG. 1C is a schematic of the top view of a silicon chip 140 similar to the one shown in FIG. 1A except that the figure shows additional spacers 146 . The triangular component, 144 is rotated at an angle with respect to the frame 138 . Indentations 152 , containing alignment portions 153 are etched at the periphery of the chip 140 . After etching of the silicon overlying an aluminum etch stop, as described with respect to FIG. 1A , the triangular component 144 , and spacers 146 remain, all attached to the outer frame, 138 by silicon bridges 147 .
FIG. 1D similarly shows how a second set of spacers are etched from a silicon chip 160 . The method of fabricating the second set of spacers is exactly the same as the method described in FIG. 1B . A piece 155 , and center portions 157 are cut out of silicon chip 160 utilizing an underlying aluminum etch stop layer (not shown) to create spacers 150 . Indentations 154 , containing alignment portions 156 are also etched into the silicon chip 160 to subsequently assist in aligning the silicon triangular components 144 shown in FIG. 1B . Once again, after stripping of the aluminum etch stop regions, the only part remaining are the spacers 150 connected to the outer frame 168 , by silicon bridges 166 , and a plurality of spacers 150 are connected to one another by silicon bridges 164 .
Once the chips with the triangular components and the spacers are generated using the method described above, components are carefully cleaned to remove masking materials on the silicon surfaces in order to prepare the components for the following process steps. Cleaning may be performed by an RCA cleaning, in a manner known in the art.
The chips are then stacked one on top of the other. For example, the chip 140 (containing second triangular component 144 ) is stacked on top of the chip 160 (containing second spacers 150 ). Next, the chip 120 (containing first spacers 129 ) is stacked on the chip 140 , and then the chip 100 (containing the first triangular component 104 ), is stacked on the chip 120 . It is understood that even though only two triangular components are shown in this illustration, more than two components and more than two sets of spacers of different shapes can be stacked on top of each other to create a particular MEMS structure. The chips in the stack of chips may then be aligned relative to each other using the indentations located on each chip frame. Alignment of the chips using a special alignment jig will be described subsequently herein. The alignment jig including the stack of chips may then be heated to a temperature adequate to activate fusion bonding of the contacting portions within the silicon chips. Standard procedures for fusion bonding are known in the art, and may be applied as appropriate, depending on the device being fabricated.
The temperatures necessary to achieve a sufficient bonding strength during fusion bonding depend on the surface conditions of the chips, such as roughness and cleanliness. To be in condition for fusion bonding, the surface condition of the chip should be such that surface roughness is no more than a few tenths of a nanometer, and the surface has been cleaned by RCA cleaning. The bonding temperature may be limited by the temperature capability of the jig in which the chips are retained. An initial pre-bonding may need to be carried out at a lower temperature, in the range of about 300° C. in vacuum. To improve the bonding strength, the stack may then be removed from the jig and heated to 1000° C. in a furnace in an inert gas at atmospheric pressure. To achieve a high bonding strength, the bonding surfaces need to be in good contact during the bonding process. The presence of hydroxyl groups on silicon surfaces helps the fusion bonding process. Hydroxyl groups may be produced on the silicon surface by using the RCA1 cleaning process as the last step of the complete RCA cleaning. At temperatures between about 200° C.–400° C., a chemical reaction of the hydroxyl groups allows a pre-bonding of the interfaces. At temperatures above about 700° C., a covalent bond of Si—O—Si is formed at the interface between contacting silicon surfaces; and at temperatures above 900° C. the oxygen on the interface diffuses into the silicon lattice and provides a Si—Si bond.
In addition to fusion bonding, other standard bonding procedures can be used, depending on the application. When the device structure requires lower temperatures, application of a sputtered thin layer of thin gold on one side of each chip, enables eutectic bonding at a temperature of about 370° C. Adhesive bonding or soldering may be used, depending on the end use application.
Subsequent to bonding of the stack of chips, the pads of the second spacers located at the bottom of the stack may then be connected to a base plate by solder bonding to a ceramic piece with metal traces, for example and not by way of limitation. Finally, the silicon bridges between components and spacers and the outer frame in which they reside are removed, to release the outer frame. In order to minimize the mechanical stress caused by the removal of the frame, the bridges are stacked over each other at the periphery of the inner components. A saw may then be used to remove the silicon bridges. In an alternative design, the indentations may be part of a component rather than located on the chip frame. In this instance, the chip frame is removed prior to assembly of components.
The space between stacked components is determined by the height of the spacers separating the components. The spacer height can be increased if a greater separation between the components is required. The space between components can be filled with an electrically insulating material if desired. Also, a vacuum may be maintained in the space between components, since vacuum is an excellent insulator. By employing a vacuum between components, contamination of the component surfaces doesn't affect the breakdown voltage between them. Other conductive materials may be used for micromachining, such as nickel, or gold. The spacers may be electrically connected by metal traces patterned on the surface of the base plate to enable application of voltage on the components. Microcolumns of various sizes and shapes may be formed using this method.
FIG. 2A shows the top view of a stack 203 which includes two triangular components 202 and 204 , of the kind described above, stacked one on top of the other. FIG. 2B shows the side view of the two component stack 203 . The triangular components 202 and 204 are separated by a distance 206 . Triangular component 204 is standing on single spacer 210 , with one spacer at each of the three points of the triangle. Triangular component 202 is standing on double spacers 208 , with one spacer at each of the three points of the triangle. Height “h” of each spacer, and the number of spacers used, determines the distance “d” 206 . The spacers themselves can also act as electrical feedthroughs to connect the components with other elements in a device circuit. In the case of microcolumns, the components may also be equipped with a hole 201 (shown in FIG. 2A ) in the center so that an electron beam can pass through hole 201 .
In another embodiment, silicon components to be used to form a device are dry etched directly from a silicon wafer. FIG. 3A shows a top view of a silicon wafer 370 , after the wafer was dry etched to produce a number of electrical device components. The component etching may be carried out using a process known in the art for etching silicon, preferably, by anisotropic dry etching. FIG. 3B illustrates an enlargement of a portions of silicon wafer 370 (shown in FIG. 3A ) which includes various components, such as an extractor 372 , a spacer 374 , a condenser 376 , an anode 378 , a blanker 380 and an aperture 382 . The components were designed for use in fabrication of a microcolumn which is employed for secondary electron detection. Etching of a variety of components in a single wafer can be particularly advantageous when the various components can be diced out for use in device fabrication.
Components are diced out with high precision dicing. The resist mask for the silicon wafer is designed so that silicon bridges 384 are formed during etching. The bridges 384 serve two purposes: To provide structural support within the silicon wafer and to provide a dicing lane. The bridges 384 are generally not part of the working component so that during dicing, a blade will be directed to the bridges, thus protecting the working component from damage during the dicing operation. In cases where the components are bonded to a borosilicate wafer, dicing of the glass and silicon typically causes chipping. By use of bridges 384 , the chipping effect is limited to the bridge areas and does not affect the functional component.
FIGS. 4A–4D show top views of chips 410 , 430 , 450 and 470 , which were etched out of a wafer. The chips 410 , 430 , 450 and 470 illustrated in FIGS. 4A–4D are similar to the chips illustrated in FIGS. 1A–1D except for the geometry, and the location of the grooves. Also, the chips in FIGS. 4A–4D maintain their respective outer frames during fabrication of the MEMS structure and are removed only after the MEMS structure fabrication is completed. With respect to FIG. 4A , chip 410 includes silicon posts 401 – 408 which are held in place by a frame 400 . Chip 410 further includes V-grooves 411 – 414 used for alignment of chip 410 . FIG. 4B illustrates another chip 430 . Chip 430 includes individual silicon posts 422 , 424 , 426 , and 428 . Chip 430 also contains a center structure 437 which includes silicon posts 421 , 423 , 425 and 427 as well as a MEMS component 438 . Depending on the device, the MEMS component 438 may be many times larger than the silicon posts 421 – 428 . FIG. 4B also includes V-grooves 431 – 434 which may be used for alignment of chip 430 . FIG. 4C illustrates another chip, 450 , similar to chip 410 shown in FIG. 4A . The chip 450 includes silicon posts 442 – 445 which are held in place by silicon frame 440 . V-grooves 451 – 454 are machined into the frame 440 to be used for alignment. FIG. 4D illustrates another chip, 470 , which includes a MEMS component 478 and silicon posts 462 – 465 which are held in place by silicon frame 460 . V-grooves 471 – 474 are machined into the frame 460 to be used for alignment of chip 470 .
In order to fabricate a MEMS structure, chip 430 is placed on top of chip 410 , chip 450 is placed on top of chip 430 , and chip 470 is placed on top of chip 450 creating a stack of the chips. The stack may then be aligned and bonded together. Alignment and bonding can be performed by any of the methods known in the art. If the bonding method used is silicon fusion bonding, then the chips may be aligned and pre-bonded at 300° C. on an alignment jig which is described in detail in a later section. After pre-bonding, the stack alone, without the alignment jig, may be fusion bonded in a furnace at a temperature above 900° C. If low temperature is required, then eutectic bonding would be ideal. For eutectic bonding, each chip may be coated on one side with a gold layer prior to bonding. The gold forms an alloy with silicon at a temperature higher than 363° C. Eutectic bonding of silicon with gold or aluminum can be completed on the alignment jig, because the temperature required for eutectic bonding is below the maximum operating temperature of the alignment jig which may be made of materials such as stainless steel.
FIG. 4E illustrates a top view of a stack 480 of chips used to form MEMS structure. The stack 480 is prepared by placing chip 430 on top of 410 , then placing chip 450 on top of chip 430 , and then placing chip 470 on top of chip 450 , the stack 480 of chips is then bonded together to form a MEMS structure. The chip 410 is soldered onto a conductive base plate 490 (not shown) with a solder such as an indium-tin solder. Frames 400 , 420 , 440 and 460 of chips 410 , 430 , 450 and 470 respectively are then removed from the stack by cutting through the stack along lines 482 , 484 , 486 and 488 , up to the base plate 490 (not shown) and not through the base plate 490 .
FIG. 4F shows a cross section of a MEMS structure 495 . The cross section of MEMS structure 495 includes a base plate 490 which underlies silicon posts 401 and 406 from chip 410 (shown in FIG. 4A ). Overlying silicon posts 401 and 406 are MEMS component 438 and silicon post 426 respectively from chip 430 . Overlying post 426 of chip 430 is post 444 from chip 450 . Overlying post 444 of chip 450 are MEMS component 478 and silicon post 464 from chip 470 . Metal traces can be implemented into the base plate 490 if electrical connections need to be established between the silicon post 401 and the base plate 490 . As can be seen from FIG. 4F , the MEMS components 438 and 478 are separated by the silicon post 444 of chip 450 . The silicon post 444 from chip 450 essentially acts as a spacer separating MEMS components 438 and 478 . Depending on the size of the MEMS structure desired, the number of components and the number of posts separating the components, may vary. MEMS structures of different sizes and shapes may be fabricated using the above method.
FIGS. 5A–5C illustrate an alignment jig which is useful for positioning and aligning MEMS components of the kind described herein into assemblies. Further illustrated is the manner in which positioning and aligning of the components is achieved. The alignment jig was used to align a stack of ten chips to a precision of better than 2 μm with high repeatability. Further modifications and improvements to the jig might provide even better precision if needed.
FIG. 5A shows a schematic of part of an alignment jig 500 . The jig is a mechanical assembly which is precise and cost effective. With reference to FIG. 5A , the alignment jig 500 has a base plate 502 upon which a plurality of substrates such as a wafers, chips, or components 506 are placed for alignment. The base plate 502 has two fixed posts 508 and 509 mounted perpendicular to the base plate 502 . Also shown is part of a cantilever arm 510 which is used in combination with the base plate 502 . A part of the cantilever arm 510 , as shown in FIG. 5A , includes a turning head 562 , tilting frame 530 , and a pushing pin 514 . The pushing pin 514 is pressed into or supported by the tilting frame 530 so it becomes part of the tilting frame. The tilting frame 530 can rotate within bearings 561 located on each side of the turning head 562 . The rotation permits the tilting frame 530 to tilt, providing another degree of freedom, apart from those which will be described in detail below. The tilting frame 530 is attached to the turning head 562 through the ball bearings 561 described above.
FIG. 5B is a schematic of a cantilever arm 510 including the portion described above. The cantilever arm has a stand 520 which holds it in place. The stand 520 is connected to a slider 521 , which enables the stand to move in the directions indicated by an arrow 533 . Cantilever arm 510 further includes a first holder 522 which holds a leaf spring 524 . The holder 522 is in direct communication with the stand 520 . The leaf spring 524 is connected to the first holder 522 at one end and to a second holder 526 at the other end. The second holder 526 is further attached to a turning head 528 (a different model turning head from what is shown in FIG. 5A ). The turning head 528 can rotate in the direction shown by the arrow 536 . The turning head 528 is connected to a tilting frame 530 through bearings 532 located on each side of the tilting frame 530 . The tilting frame 530 can rotate within bearings which surround a shaft 532 , as indicated by the arrow 537 . The pushing pin 514 which is used to push against a component structure may be pressed into the tilting frame 530 , as previously described. Further, the turning head 528 can rotate in a circular direction in a plane which is perpendicular to the longitudinal direction of cantilever arm 510 . Hence, the flexible design of the jig provides 4 degrees of freedom which include moving along the line of pushing, moving perpendicular to the line of pushing and parallel to the base plate, rotation of the turning head and tilting with respect to the turning head. The design may include spring-loaded set screws (not shown) to regulate the pressure of the post against the components.
FIG. 5C shows a close up view of an alignment procedure, where a component 506 is placed on the base plate 502 and the two fixed alignment pins (posts) 508 and 509 , mounted on the base plate 502 , are partially aligned with V-grooves 503 at the corners of component 506 . Pushing pin 514 attached to cantilever arm 510 (not shown) as previously described, facilitates the rotation of the component 506 within a component stack (not shown) as well as rotation of the stack itself. The alignment process essentially involves pushing the wafers or components with etched V-grooves 503 , indentations, or other alignment shapes (not shown) to align with fixed posts 508 and 509 on the base plate 502 . A heating element (not shown) and thermocouples (not shown), may be integrated into the base plate in order to facilitate bonding of a stack of components in place on the base plate. Depending on the preferred bonding method or selected materials, the base plate can be heated to the required temperature. For example, a temperature of around 300° C. is required for fusion pre-bonding of silicon stacks. If the silicon layers are coated, for example, with gold on one side eutectic bonding can be achieved at a temperature above 363° C. In cases where the stack consists of silicon layers with alternating borosilicate glass layers, the base plate has to be heated to a temperature between 300° C. and 500° C. for anodic bonding. Other bonding methods like curing of spin coated resin may be used as well.
FIGS. 6A and 6B illustrate the process of aligning a component 602 using an alignment jig of the kind described above. The component 602 includes 4 V-grooves 611 , 613 , 615 and 617 . In FIG. 6A , the component 602 is randomly placed on a base plate (not shown). The posts 608 , and 609 are fitted into the V-grooves 617 , and 615 respectively, prior to aligning. The pushing pin 514 is held in its initial position 601 . Also included in FIG. 6A are parts of the jig which facilitate the movement of the pushing pin 514 . For example, the stand 520 on the slider 521 (shown in detail in FIG. 5B ), which is indirectly connected to the pushing pin 514 . With respect to FIG. 6B , the pushing pin 514 is flexibly 524 connected. First, the pushing pin 514 , flexibly attached via leaf spring 524 , is released from its initial position 601 (shown in FIG. 6A ) and is brought to a second position 603 as the stand 520 slides along the direction shown by the arrow 533 . As the pushing pin 514 takes its second position 603 , it pushes against at least one wall of V-groove 613 giving the component 602 a rotation and a shift in the direction indicated by the arrow, 616 . As a result, the component 606 rotates around a first post 608 in the direction indicated by the arrow 616 . The second post 609 acts as a stop for the rotation. In practice, the optimum pushing direction 621 of the pushing pin 514 is different from the moving direction 621 of stand 520 . By having a flexible connection such as a leaf spring 524 , between the stand 520 and the pushing pin 514 , any misalignment of the slider 521 may be corrected. As can be seen in FIG. 6B , by having the flexible leaf spring 524 , the pushing pin 514 is deflected from its normal course 621 provided by the movement of the stand 520 to a different course 622 where the two courses are separated by a distance Δd. Also illustrated by dotted lines are the final position 514 ′ of pushing pin 514 if the pushing pin were not deflected. Figure illustrates only two degrees of freedom, shown by arrows 533 and 535 , two additional degrees of freedom are achieved by other elements of the apparatus which will be discussed in detail subsequently herein.
The machining tolerances of the V-grooves patterned using optical lithography, for example, and etched by anisotropic dry etching techniques well known in art, are typically one to two orders of magnitude smaller in comparison with alignment jig dimensions and therefore the V-groove tolerances are insignificant in misalignment calculations.
It is particularly important that the fixed posts 608 and 609 be mounted precisely perpendicular to the base plate (not shown). In addition, the diameter of fixed posts 608 and 609 needs to be carefully fabricated with minimal variation as possible. Polished steel or another hard material functions well as a post material. Smooth surfaces on the V-grooves also helps provide better precision alignment.
FIGS. 6C–6E further illustrate alignment process of two components using the process described above. FIG. 6C shows a schematic of the top view of two components 644 and 646 placed randomly on a base plate 642 . Each of the components 644 and 646 include 4 V-grooves 651 , 653 , 655 and 657 . The fixed posts 656 and 658 and pushing pin 654 are fitted into the V-grooves 655 , 657 and 653 respectively. FIG. 6D shows the step where the pushing pin 654 pushes against at least one wall of V-groove 653 . The push causes the components 644 and 646 to rotate around the first fixed post 658 in the direction indicated by the arrow 659 . The second fixed post 656 acts as a stop for the rotation. The components are aligned by rotating the components around a fixed axis at first fixed post 658 and then jamming them against a second fixed post 656 . FIG. 6E shows a top view of components 644 and 646 after the two components are aligned. Ones skilled in art will contemplate that a large number of components or even more than one stack of components may be aligned at the same time using this jig.
Theoretically, any amount of misalignment is constant, and is determined by misalignment of the two fixed poles on the base plate, rather than by the action of the pushing pin. This is because the design of the jig makes the pushing pin extremely flexible and the frictional component is negligible. Experiments with different pusher arm designs revealed that a highly flexible cantilever arm such as that previously described with reference to FIG. 5B resulted in the smallest misalignment. Modification of the design to provide further flexibility to the cantilever arm design is possible.
As described above, the misalignment of the components aligned using the jig is normally caused by the precision in fabrication of the jig itself. For example, the precision of the placement of the posts with respect to the base plate. The precision may depend on the diameter variation of the posts and the pushing pin. Since the same jig is being used over and over, the alignment error caused by the jig becomes a systematic error. This type of systematic error can be compensated through other means. For example, when the misalignment of each component associated with a particular jig is figured out, then that error can be compensated for in the design of the components; for example, the center of the component may be shifted by an amount to correct this error.
The alignment jig of the kind described above can be used to align other types of components than those described above. FIGS. 7A–7F illustrate, as an example, components which are comprised of bonded silicon and glass layers, which components may be aligned using the alignment jig described above. FIG. 7A shows an extractor component 720 which includes a silicon structure 772 mounted on a glass structure 773 . V-grooves 784 are etched at the four corners of the extractor component 720 , which v-grooves may be used for aligning components using the kind of alignment jig described above. FIG. 7B shows a spacer component 730 which includes a silicon structure 774 mounted on a glass structure 775 . The spacer component 730 also includes V-grooves 785 etched at its four corners. FIG. 7C shows a condenser component 740 which includes a silicon structure 776 mounted on a glass structure 777 . The condenser component 740 also has V-grooves 786 etched at its four corners. FIG. 7D shows an anode component 750 which includes silicon structure 778 mounted on a glass structure 779 . The anode component also has V-grooves 787 etched at its four corners. FIG. 7E shows a blanker component 760 which includes a silicon structure 780 mounted on a glass structure 781 . The blanker component 780 also has V-grooves 788 etched at its four corners. FIG. 7F shows an aperture component 770 which includes a silicon structure 782 mounted on a glass structure 783 . The aperture component 770 also has V-grooves 789 etched at its four corners.
FIG. 7G shows top view of a stack of extractor components 700 of the kind shown individually in FIG. 7A as component 720 . The extractor components in stack 700 may be bonded together to create a MEMS structure. As previously described, the extractors 720 , within the component stack 700 include alternating layers of a silicon structure 772 and glass a structure 773 . The extractor component 720 further includes V-grooves 784 , which may be used for aligning the components using the kind of alignment jig described above.
The glass structures 773 (which could also be fabricated from an electrically insulative material other than glass) may be micromachined using techniques known in the art. However, the drilling of the glass is generally less precise compared to the etching of the silicon. Therefore, the glass may be recessed from the edge of the component so that only the silicon v-grooves contact the alignment posts in the alignment jig. Generally, for most applications, the alignment inaccuracy which might occur due to less precise machining of glass can be avoided. Generally, with respect to aligning a stack of components such as those shown in FIG. 7G , over etching or under etching will not affect the alignment as long as all components of a stack are fabricated on one wafer, so that each component over or under etched to the same degree.
The above described preferred embodiments are not intended to limit the scope of the present invention, as one skilled in the art can, in view of the present disclosure, expand such embodiments to correspond with the subject matter of the invention claimed below.
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Disclosed herein are methods of fabricating three dimensional Micro-Electro-Mechanical-Systems (MEMS). This method involved stacking of silicon-containing components which are separated by spacers. The stacked components are precision aligned and then may be bonded, retained or fastened together to form a rigid structure. Spaces created between MEMS device components by the separations may be filled with an electrically isolating fluid such as a gas or vacuum. Also disclosed is a method of aligning components relative to each other and an alignment jig which may be used to align the components.
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RELATED APPLICATIONS
[0001] Under 35 USC 119, this application claims the benefit of the Mar. 14, 2014 priority date of U.S. Provisional Application 61/953,303 and the Mar. 14, 2014 priority date of U.S. Provisional Application 61/953,270, the contents of which are herein incorporated by reference.
FIELD OF DISCLOSURE
[0002] This invention relates to power converters, and in particular, to charge pumps.
BACKGROUND
[0003] In many circuits, the power that is available to drive the circuit may not be in a form that the circuit demands. To correct this, it is useful to provide a power converter that converts the available power into a form that conforms to the circuit's requirements.
[0004] One common type of power converter is a switch-mode power converter. A switch-mode power converter produces an output voltage by switching reactive circuit elements into different electrical configurations using a switch network. A switched capacitor power converter is a type of switch-mode power converter that primarily utilizes capacitors to transfer energy. Such converters are called “charge pumps.” The capacitors are called “pump capacitors.”
[0005] In operation, a charge pump transitions from one pump-state to the next in a sequence of pump-states. Each pump-state is characterized by a residence time in which the charge pump remains in that pump-state, and transition times, in which the charge pump is between pump-states. The sum of the residence times for all pump-states and the intervening transition times between those pump-states is the period for one cycle of the charge pump.
[0006] For correct operation, each pump capacitor should begin and end each cycle with zero change in charge. If this is not the case, charge will accumulate on the pump capacitor over the course of several cycles in the case of positive non-zero change in charge. Since the voltage across a capacitor is linearly proportional to the charge, this charge accretion/depletion will cause the voltage across the pump capacitor to drift over time.
[0007] In many charge pumps, a switch connects adjacent pump capacitors. The voltage across the switch thus depends on the voltages across adjacent pump capacitors. If voltages across these capacitors drift unevenly, the voltage across the switch may exceed its rating. This may cause the switch to overheat, thus destroying the switch, and the charge pump as well.
[0008] Procedures for managing charge on a pump capacitor depend in part on how the charge got there. In general, there are two ways to put charge into a capacitor: using a voltage source, or using a current source.
[0009] When a voltage source is used, management of charge is relatively simple. The charge present at a capacitor is a linear function of the voltage. Thus, dropping the voltage to zero is sufficient to remove the charge from the capacitor.
[0010] When a current source is used, management of charge is not so simple. This is because the charge on a pump capacitor is related to an integral of the current, and not to the instantaneous value of current.
[0011] On Nov. 8, 2012, Patent Publication WO 2012/151466, which is incorporated herein by reference, made public configurations of charge pumps in which one terminal was connected to a regulator. Because of its inductor, and because of the relevant time scales associated with the switches involved, as far as these charge pump configurations are concerned, the regulator behaved like a current source. This made management of how much charge is in the pump capacitors more challenging.
SUMMARY
[0012] The inventive subject matter described herein relates to stabilizing a charge pump coupled with a current source or load by ensuring that each pump capacitor of the charge pump begins a cycle in the same condition for every cycle. This avoids charge accretion that occurs when residual charge from the end of a first cycle is added to the beginning of a second cycle, thus causing the voltage of the capacitor to drift over time.
[0013] In one aspect, the invention features an apparatus for power conversion. Such an apparatus includes a switching network, and a charge management subsystem. The switching network controls interconnections between pump capacitors in a capacitor network that has a terminal coupled to a current source. In operation, the switching network causes the capacitor network to execute charge-pump operating cycles during each of which the capacitor network adopts different configurations in response to different configurations of the switching network. At the start of a first charge-pump operating cycle, each pump capacitor assumes a corresponding initial state. The charge-management subsystem restores each pump capacitor to the initial state by the start of a second charge-pump operating cycle that follows the first charge-pump operating cycle.
[0014] In some embodiments, a controller in the charge-management subsystem controls residence time. One such embodiment features a controller that controls a first residence time during which the switching network is in a first configuration. Another embodiment features a controller that controls a first residence time during which the switching network is in a first configuration, and a second residence time during which the switching network is in a second configuration. Also included are embodiments in which the controller causes the switching network to cause the capacitor network to assume a dead-time configuration.
[0015] In some embodiments, a cycle includes a first configuration and a second configuration, and a controller of the charge-management subsystem controls a second configuration of the switching network based on a result of having had the switching network assume the first configuration. In other embodiments, the switching network passes through a present cycle and at least one past cycle, and the controller controls the present cycle based at least in part on performance of the switching network during at least one of the past cycles. In yet other embodiments, the switching network passes through a present cycle after having passed through past cycles, and the charge-management subsystem includes a proportional-integral-derivative controller that controls the present cycle based at least in part on performance of the switching network during at least one of the past cycles.
[0016] Embodiments also include those in which the charge-management system includes a controller configured to exercise control over configurations of the switching network. Among these are embodiments in which the controller includes a feedback controller configured to control the different configurations of the switching network based on an output of the capacitor network, and those in which the controller includes a threshold-logic circuit controller configured to control the different configurations of the switching network based on an output of the capacitor network.
[0017] Yet other embodiments do not rely on controlling the switching network. In one such embodiment, the charge-management system includes a controller configured to exercise control over the current source to which the capacitor network is coupled. Among these embodiments are those in which the capacitor network has two terminals, one of which is a low-voltage terminal, and the terminal that is coupled to the current source is a low-voltage terminal. Also among these embodiments is the converse case, in which the capacitor network has two terminals, one of which is a high-voltage terminal, and the terminal that is coupled to the current source is a high-voltage terminal.
[0018] In some embodiments, the charge-management system includes a stabilizing capacitance connected to the current source.
[0019] Other embodiments include a trim-capacitor network that includes switches that are selectively configured to define an interconnection of one or more trim capacitors, thereby defining an aggregate capacitance that reduces a mismatch between the aggregate capacitance and a desired capacitance. In some of these embodiments, the desired capacitance is a stabilizing capacitance connected to the current source. In others, the desired capacitance is a desired capacitance of a pump capacitor.
[0020] Embodiments also include those in which the charge-pump operating cycle has a constant time duration, and those in which the charge-pump operating cycle has a variable time duration.
[0021] In some embodiments, the second charge-pump operating cycle that follows the first charge-pump operating cycle is a charge-pump cycle that immediately follows the first charge-pump operating cycle. However, in some cases, complete restoration cannot be done in one cycle. Thus, in certain embodiments, the second charge-pump operating cycle that follows the first charge-pump operating cycle is a charge-pump cycle that is separated from the first charge-pump operating cycle by at least one intervening charge-pump operating cycle.
[0022] The invention also includes embodiments that include the capacitor network that the switching network is configured to control.
[0023] Embodiments of the invention also include those in which the switching network causes execution of a charge pump operating cycle that consists of no more than two configurations during which transfer of charge between capacitors occurs, as well as those in which switching network causes execution of a charge pump operating cycle that consists of at least three configurations during which transfer of charge between capacitors occurs.
[0024] In some embodiments, the capacitor network and the switching network define a charge pump. Among these are embodiments in which the charge pump includes a multi-stage charge pump, embodiments in which the charge pump includes a cascade multiplier, embodiments in which the charge pump includes a multi-phase charge pump, and embodiments in which the charge pump includes a single-phase charge pump.
[0025] A variety of devices function as current sources within the meaning of the invention. One such device is a regulator. Among the regulators that function as current sources are switch-mode power converters, and buck converters.
[0026] In some embodiments, the charge management subsystem restores at least one of the pump capacitors to an initial state thereof at least in part by changing an amount of charge stored on the at least one pump capacitor. Among these embodiments are those in which the charge management subsystem changes an amount of charge stored one the pump capacitor by causing flow between that pump capacitor and a repository of charge. Suitable repositories include another pump capacitor or ground.
[0027] In another aspect, the invention features a method for controlling a charge pump. Such a method includes causing a charge-pump switching network to cause a network of pump capacitors to which the charge pump switching network is coupled to execute charge-pump operating cycles during each of which the network of pump capacitors adopts different configurations in response to different configurations of the switching network. At the start of a first charge-pump operating cycle, each pump capacitor assumes a corresponding initial state. The method then proceeds by restoring each pump capacitor to the initial state by the start of a second charge-pump operating cycle that follows the first charge-pump operating cycle.
[0028] In some practices, restoring each pump capacitor to the initial state includes restoring each pump capacitor to the initial state by the start of a second charge-pump operating cycle that immediately follows the first charge-pump operating cycle. However, there are also practices of the invention in which restoring each pump capacitor to the initial state includes restoring each pump capacitor to the initial state by the start of a second charge-pump operating cycle that is separated from the first charge-pump operating cycle by at least one charge-pump operating cycle.
[0029] Some practices restore each pump capacitor to the initial state by controlling residence time. One such practice includes controlling a first residence time during which the switching network is in a first configuration. However, in another practice, restoring each pump capacitor to the initial state includes controlling a first residence time during which the switching network is in a first configuration, and also controlling a second residence time during which the switching network is in a second configuration. Yet other practices include controlling residence times for additional configurations, some of which involve charge transfer and some of which do not. For example, in one practice, restoring each pump capacitor to the initial state includes causing the capacitor network to assume a dead-time configuration.
[0030] Practices also include those in which a cycle includes a first configuration and a second configuration, and restoring each pump capacitor to the initial state includes controlling a second configuration of the switching network based on a result of having had the switching network assume a first configuration.
[0031] In other practices, the switching network passes through a present cycle and at least one past cycle, and restoring each pump capacitor to the initial state includes controlling the present cycle based at least in part on performance of the switching network during the at least one past cycle.
[0032] In yet other practices, the switching network passes through a present cycle after having passed through past cycles, and restoring each pump capacitor to the initial state includes implementing proportional-integral-derivative control over the present cycle based at least in part on performance of the switching network during at least one of the past cycles.
[0033] Some practices of the invention are those in which restoring each pump capacitor to the initial state includes exercising control over configurations of the switching network. Among these are practices in which exercising control over configurations of the switching network includes exercising feedback control of the different configurations of the switching network based on an output of the capacitor network, and those in which exercising control over configurations of the switching network includes exercising threshold-logic control over the different configurations of the switching network based on an output of the capacitor network.
[0034] In yet other practices, restoration of each pump capacitor to the initial state includes exercising control over a current source to which the capacitor network is coupled. Among these practices are those that include exercising control over a current source that is coupled to a low-voltage terminal, and those that include exercising control over a current source that is coupled to a high-voltage terminal.
[0035] Yet other practices are those in which restoring each pump capacitor to the initial state includes connecting a stabilizing capacitance connected to the current source.
[0036] Other practices include those in which restoring each pump capacitor to the initial state includes interconnecting one or more trim capacitors to define an aggregate capacitance that minimizes an error between the aggregate capacitance and a desired capacitance. Examples of a desired capacitance include a desired capacitance of a stabilizing capacitor connected to a current source, and a desired capacitance of a pump capacitor.
[0037] In other practices, causing a charge-pump switching network to cause a network of pump capacitors to which the charge pump switching network is coupled to execute charge-pump operating cycles includes causing execution of charge-pump operating cycles having a constant time duration. However, in other practices, the time duration is variable.
[0038] Some practices feature starting the second charge-pump operating cycle that follows the first charge-pump operating cycle immediately after finishing the first charge-pump operating cycle. However, in other practices, starting the second charge-pump operating cycle that follows the first charge-pump operating cycle occurs only after having finished at least one intervening charge-pump operating cycle.
[0039] In some practices, causing a charge-pump switching network to cause a network of pump capacitors to which the charge pump switching network is coupled to execute charge-pump operating cycles includes causing execution of a charge pump operating cycle that consists of no more than two configurations during which transfer of charge between capacitors occurs. However, in others, this is carried out instead by causing execution of a charge pump operating cycle that consists of at least three configurations during which transfer of charge between capacitors occurs.
[0040] Certain practices include forming a charge pump by combining the capacitor network and the switching network. Among these are practices in which the charge pump thus formed is a multi-stage charge pump. However, other charge pumps, such as a cascade multiplier, a multi-phase charge pump, or a single-phase charge pump, can also be formed.
[0041] In some practices, exercising control over a current source to which the capacitor network is coupled includes exercising control over a regulator. This can include exercising control over many different kinds of regulators, all of which effectively function as current sources. Such regulators include switch-mode power converters, and buck converters.
[0042] Other practices are those in which restoring each pump capacitor to the initial state includes restoring at least one of the pump capacitors to an initial state thereof at least in part by changing an amount of charge stored on the at least one pump capacitor. Practices of this kind can include causing flow between the at least one pump capacitor and a repository of charge. Examples of a suitable repository include another pump capacitor, or ground.
[0043] One effect of using a current-based load (or source) with a charge pump is that there may be situations when fixed switch timing used with current-based loads and/or sources results in charge imbalance across capacitors. Such imbalance can result in (or can co-occur with) larger than necessary ripple, extremes in voltage and/or current internal to or at terminals of the charge pump, drift in average and/or peak voltages internal or at terminals of the charge pump, and/or instability, which may be manifested by growing amplitude of voltage variation between points internal to and/or terminals of the charge pump.
[0044] In another aspect, in general, an approach to avoiding and/or mitigating the effects related to charge imbalance is by adjusting the switch timing in a feedback arrangement. In some examples, a pattern of switch timing is adapted based on electrical measurements at the terminals and/or internal to the charge pump. In some examples, the instants of transition of switch states are determined by such electrical measurements.
[0045] These and other features of the invention will be apparent from the following detailed description, and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 shows a single-phase charge pump;
[0047] FIG. 2 shows a time-line associated with the operation of the single-phase charge pump of FIG. 1 ;
[0048] FIG. 3 shows circuit configurations associated with a cycle of the single-phase charge pump of FIG. 1 ;
[0049] FIG. 4 shows a two-phase charge pump;
[0050] FIG. 5 shows circuit configurations associated with a cycle of the two-phase charge pump of FIG. 4 ;
[0051] FIG. 6 shows a first controller for controlling pump-state residence times in the charge pump of FIG. 1 ;
[0052] FIG. 7 shows a second controller for controlling pump-state residence times in the charge pump of FIG. 1 ;
[0053] FIG. 8 shows an implementation of the second feedback circuit in FIG. 7 ;
[0054] FIG. 9 shows an implementation of the second timing circuit in FIG. 7 ;
[0055] FIG. 10 shows a third controller for controlling pump-state residence times in the charge pump of FIG. 1
[0056] FIG. 11 shows a fourth controller for controlling current at a load;
[0057] FIG. 12 shows a fifth controller for controlling current at a regulator;
[0058] FIG. 13 shows a switching network for attaining a desired capacitance for a pump capacitor in FIG. 1 ; and
[0059] FIG. 14 shows a switching network for attaining a desired stabilization capacitance.
DETAILED DESCRIPTION
[0060] FIG. 1 shows a first example of a charge pump 10 coupled to a load 12 that is modeled as an ideal current source. The charge pump 10 is a multi-stage charge pump, also known as a cascade multiplier. Although the current shown is actually being drawn from the charge pump 10 , this distinction amounts to a mere sign change. The important feature of a current source is that it relentlessly drives a constant flow of current.
[0061] Throughout this specification, reference will be made to a “current source.” As is well known, an ideal “current source” is an abstraction used for circuit analysis that does not in fact exist. However, for the time scales of interest, there are a variety of devices that effectively function as a current source. Examples include regulators, such as linear regulators, DC motors, depending on the load, and an IDAC, which is an active circuit that sets the current through LEDs. Thus, throughout this specification, “current source” or “current load” is understood to mean real devices, including but not limited to those enumerated herein, that effectively function as a current source.
[0062] The load 12 can be viewed as a non-zero constant current, or a pulsed current that alternates between two values, one of which can be zero. Charge transfer occurs whenever the current at the load is non-zero. When the current is non-zero and constant, the charge transfer will be referred to as “soft charging,” or “adiabatic charging.”
[0063] The charge pump 10 has first and second terminals 14 , 16 . One terminal is a high voltage that carries a low current. The other terminal is a low voltage that carries a high current. In the particular example described herein, the second terminal 16 is the low voltage terminal. However, in other embodiments, the second terminal 16 is the high voltage terminal.
[0064] Between the terminals 14 , 16 are four identical pump capacitors: outer pump capacitors C 1 , C 4 and inner pump capacitors C 2 , C 3 . A first phase-node P 1 couples with the negative terminal of the first and third pump capacitors C 1 , C 3 , and a second phase-node P 2 couples with the negative terminal of the second and fourth pump capacitors C 2 , C 4 .
[0065] A first switch-set 1 and a second switch-set 2 cooperate to cause the charge pump 10 to reconfigure the pump capacitors C 1 -C 4 between first and second pump-states 18 , 20 as shown in FIG. 2 . Through operation of the first and second switch-sets 1 , 2 , the charge pump 10 maintains a transformation ratio M:N between the voltages at the first and second terminals 14 , 16 . In the particular charge pump 10 shown in FIG. 1 , the transformation ratio is 5:1.
[0066] In operation, the charge pump 10 executes a series of charge pump cycles. Each charge pump cycle has a first pump-state 18 and a second pump-state 20 , as shown in FIG. 2 . To transition from the first pump-state 18 to the second pump-state 20 , the switches in the first switch-set 1 are opened and the switches in the second switch-set 2 are closed. Conversely, to transition from the second pump-state 20 into the first pump-state 18 , the switches in the first switch-set 1 are closed and the switches in the second switch-set 2 are opened.
[0067] FIG. 2 shows the configuration of the switches as “Config X/Y” where X and Y are binary variables that indicate the disposition of the switches in the first and second switch-sets 1 , 2 respectively. A binary zero indicates that the switches in a particular switch-set are open and a binary one indicates that the switches in a particular switch-set are closed.
[0068] During the first pump-state 18 , the switches in the first switch-set 1 are all closed and the switches in the second switch-set 2 are all opened. The first pump-state 18 consists of a first pump-state redistribution interval 18 A and a first pump-state steady-state interval 18 B.
[0069] The first pump-state 18 begins with the opening of the switches in the second switch-set 2 and the closing of the switches in the first switch-set 1 . This begins a first pump-state redistribution interval 18 A characterized by a rapid redistribution of charge. For a brief period, the current associated with this charge distribution dwarfs that associated with the current through the load 12 .
[0070] Eventually, the current associated with charge redistribution dies down and the charge pump 10 settles into a first pump-state steady-state interval 18 B. During the first pump-state steady-state interval 18 B, current through the charge pump 10 is dominated by the current through the load 12 . The sum of the time spent in the first pump-state steady-state interval 18 B and the first pump-state redistribution interval 18 A is the first residence time.
[0071] During the second pump-state 20 , the switches in the first switch-set 1 are all opened and the switches in the second switch-set 2 are all closed. The second pump-state 20 consists of a second pump-state redistribution interval 20 A and a second pump-state steady-state interval 20 B.
[0072] The second pump-state 20 begins with the closing of the switches in the second switch-set 2 and the opening of the switches in the first switch-set 1 . This begins a second pump-state redistribution interval 20 A characterized by a rapid redistribution of charge. For a brief period, the current associated with this charge distribution dwarfs that associated with the current through the load 12 .
[0073] Eventually, the current associated with charge redistribution dies down and the charge pump 10 settles into a second pump-state steady-state interval 20 B. During the second pump-state steady-state interval 20 B, current through the charge pump 10 is once again dominated by the current through the load 12 . The sum of the time spent in the second pump-state steady-state interval 20 B and the second pump-state redistribution interval 20 A is the second residence time.
[0074] In the course of transitioning between the first and second pump-states 18 , 20 the voltage at the first phase-node P 1 alternates between ground and the voltage at the second terminal 16 . Meanwhile, the voltage at the second phase-node P 2 is 180 degrees out-of-phase with the first phase-node P 1 .
[0075] Between the first pump-state 18 and the second pump-state 20 there is a dead-time interval 21 during which both the switches in the first switch-set 1 and the switches in the second switch-set 2 are open. Although not, in principle, required, this dead-time interval is a practical necessity because switches do not transition instantaneously. Thus, it is necessary to provide a margin to avoid the undesirable result of having switches in the first and second switch-sets 1 , 2 closed at the same time.
[0076] To avoid having to introduce complexity that would only obscure understanding of the principles of operation, FIG. 3 shows currents passing through the pump capacitors C 1 -C 4 in both the first and second pump-states 18 , 20 assuming instantaneous charge-redistribution, no dead-time, and the same non-zero current, I X , at the second terminal 16 in both pump-states.
[0077] In FIG. 3 , the time spent in the first pump-state redistribution interval 18 A is t 1 a ; the time spent in the first pump-state steady-state interval 18 B is t 1 b ; the time spent in the second pump-state redistribution interval 20 A is t 2 a ; and the time spent in the second pump-state steady-state interval 20 B is t 2 b . Lastly, the total length of one cycle is tsw. The first residence time is therefore t 1 a +t 1 b ; and the second residence time is t 2 a +t 2 b . The assumption of instantaneous charge redistribution is manifested by setting t 1 a and t 2 a to zero, resulting in tsw being equal to t 1 b +t 2 b.
[0078] During the first pump-state steady-state interval 18 B, the outer pump capacitors C 1 , C 4 carry a current having a magnitude of 0.4I X while the inner pump capacitors C 2 , C 3 carry a current having half of the magnitude carried by the outer pump capacitors C 1 , C 4 . This is because the inner pump capacitors C 2 , C 3 are in series and the outer pump capacitors C 1 , C 4 are by themselves.
[0079] During the second pump-state steady-state interval 20 B, each outer pump capacitor C 1 , C 4 is placed in series with one of the inner pump capacitors C 2 , C 3 , respectively. As a result, each pump capacitor C 1 -C 4 carries a current with magnitude 0.5I X . Note that the inner pump capacitors C 2 , C 3 are always in series with another pump capacitor, whereas the outer pump capacitors C 1 , C 4 are only in series with another pump capacitor during one pump-state.
[0080] In the limiting case where charge is redistributed instantly, the current sources can be removed during the first and second pump-state redistribution intervals 18 A, 20 A as in FIG. 3 . The amount of charge that is redistributed depends upon the voltages across the pump capacitors C 1 -C 4 prior to a pump-state change.
[0081] In general, it is desirable that the net charge change at any pump capacitor C 1 -C 4 be zero during the course of a particular cycle. Otherwise, increasing/decreasing amounts of charge will collect in the pump capacitors C 1 -C 4 over several cycles. This charge accretion/depletion over multiple cycles causes instability.
[0082] Since the quantity of charge transferred is the product of current and the amount of time the current flows, it follows that one can control the quantity of charge transferred to a pump capacitor C 1 -C 4 in any portion of the cycle by controlling the amount of time that the charge pump 10 spends in that portion of the cycle. This provides a way to ensure that the net charge change at each pump capacitor C 1 -C 4 is zero during one cycle of the charge pump 10 .
[0083] If the above constraint is applied to each distinct capacitor current in a charge pump 10 , it is possible to generate a system of linear equations in which the times spent in each pump-state are the unknowns. The solution to that system will be the residence times for each pump-state 18 , 20 that avoid instability.
[0084] To avoid instability in this example, assuming instantaneous charge redistribution, the first residence time should be 3/5·tsw and the second residence time should be 2/5 ·tsw. This results in an equal amount of charge being transferred from inner pump capacitors C 2 , C 3 to the first pump capacitor C 1 and to the fourth pump capacitor C 4 during the first pump-state redistribution interval 18 A; and zero redistribution charge during the second pump-state redistribution interval 20 A.
[0085] Solutions for various transformation ratios M:N are shown below in tabular form:
[0000]
First residence
Second residence
M:N
time (sec)
Time (sec)
3:1
2/3 · tsw
1/3 · tsw
4:1
1/2 · tsw
1/2 · tsw
5:1
3/5 · tsw
2/5 · tsw
6:1
1/2 · tsw
1/2 · tsw
7:1
4/7 · tsw
3/7 · tsw
8:1
1/2 · tsw
1/2 · tsw
9:1
5/9 · tsw
4/9 · tsw
[0086] Although there is no guarantee that every topology will have a solution, in the case of charge pumps like that in FIG. 1 , a solution exists. As a result of symmetry in current flow during the first and second pump-state redistribution intervals 18 A, 20 A, the solution for cases in which the transformation ratio is 2k:1 for a positive integer k, the first and second residence times will be equal. Additionally, when M is odd and N is 1, the first residence time is tsw·(M+1)/2M while the second residence time is tsw·(M−1)/2M.
[0087] In the case of a two-phase charge pump 10 , such as that shown in FIG. 4 , the currents in the first and second pump-state redistribution intervals 18 A, 20 A are inherently symmetric, as shown in FIG. 5 . Hence, the first and second pump-state residence times are equal, unlike in the single-phase charge pump 10 shown in FIG. 1 , even though both charge pumps have the same transformation ratio M:N.
[0088] In general, the first and second pump-state residence times, in the case of charge pumps like that in FIG. 4 , will be equal for any transformation ratio k:1, where k is a positive integer. This inherent symmetry provides two-phase charge pumps with an advantage over single-phase charge pumps when it comes to stability.
[0089] However, analysis based on principles of linear circuit theory is based on an idealization of the circuit. In practice, for example, due to differences in the capacitances of the various pump capacitors C 1 -C 4 of FIG. 1 , difference in circuit resistances, (e.g., through transistor switches and/or signal traces), or inexact timing of the pump-state durations, it can be difficult to manage charge accretion/depletion in the pump capacitors C 1 -C 4 .
[0090] One method for managing charge accretion/depletion is to use feedback to control the residence times. FIG. 6 shows an apparatus to carry out such control.
[0091] For convenience in discussion, FIG. 6 shows the charge pump 10 as divided into a capacitor array 26 and a switch circuit 28 . The capacitor array 26 includes the pump capacitors C 1 -C 4 and the switch circuit 28 includes the first and second switch-sets 1 , 2 .
[0092] A first controller 100 identifies suitable residence times for each pump-state and stores those in first and second residence-time buffers 32 , 34 . At appropriate times, a first timing circuit 36 A, which includes a clock to keep time, reads the residence-time buffers 32 , 34 and causes the switches in the switch circuit 28 to transition at appropriate times.
[0093] To determine the correct values of the residence times, the first controller 100 includes a first feedback circuit 38 A. In general, a feedback circuit will have a measured variable, and a manipulated variable that is to be manipulated in response to the measured variable in an effort to achieve some set point. For the first feedback circuit 38 A, the manipulated variable is the pair of residence times, and the measured variable includes a voltage measured at the second terminal 16 . Optionally, the measured variable for the first feedback circuit 38 A includes measurements obtained from within the charge pump 10 , hence the dotted lines within FIG. 6 . Examples of such measurements include voltages across the switches in the first and second switch-sets 1 , 2 or across pump capacitors C 1 -C 4 .
[0094] In one embodiment, the first feedback circuit 38 A determines residence time values based on measurements taken over a sequence of cycles. The manipulated variable of the first controller 100 is chosen based on historical values. A suitable first controller 100 is a PID (proportional-integral-derivative) controller.
[0095] An advantage of the first controller 100 shown in FIG. 6 is that the frequency of the charge pump 10 is fixed. Another embodiment, shown in FIG. 7 , features a second controller 101 that is configured to determine residence time values based on measurements obtained during the current cycle only. This allows residence time values to be determined on a cycle-by-cycle basis. As a result, the cycle length of the charge pump 10 can vary when using the second controller 101 .
[0096] The second controller 101 includes a second timing circuit 36 B that is similar to first timing circuit 36 A described in FIG. 6 . However, the second feedback circuit 38 B is implemented as a threshold logic circuit that relies on comparing voltages.
[0097] A second timing circuit 36 B provides state control signals to the switch circuit 28 . During normal operation, the second timing circuit 36 B causes transitions between the first and second pump-states 18 , 20 using nominal first and second residence times. The nominal residence times can be based on circuit analysis assuming ideal circuit elements.
[0098] The second timing circuit 36 B also includes first and second skew inputs 44 , 46 to receive corresponding first and second skew signals 48 , 50 from the second feedback circuit 38 B. The second feedback circuit 38 B asserts one of the first and second skew signals 48 , 50 to prematurely force the charge pump 10 to change pump-states. The second feedback circuit 38 B makes the decision to assert one of the first and second skew signals 48 , 50 based on feedback from one or more sources. This feedback includes measurements of electrical parameters made at one or more of: the first terminal 14 , the second terminal 16 , inside the switch circuit 28 , and inside the capacitor array 26 .
[0099] If the second feedback circuit 38 B does not assert either skew signal 48 , 50 , then the second timing circuit 36 B causes the charge pump 10 to transition between its first and second pump-states 18 , 20 according to the nominal first and second residence times. If, while the charge pump 10 is in the first pump-state 18 , the second feedback circuit 38 B presents an asserted first skew signal 48 to the first skew input 44 , the second timing circuit 36 B immediately causes the charge pump 10 to transition from the first pump-state 18 to the second pump-state 20 . Conversely, if the second feedback circuit 38 B presents an asserted second skew signal 50 to the second skew input 46 while the charge pump 10 is in the second pump-state 20 , the second timing circuit 36 B immediately causes the charge pump 10 to transition from the second pump-state 20 to the first pump-state 18 .
[0100] An advantage of the second controller 101 is that it reacts immediately on a cycle-by-cycle basis. This means that the capacitors inside the capacitor array 26 can be stabilized faster. In fact, since the second controller 101 operates by prematurely terminating charge pump-states 18 , 20 , the notion of a frequency is not well defined.
[0101] Note that shortening the first residence time while keeping the second residence time constant will generally result in an upward drift and/or a reduction in the amplitude of a lower excursion of output voltage ripple. Therefore, in one example, when the second feedback circuit 38 B detects either a downward drift in the average output or an excessive lower excursion of the output ripple, it presents an asserted first skew signal 48 to the first skew input 44 , thus truncating the first pump-state 18 and shortening the first residence time.
[0102] Conversely, in another example, upon detecting an upward drift and/or an excessive upward excursion of the ripple, the second feedback circuit 38 B presents an asserted second skew signal 50 to the second skew input 46 , thereby truncating the second pump-state 20 and shortening the second residence time.
[0103] As noted above, the second feedback circuit 38 B receives measurements of electrical parameters from one or more locations. However, these measurements would be meaningless without some way for the second feedback circuit 38 B to know whether the measured values are normal or not. To remedy this, it is desirable to provide expected values of these electrical parameters.
[0104] The thresholds provided to the second feedback circuit 38 B can be derived in many ways. One way is through analysis of an ideal circuit corresponding to the charge pump 10 . Another way is through simulation of a physical charge pump 10 . Either of these techniques can be used to provide expected values for an average output voltage (e.g., as a multiple of the input voltage) and expected maximum and minimum values of output voltage ripple about that average. The second feedback circuit 38 B uses such pre-computed values in setting the thresholds at which the skew signals 48 , 50 are asserted. Similar logic can be used to implement the first feedback circuit 38 A discussed in connection with FIG. 6 . FIG. 8 shows an implementation of the second feedback circuit 38 B shown in FIG. 7 that limits the peaks not valleys. The illustrated feedback circuit 38 B uses first and second peak-detectors to sense the peak voltage at the second terminal 16 during the first and second pump-states 18 , 20 respectively. The first peak-detector comprises a first voltage-buffer and a first diode D 1 . The second peak-detector comprises a second voltage-buffer and a second diode D 2 . The first peak-detector stores the peak voltage during the first pump-state 18 in a first peak-storage capacitor C 1 . The second peak-detector stores the peak voltage during the second pump-state 20 in a second peak-storage capacitor C 2 .
[0105] The stored peak voltages on the first and second peak-storage capacitors C 1 , C 2 can then be connected to the inputs of corresponding first and second peak-voltage comparators by closing first and second switches S 1 a , S 2 a simultaneously. This compares the peak voltages that were stored on the first and second peak-storage capacitors C 1 , C 2 during the preceding first and second pump-states 18 , 20 .
[0106] If the peak voltage during the first pump-state 18 exceeded that of the second pump-state 20 by a first threshold V 1 , then the first peak-voltage comparator asserts the first skew signal 48 . Conversely if the peak voltage during the second pump-state 20 exceeded that of the first pump-state 18 by a second threshold V 2 , then the second peak-voltage comparator asserts the second skew signal 50 .
[0107] The first and second skew signals 48 , 50 from the second feedback circuit 38 B make their way to the second timing circuit 36 B, an implementation of which is shown in FIG. 9 . The second timing circuit 36 B uses these first and second skew signals 48 , 50 to generate non-overlapping signals that control the first and second switch-sets 1 , 2 . In the illustrated embodiment, there is no gap between the two pump-states 18 , 20 . The first pump-state 18 starts upon a transition from the second pump-state 20 , and vice-versa.
[0108] In operation, the circuit shown in FIG. 9 begins the first pump-state 18 by closing a first switch S 4 . This resets a first timing-capacitor C 4 to be low. Meanwhile, a first SR latch U 4 is in the reset state. During the first pump-state 18 , an open second switch S 3 allows a first bias-current I 3 to charge a second timing-capacitor C 3 . Eventually, the first bias-current I 3 will have deposited enough charge in the second timing-capacitor C 3 to raise its voltage beyond a first voltage-threshold V 3 at the input of a first voltage comparator. When this happens, the first voltage comparator outputs a logical high. This, in turn, sets a second SR latch U 3 , thus terminating the first pump-state 18 . Thus, in the absence of an asserted first skew signal 48 , the residence time of the first pump-state 18 depends upon the first bias-current I 3 , the capacitance of the second timing-capacitor C 3 , and the first voltage-threshold V 3 .
[0109] Upon terminating the first pump-state 18 , the second pump-state 20 begins. The operation during the second pump-state 20 is similar to that described above for the first pump-state 18 .
[0110] At the start of the second pump-state 20 , the first switch S 4 opens, thus allowing a second bias-current I 4 to charge the first timing-capacitor C 4 . Eventually, the second bias-current I 4 will have deposited enough charge in the first timing-capacitor C 4 to raise its voltage past a second voltage-threshold V 4 at the input of a second voltage comparator. In response to this, the second voltage comparator outputs a logical high that sets the first SR latch U 4 , thus terminating the second pump-state 20 . During the second pump-state 20 , the second timing-capacitor C 3 is reset low when the second switch S 3 is closed, and the second SR latch U 3 is in the reset state. In the absence of an asserted second skew signal 50 , the residence time of the second pump-state 20 is set by the second bias-current I 4 , the capacitance of the first timing-capacitor C 4 , and the second voltage-threshold V 4 .
[0111] The first skew signal 48 and the output of the first voltage comparator are inputs to a first OR-gate. Thus, the first pump-state 18 can be terminated in two ways. In the first way, already described above, the first pump-state 18 lasts for its nominal residence time and terminates once enough charge has accumulated in the second timing-capacitor C 3 . However, while the second timing-capacitor C 3 is still being filled with charge, the second feedback circuit 38 B may assert the first skew signal 48 , thus bringing the first pump-state 18 to a premature end.
[0112] It will be apparent from the symmetry of the circuit shown in FIG. 9 that the second pump-state 20 can be truncated in the same way by assertion of the second skew signal 50 . The second feedback circuit 38 B is thus able to shorten the first residence time relative to the second by asserting the first skew signal 48 but not the second skew signal 50 .
[0113] After each comparison of the peak voltage in the first and second pump-states 18 , 20 , the first and second peak-storage capacitors C 1 , C 2 of the second feedback circuit 38 B are reset by closing third and fourth switches S 1 b , S 2 b and opening the first and second switches S 1 a , S 2 a . Also, the voltage buffers that sense the voltage at the second terminal 16 can be disabled or tri-stated while the first and second peak-storage capacitors C 1 , C 2 are reset. Each sample-compare-reset cycle can occur once per charge pump cycle or once per set of multiple consecutive charge pump cycles.
[0114] In the methods described above, there have been only two pump-states 18 , 20 and two residence times. However, the principles described are not limited to merely two pump-states 18 , 20 . For example, it is possible to implement a dead time interval during which the charge pump 10 is not doing anything. This dead time interval can be used in connection with the embodiment described in FIG. 7 to cause fixed frequency operation. To do so, the dead time interval is set to be the difference between a nominal charge pump period and the sum of the first and second pump-state intervals.
[0115] FIG. 10 shows one implementation for carrying out a three-state charge pump that defines a dead time as its third state. The embodiment shown in FIG. 10 , features a third controller 102 that uses a third feedback circuit 38 C connected to a third timing circuit 36 C to exercise control over only a second residence time in the second residence-time buffer 34 , and not the first residence time. In this embodiment, the first residence time is always set to some nominal value. The third controller 102 features an input from the switch circuit 28 that provides information on the state of the first switch-set 1 . Based on this information, if the third controller 102 determines that the switches in the first switch-set 1 are open, it has two choices. The first choice is to close the switches in the second switch-set 2 . This initiates the second residence time. The second choice is to leave the switches in the second switch-set 2 open. This initiates a dead-time interval. For proper operation, the first and second residence times must be non-zero.
[0116] The dead-time interval is an example of a third pump-state in which no charge transfer occurs. However, it is also possible to operate a charge pump in three or more states, each one of which permits charge transfer between capacitors. An example of such multi-state charge pump control is given in U.S. Provisional Application 61/953,270, in particular, beginning on page 11 thereof, the contents of which are herein incorporated by reference.
[0117] The rate at which charge accumulates on a capacitor depends on the current and the amount of time the current is allowed to flow. The methods disclosed thus far manage charge accumulation by controlling the second of these two parameters: the amount of time current is allowed to flow. However, it is also possible to control the first of these two parameters, namely the amount of current that flows. Embodiments that carry out this procedure are shown in FIGS. 11 and 12 .
[0118] FIG. 11 shows a fourth controller 103 similar to the second controller 101 shown in FIG. 7 but with no connection between a fourth feedback circuit 38 D and a fourth timing circuit 36 D. Thus, unlike the second controller 101 , the fourth controller 103 does not vary the first and second residence times. Instead, the fourth feedback circuit 38 D of the fourth controller 103 adjusts the current drawn by the load 12 , such as an IDAC within a LED driver, while allowing the first and second residence intervals to be derived from a constant clock signal CLK. The fourth feedback circuit 38 D makes the decision on an extent to which to vary the current drawn by the load 12 based on feedback measurements from one or more sources. These include measurements of electrical parameters made at one or more of the first terminal 14 , the second terminal 16 , inside the switch circuit 28 , and inside the capacitor array 26 .
[0119] FIG. 12 shows a fifth controller 104 that is similar to the fourth controller 103 except that instead of controlling current drawn by a load 12 , the fifth controller 104 controls current through a regulator 56 , which is modeled in the illustrated circuit as a current source. In the fifth controller 104 , a fifth timing circuit 36 E responds only to a clock signal CLK. A fifth feedback circuit 38 E decides how much to vary the current through the regulator 56 based on feedback measurements from one or more sources. These include measurements of electrical parameters made at one or more of the first terminal 14 , the second terminal 16 , inside the switch circuit 28 , and inside the capacitor array 26 .
[0120] The control methods described above are not mutually exclusive. As such, it is possible to implement hybrid controllers that implement two or more of the control methods described above.
[0121] One reason that charge accretion/depletion becomes a problem is that, as a practical matter, it is next to impossible to manufacture pump capacitors C 1 -C 4 that all have the same desired capacitance. Referring now to FIG. 13 , a remedy for this is to compensate for an error in the value of a pump capacitor's capacitance by switching other capacitors in series or in parallel with that pump capacitor. These capacitors are referred to as “trim” capacitors because they trim a capacitance to a desired value. The term “trim” is not be construed as “reducing” but rather in the sense of making fine adjustments in any direction in an effort to attain a desired value. Capacitance of a pump capacitor can be raised or lowered by connecting another capacitor in parallel or in series respectively.
[0122] FIG. 13 shows a trim-capacitor network 70 having two trim capacitors C 5 , C 6 , either one of which can be placed in parallel with the fourth pump capacitor C 4 . Although only two trim capacitors C 5 , C 6 are shown, a practical trim-capacitor network 70 has an assortment of capacitors with various values that can be selectively switched in series or in parallel with the fourth pump capacitor C 4 . The illustrated trim-capacitor network 70 is shown connecting one trim capacitor C 6 in parallel with the pump capacitor C 4 , thus raising the effective capacitance of the combination. Only two trim capacitors C 5 , C 6 are shown for clarity. However, it is a simple matter to add more, thus allowing greater variability in adjustment. In addition, for the sake of simplicity, the trim-capacitor network 70 shown only places trim capacitors C 5 , C 6 in parallel. However, it is a relatively simple matter to design a circuit to switch trim capacitors C 5 , C 6 in series with the fourth pump capacitor C 4 . Additionally, in FIG. 13 , a trim-capacitor network 70 is shown only for the fourth pump capacitor C 4 . In practice, each pump capacitor C 1 -C 4 would have its own trim-capacitor network 70 .
[0123] By switching in the proper combination of trim capacitors in the trim-capacitor network 70 , the overall capacitance of the pump capacitor C 4 combined with that of the trim capacitors C 5 , C 6 can be made to approach or even equal a target value. This trimming procedure may only need to be carried out once in the lifetime of the charge pump 10 or can be carried out during normal operation because the capacitance of practical capacitors normally vary with the voltage across their terminals as well as temperature.
[0124] Rather than being used once to adjust for manufacturing errors, a trim-capacitor network 70 as shown can also be used during operation of the circuit as a way to control the quantity of charge on a particular pump capacitor C 4 by transferring charge between a particular capacitor, e.g. the pump capacitor C 4 , and some other charge repository, such as a trim capacitor C 5 , C 6 within the trim-capacitor network 70 , or to the ultimate repository, which is ground. This provides an alternative way to adjust the charge on each capacitor in an effort to restore all pump capacitors to their respective initial voltages at the start of a charge pump cycle.
[0125] Alternately, a current sink could be coupled to each pump capacitor C 1 -C 4 allowing it to bleed any excess charge to another location or multiple locations, such as the first terminal 14 , the second terminal 16 , a terminal inside the switch circuit 28 , a terminal inside the capacitor array 26 , and even ground.
[0126] Another use for the trim-capacitor network 70 , shown in FIG. 14 , is to act as a stabilizing capacitance between the charge pump 10 and the load 12 . To reduce losses, the stabilizing capacitance is preferably just sufficient to stabilize the charge pump 10 . A larger stabilizing capacitance value than necessary may increase power loss during charge pump operation. Because of manufacturing tolerances, it will, in general, not be possible to either predict the required value of the stabilizing capacitance or, even if a prediction were available, to ensure that it has the required value over all operating conditions. Thus, one can use a technique similar to that described in connection with FIG. 13 to switch a selected trim capacitor C 5 , C 6 from the trim-capacitor network to act as a stabilizing capacitance.
[0127] The charge pump 10 can be implemented using many different charge pump topologies such as Ladder, Dickson, Series-Parallel, Fibonacci, and Doubler. Similarly, suitable converters for the regulator 56 and for the load 12 when implemented as a regulator include: Buck converters, Boost converters, Buck-Boost converters, non-inverting Buck-Boost converters, Cuk converters, SEPIC converters, resonant converters, multi-level converters, Flyback converters, Forward converters, and Full Bridge converters.
[0128] Having described the invention, and a preferred embodiment thereof, what is claimed as new, and secured by letters patent is:
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An apparatus for power conversion includes a switching network that controls interconnections between pump capacitors in a capacitor network that has a terminal coupled to a current source, and a charge-management subsystem. In operation, the switching network causes the capacitor network to execute charge-pump operating cycles during each of which the capacitor network adopts different configurations in response to different configurations of the switching network. At the start of a first charge-pump operating cycle, each pump capacitor assumes a corresponding initial state. The charge-management subsystem restores each pump capacitor to the initial state by the start of a second charge-pump operating cycle that follows the first charge-pump operating cycle.
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FIELD OF THE INVENTION
[0001] The present invention relates to a sealing system particularly for industrial safety valves, more particularly for industrial ball valves, as well as a valve comprising said sealing system.
PRIOR ART
[0002] Safety valves, in particular ball valves, are complex systems comprising a plurality of components, which can generally be operated by means of a mechanical actuator.
[0003] In the case of ball valves, these basically comprise at least one main body, at least one seat or seating, and at least one ball.
[0004] Between the seat and the ball of the valve, at least one sealing element is provided for ensuring proper sealing of the valve and at the same time allowing relative movement between seat and ball to realizing opening and closing of said valve.
[0005] Said sealing elements known from the prior art generally consist of rubber O-rings to provide hermetic closure between the seat and the ball. The use of a rubber sealing element offers numerous advantages, making it the preferred solution compared with the use of other materials.
[0006] These advantages are mainly connected with the good capacity of rubber in providing excellent sealing even in the case of a surface finish of the ball that is not defect-free or indeed has a certain degree of surface roughness. The use of a rubber sealing element therefore allows excellent sealing to be obtained, while keeping manufacturing costs lows as it is not necessary to specify exacting requirements on tolerances, surface finish and ball form errors.
[0007] At the same time, however, the use of an O-ring seal as the sealing element has some drawbacks, primarily the risk of the valve “seizing”, i.e. in the case of high operating pressures there is deformation of the rubber O-ring and the seat comes in contact with the ball. The metal-to-metal contact between seat and ball can ultimately cause seizing of the valve or at least deformation of the ball surface, even to an irreparable extent.
[0008] Yet another drawback affecting valves is that particulates, dust and dirt in general present in the fluid can get between seat and ball, reaching the sealing element and in the long run compromising its operation even to the extent of seizing of the valve itself.
[0009] Thus, a limitation of valves comprising only a rubber gasket of the O-ring type as the sealing element is that they are unreliable for high pressures of the fluid, high pressures meaning pressure values above 100 bar.
[0010] To improve valve sealing even at higher values of pressure of the fluid, solutions are available on the market that envisage, as the sealing element, a ring that has a substantially trapezoidal cross-section, more precisely of delta shape, known as a delta-ring. Even this solution, although offering improvements in terms of sealing at high pressures, has not proved entirely satisfactory for overcoming the drawbacks mentioned above.
[0011] Besides these solutions that envisage the use of rubber sealing rings, valves are known in this sector that use elements made of thermoplastics for providing the seat-ball seal. Examples of materials used are PTFE (with various compounds), nylon, PEEK, and similar thermoplastic polymers with high hardness.
[0012] These sealing elements made of plastics have the advantage, relative to the rubber O-rings or delta-rings, of preventing metal-to-metal contact between seat and ball even at high operating pressures as they are less easily deformable compared with rubber. Conversely, a drawback connected with the use of thermoplastics for making the sealing element of an industrial valve of the type in question arises from the need to have greatly reduced tolerances on machining and/or misalignments in assembly of the valve components and a greatly reduced surface roughness of the ball, which must accordingly have a polished surface finish, in order to guarantee good sealing.
[0013] The need to provide this quality of machining and control of tolerances during component manufacture leads to a notable increase in costs of production, making the valves provided with sealing elements made of thermoplastics much more expensive, and presenting the risk that manufacturing defects may have repercussions on good sealing of the valve itself.
[0014] To overcome these drawbacks, the same applicant has designed a new sealing system, which was the object of patent application WO2011/033536.
[0015] Said sealing system for industrial valves, in particular for two-way single-action or double-action piston ball valves, comprises at least one seat suitable for insertion in the housing of a ball valve, and a sealing element made of elastomeric material able to provide fluid sealing between said seat and the ball of said valve, and is further characterized in that it comprises, on the surface of said seat that is intended to be opposite said ball, at least one further element made of thermoplastic material.
[0016] Referring in particular to FIG. 1 , this shows an example of an embodiment of the sealing system that is the object of this patent application.
[0017] The sealing system 1 illustrated in application WO2001/033536 comprises a seat 20 for sealing on a ball 30 and able to interact with a valve body 10 . The seat 20 interacts with the valve body 10 as is known from the prior art, therefore, for example, a helical spring 40 , an O-ring seal, a “U” collar 60 and two “BK” collars 70 can advantageously be provided between said seat 20 and said valve body 10 .
[0018] The operation of the safety valves under discussion is known. The pressure exerted by the fluid acting on the external part of seat 20 pushes said seat against the ball 30 .
[0019] The operation of the sealing system therefore envisages that the spring 40 that acts between seat and valve body ensures sealing for low pressure values, while as the pressure increases it is the fluid itself that exerts an action of pressure of the seat against the ball, which provides the sealing of the valve.
[0020] As shown in the drawings, the sealing of the seat on the ball is effected by a sealing element made of elastomeric material positioned in a seating suitably provided on the face of seat 20 that is opposite the ball 30 , said sealing element coming into contact with said ball 30 .
[0021] Said sealing element made of elastomeric material consists of a ring 2 b of triangular cross-section, similar to the Greek capital letter delta, that's why is called a “delta-ring”.
[0022] This sealing system is characterized in that it comprises a second element made of thermoplastic material 3 b, which is also positioned between said seat 20 and said ball 30 . In particular, said thermoplastic element is in the shape of a ring preferably of trapezoidal section and is held in a second seating suitably provided, again on the face of said seat that is opposite the ball 30 .
[0023] Said ring made of thermoplastic material, indicated with 3 b in the drawing, can advantageously be positioned corresponding to the lubrication holes 21 provided in seat 20 .
[0024] According to a second configuration of the system, shown in FIG. 2 , said ring made of thermoplastic material 3 b can advantageously be positioned close to said sealing ring made of elastomeric material 2 b. In this configuration of the system, in which the thermoplastic element is positioned close to the elastomeric sealing ring, the pressure thrust band on the seat, given by the difference between the sealing diameter Y and the thrust diameter X, has a different dimension compared with that of a system in which sealing is achieved exclusively by the elastomeric ring 2 b, as it is suitably dimensioned so that the thermoplastic ring 3 b, once it is acted upon by the thrust increase under pressure and has come into contact with the ball 30 , can also develop a sealing action on the ball, without thereby causing an increase in torque.
[0025] Attainment of this situation will mean that the metallic seat follows the deformations of the ball, preserving the stability of the “delta-ring” 2 b within its seating, no longer compelled to become destabilized to guarantee sealing.
[0026] Still referring to FIGS. 1 and 2 , it can be seen that said “delta-ring” elastomeric sealing element 2 b is held in position by a retaining element 50 , which is inserted in a seating suitably provided in said seat 20 and projects from said seat and faces said ball 30 , remaining with at least a part of one of its sides in contact with the elastomeric sealing element 2 b.
[0027] The function of said retaining element 50 is to hold the elastomeric sealing element 2 b in its seating, which requires, for performing its function, a seating that is sufficiently open towards said ball 30 to permit deformation of element 2 b.
[0028] Valve sealing, particularly at high working pressures, is in fact ensured by the possibility that the seat can deform to follow the deformation of the ball valve. In fact, with the valve closed, the fluid, moving along the direction of axis A, flows round the ball 30 and, at high pressures, the ball deforms under the action of the thrust of the fluid.
[0029] When the ball deforms, seat 20 is unable to follow the deformation of the ball, and sealing is provided substantially by the capacity of the sealing element 2 b to deform as well, compensating the deformation of the ball.
[0030] More particularly, the “delta-ring” sealing element 2 b is deformed by the fluid pressure P that acts tangentially on said element, tending to extrude it from its seating.
[0031] The problem of securing the sealing element 2 b in its seating is further accentuated during valve opening/closing operations, with the valve under pressure.
[0032] The problem just illustrated, namely the need to ensure that the elastomeric sealing element 2 b deforms to provide sealing, is accentuated on valves of large diameter and as the pressures increase. It should be recalled that the ball 30 swivels on a vertical rotation axis. This translates into accentuated deformation of the ball corresponding to points farthest from the rotation axis, and almost zero deformation corresponding to points close to the rotation axis. For valves of moderate diameter, in which the distance of the points of the ball from the vertical rotation axis is small, the fluid pressures are very high, whereas for valves with larger diameters, for which the fluid pressures are generally not so high, there are points of the ball that are more distant from said rotation axis, and are therefore more liable to deform.
[0033] Referring to FIG. 3 , seat 20 also deforms under the action of the pressure, which presses it against the valve, however this too will be maintained substantially in the initial position, undeformed from bearing on the ball corresponding to the central points C and C′ substantially in line with the rotation axis of the ball, while it will tend to deform at points D and D′ that are farther from the axis.
[0034] As already said, the solution of the type known from the prior art envisages that the sealing element 2 b is always held in its seating by the presence of the retaining element 50 .
[0035] This retaining element 50 , generally made of a metallic material, is inserted in a suitable seating provided directly on seat 20 , adjacent to the seating of said sealing element 2 b.
[0036] As can be seen from FIG. 2 , in particular, the presence of the retaining element 50 , while on the one hand making it easier to insert said sealing element 2 b in its seating, as the latter has a quite wide opening, on the other hand leads to weakening of the seat itself, as it becomes necessary to provide an additional seating for the retaining element 50 and this seating, being adjacent to the seating of said sealing element 2 b, reduces the rigidity of seat 20 .
[0037] Accordingly, the solution of the type known from the prior art, shown in FIGS. 1 and 2 , has the drawback that the seat is not as strong, as it is of reduced section, because of the need to provide an additional seating for insertion of the retaining element 50 .
[0038] Moreover, another drawback affecting this sealing system of the known type consists of reduced rigidity of the entire seat, bearing in mind the clearances that are in any case present between said retaining element 50 and seat 20 , and between the retaining element 50 and the elastomeric sealing element 2 b. Yet another drawback of the system described so far, known from the prior art, is the difficulty of machining the seatings, both the seating of the sealing element 2 b and the seating of the retaining element 50 , owing to the very small tolerances and the limited mating clearances.
SUMMARY OF THE INVENTION
[0039] The problem to be solved by the present invention is to provide an improved sealing system for two-way industrial safety valves that that can overcome the drawbacks that affect the systems of the type known from the prior art.
[0040] Within said problem, one of the aims of the present invention is to provide a sealing system for two-way industrial valves that enables the mechanical characteristics of the seat to be optimized.
[0041] In particular, one aim of the present invention is to provide a sealing system that makes it possible to increase, relative to the systems of the known type, the rigidity of the system, in particular of the seat and of the elastomeric sealing element.
[0042] A further aim of the present invention is to provide a sealing system that requires simpler operations for machining the seating of said sealing element and simpler operations for assembly of said sealing element in its seating.
[0043] Yet another aim of the present invention is to provide an improved sealing system that makes it possible, at equal diameter of the valve, to reach higher fluid pressures, or, at equal pressures, to be able to produce valves of larger diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Further characteristics and advantages of the present invention will become clearer from the following detailed description, given as a non-limiting example and illustrated in the appended drawings, in which:
[0045] FIG. 1 shows a sealing system for industrial double-acting piston valves of the type known from the prior art;
[0046] FIG. 2 shows a variant of the sealing system of the known type shown in FIG. 1 ;
[0047] FIG. 3 shows a front view of a seat according to the sealing system according to the present invention;
[0048] FIG. 4 shows a section through the seat of FIG. 3 according to the present invention, indicating the dual sealing function of elements 500 and 600 in contact with ball 300 ;
[0049] FIG. 5 shows a longitudinal section of the safety valve comprising two seats according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Referring in particular to FIG. 4 , the sealing system 100 according to the present invention comprises a seat 200 for sealing on a ball 300 and able to interact with a valve body 700 , seen more clearly in FIG. 5 .
[0051] The seat 200 interacts with the valve body in the manner known from the prior art, therefore, for example, a helical spring 201 and an O-ring seal, a “U” collar 60 and two “BK” collars 70 can advantageously be provided between said seat 200 and said valve body.
[0052] The operation of two-way, single-action or double-action piston safety valves, of the type to which the sealing system according to the present invention applies, is known.
[0053] The pressure exerted by the fluid that acts on the external part of seat 200 pushes said seat against ball 300 , while the pressure that acts on the internal part of the seat moves it away from ball 300 .
[0054] The sealing system according to the present invention comprises a sealing element made of elastomeric material 500 positioned in a seat 400 and of a sealing element made of thermoplastic material 600 positioned in a seat 405 , suitably provided on the face of seat 200 that is opposite ball 300 , said sealing elements coming into contact with said ball 30 when the sealing system is assembled in a valve.
[0055] Said sealing element made of elastomeric material 500 consists of a ring of triangular cross-section, similar to the Greek capital letter delta, and therefore called a “delta-ring”.
[0056] This sealing system is characterized in that it comprises a second element made of thermoplastic material 600 , also positioned between said seat 200 and said ball 300 . In particular, said thermoplastic element has the shape of a ring preferably of trapezoidal section and is housed in a second seat 600 a, again suitably provided on the face of said seat that is opposite ball 300 .
[0057] Said ring made of thermoplastic material, indicated in the drawing with 600 , is advantageously positioned close to the elastomeric element 500 for the purpose of retaining it in the seating and of becoming a second sealing element as the pressure rises.
[0058] The sealing system according to the present invention is thus more compact than the system provided with a retaining element 50 known from the prior art, and the compactness of the seat translates into a reduction of the final costs of the seat and of the whole valve in which the seat is assembled.
[0059] In this way there is the further result that it allows the technician to install the seat according to the present invention even in situations in which the designer cannot alter the existing design for reasons of costs and overall dimensions.
[0060] The new seat design is able to increase the performance of seals of seats, and makes it possible to optimize the function of rubber gaskets even in extreme operating conditions.
[0061] In fact, it has been stated that the problem of valve sealing is associated with the deformations of the ball and seat in operation.
[0062] Now, with the new sealing system it is possible to make a seat, as mentioned, of optimized resisting section compared with the seats of the known type, and the particular configuration means that said seat can follow the deformations of the ball, safeguarding the elastomeric element 2 b even in conditions of high pressure.
[0063] It should also be pointed out that this type of solution with double sealing, in which at high pressures sealing is provided both by the elastomeric element 500 and by the thermoplastic element 600 , also makes it possible to obtain sealing called “PRIMARY METAL-SECONDARY SOFT”, by suitable dimensioning and machining of the projections of the rubber and thermoplastic inserts relative to the seat 200 , which allow the elastomeric element 500 to go back into its seating sufficiently. Moreover, it permits application to so-called “FIRE SAFE” seals, by suitable machining of the metallic seat “downstream” of the sealing gaskets.
[0064] As shown in the appended drawings, in particular in FIG. 4 , seat 200 according to the present invention has a seating 400 suitably arranged for receiving said elastomeric element 500 and said thermoplastic element 600 .
[0065] Seating 400 is thus configured in order to have its opening facing ball 300 , when the seat is mounted in a valve. Overall, therefore, seat 400 allows the elastomeric sealing element 500 and the thermoplastic element 600 to project from the seat in order to come into contact with ball 300 , when the seat is installed.
[0066] In even more detail, seating 400 of sealing element 500 will have an internal profile comprising at least one first seating 405 suitable for receiving said thermoplastic element 600 , having a cross-section, as can be seen in FIG. 4 , that is substantially rectangular with a horizontal longitudinal extension and open at the front, which is joined by a first rounded section 404 to a bottom edge 403 that is substantially flat and is inclined in a direction substantially tangential to the section of external surface of ball 300 towards which said seat 400 faces.
[0067] The bottom edge 403 is then joined via a second rounded section 402 to a final section 401 , the direction of which forms an acute angle with the direction of said bottom edge 403 , said final section 401 thus defining a substantially vertical direction, where the horizontal and vertical directions are those that can be derived from the orientation shown in FIGS. 4 and 5 : the horizontal direction substantially coincides with the direction of the flow Q, indicated in FIG. 5 , that passes through the valve, while the vertical direction is the direction orthogonal thereto.
[0068] Clearly, FIG. 4 shows the orientation of the seat and of the components of the sealing system in one assembled valve configuration.
[0069] Therefore, as described thus far, the thermoplastic element 600 and the elastomeric sealing element 500 are assembled on the seat by fitting them in seating 400 according to dimensional tolerances that allow stable and functional assembly thereof.
[0070] In particular, the functionality of the elastomeric sealing element 500 envisages, as already mentioned, that the same element is able to deform elastically when, under the effect of the pressures, seat 200 is pushed against ball 300 , and said elastomeric element is called upon to effect sealing on the ball. For this reason the assembly of the elastomeric element 500 in seating 400 envisages that it comes into contact with the bottom edge 403 of said seating, while there is a clearance between said sealing element 500 and the rounded sections 402 and 404 with the element assembled.
[0071] This clearance permits deformation of the sealing element 500 in operation. Moreover, the final section 401 and the lateral surface of the thermoplastic element 600 that is in contact with said sealing element 500 , constrain the latter to project towards the ball 300 over a predetermined section, which permits sealing and deformability of the elastomeric element 500 but, at the same time, prevents this being able to come out of its seating when stressed during operation of the valve.
[0072] It has thus been shown that the sealing system for industrial valves according to the present invention achieves the proposed purpose and objects.
[0073] In particular, it has been illustrated how the system according to the present invention makes it possible to obtain optimum sealing even at very high working pressures.
[0074] The particular conformation of the seating for the respective sealing and thermoplastic elements provided by the seat according to the present invention differs from every other type of seat in compactness and better protection of sealing, owing to the greater efficiency of the part made of rubber, safeguarded by the thermoplastic insert, and the effective barrier to high pressures of the second seal, again made possible by this second thermoplastic element.
[0075] The overall process of manufacture of the seats of valves with a single-acting or double-acting piston of the type considered here was investigated in detail and industrialized so as to obtain constant performance while varying the dimensions of the seats. In fact, the section profiles were varied dimensionally for the various ranges of nominal diameter, from 1.½″ up to 56″ with different profiles with respect to volumes of rubber and dimensions of the elastomeric and thermoplastic elements, always complying with the structure described here. In addition, combinations of materials in rubber and engineering polymer were investigated and tested appropriately, as well as the processes for machining, assembly and finishing for qualitatively guaranteeing the final product.
[0076] The sealing system according to the present invention has the further advantage of smaller overall manufacturing dimensions, with consequent reduction of the final costs of the seat and of the whole valve.
[0077] All these features make it possible to obtain a product of high technical content, able to cover a very wide range of applications.
[0078] Numerous modifications can be made by a person skilled in the art without departing from the scope of protection of the present invention.
[0079] Accordingly, the scope of protection of the claims is not to be limited by the illustrations or by the preferred embodiments shown as examples in the description, but rather the claims must comprise all the characteristics of patentable novelty deducible from the present invention, including all characteristics that would be treated as equivalent by a person skilled in the art.
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The present invention relates to a sealing system particularly for industrial safety valves, more particularly for industrial ball valves. Thus, the present invention relates both to a sealing system and to a ball valve comprising said sealing system. The sealing system according to the present invention is of the type comprising an elastomeric element ( 500 ) and a thermoplastic element ( 600 ), and is characterized in that the elastomeric element ( 500 ) that provides fluid sealing is held in its seating exclusively by a thermoplastic element ( 600 ) and by the particular shape of the seating ( 400 ) of said elements within the seat ( 200 ), and is held stably in position by these.
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FIELD OF THE INVENTION
[0001] The present invention relates to electrostatic discharge (ESD) protection generally and, more particularly, to a method and/or apparatus for implementing automatic placement based ESD protection insertion.
BACKGROUND OF THE INVENTION
[0002] At the deep sub-micron level, such as 90 nm or 65 nm structures, the protection of transistor gates has become important. One example of a design rule in deep sub-micron technologies is that the gate voltage should not be larger than the supply voltage of a transistor. In an application specific integrated circuit (ASIC) design, thousands of gates and/or pins are each connected either to a static “logic one” or “logic zero” The gate and/or pins need to be connected to a voltage VDD or a voltage VSS. The voltage VDD or VSS is connected to the gate of the transistors. This approach is called “tie up” or “tie down” of a signal and/or gate.
[0003] Conventional tie up and tie down nets generally provide one of the largest contributions to high fanout “signal” nets in designs. In 90 nm or 65 nm technologies, design rules generally prohibit the voltage at a gate from being larger than the voltage for the supply of the transistor. With conventional methods, the gate input of the transistor is tied to the logic zero and/or the logic one. A cell power rail and/or a thick power rail is directly connected to the gate input of a transistor. The transistor is tied to the logic zero and/or logic one. Conventional approaches cannot assure that the gate input voltage of the transistor is lower than the voltage of the power supply.
[0004] Conventional approaches attempt to solve this issue by inserting an electrostatic discharge (ESD) buffer and/or decoupling buffer to avoid the direct connection of the logic gate to the VDD or VSS net. The inserted buffer is a global cell that connects global signals. The buffer is manually inserted in the netlist. The manual connection is made by the designer.
[0005] Referring to FIG. 1 , a block diagram of a circuit 10 illustrating a conventional approach for connecting one or more standard cells is shown. The circuit 10 generally comprises a number of I/O cells 12 a - 12 n , a global tie down cell 14 , a global tie up cell 16 , a number of standard cells 18 a - 18 n , and a number of standard cells 20 a - 20 n . The standard cells 18 a - 18 n are coupled to the global tie down cell 14 . The global tie down cell 14 is coupled to the I/O cell 12 c . The voltage VSS is supplied to the I/O cell 12 c . The standard cells 20 a - 20 n are coupled to the global tie up cell 16 . The global tie up cell 16 is coupled to the I/O cell 12 b . The voltage VDD is supplied to the I/O cell 12 b.
[0006] With the circuit 10 , only one global tie up cell 14 and one global tie down cell 16 are implemented. The single global tie up cell 16 and the single global tie down cell 14 do not link to the real design. The global tie down cell 14 and tie up cell 16 generate interconnect signals that can be the root cause of many issues in the subsequent design flow. The global tie down cell 14 and tie up cell 16 can significantly hurt the design closure flow by generating severe congestion during the design routing phase.
SUMMARY OF THE INVENTION
[0007] The present invention concerns an apparatus comprising a plurality of input cells, two or more local tie up cells, and two or more local tie down cells. The plurality of input cells may be configured to provide (i) one or more gate voltage signals and (ii) one or more supply voltage signals. The two or more local tie up cells may be configured to provide electrostatic discharge (ESD) protection to one or more first standard cells. Each of the local tie up cells may be coupled to (i) the one or more first standard cells and (ii) each of the gate voltage signals. The two or more local tie down cells may be configured to provide ESD protection to one or more second standard cells. Each of the local tie down cells may be coupled to (i) the one or more second standard cells and (ii) each of the supply voltage signals.
[0008] The objects, features and advantages of the present invention include providing localized tie up and tie down cells that may (i) be connected to the VDD and the VSS net without destruction of the ESD buffer and/or (ii) avoid ESD damage on any input pin of a cell in a register transfer logic (RTL) netlist and/or a pre-layout gate level netlist.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other objects, features and advantages of the present invention will be apparent from the following detailed description and the appended claims and drawings in which:
[0010] FIG. 1 is a block diagram of a conventional approach for cell connection of standard cells;
[0011] FIG. 2 is a block diagram of a preferred embodiment of the present invention;
[0012] FIG. 3 is a detailed block diagram illustrating ESD protection on localized tie up nets; and
[0013] FIG. 4 is a flow chart illustrating ESD protection in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to FIG. 2 , a block diagram of a system 100 is shown in accordance with a preferred embodiment of the present invention. The system 100 generally comprises a number of cells 102 a - 102 n , a number of cells 104 a - 104 n , a number of cells 106 a - 106 n , a number of cells 108 a - 108 n , a number of circuits 120 a - 120 n , and a number of a number of circuits 122 a - 122 n , a number of circuits 124 a - 124 n , a number of circuits 126 a - 126 n , a number of circuits 140 a - 140 n , a number of circuits 142 a - 142 n , a number of circuits 144 a - 144 n and a number of circuits 146 a - 146 n.
[0015] The circuit 100 may be implemented on a single integrated circuit package. The circuits 120 a - 120 n may be implemented as local tie up cells. The circuits 122 a - 122 n , the circuits 124 a - 124 n , and the circuits 126 a - 126 n may be implemented as standard cells. The circuits 140 a - 140 n may be implemented as local tie down cells. The circuits 142 a - 142 n , the circuits 144 a - 144 n , and the circuits 146 a - 146 n may be implemented as standard cells.
[0016] The local tie up cell 120 a may be coupled to the standard cells 122 a - 122 n . The local tie up cell 120 b may be coupled to the standard cells 124 a - 124 n . The local tie up cell 120 n may be coupled to the standard cells 126 a - 126 n . The local tie down cell 140 a may be coupled to the standard cells 142 a - 142 n . The local tie down cell 140 b may be coupled to the standard cells 144 a - 144 n . The local tie down cell 140 n may be coupled to the standard cells 146 a - 146 n . The standard cells may be implemented as transistors. The particular type of transistors used may be varied to meet the design criteria of a particular implementation.
[0017] The local tie up cells 120 a - 120 n and the local tie down cells 140 a - 140 n may be implemented as buffers (e.g., an electrostatic discharge (ESD) buffer and/or a decoupling buffer). The particular type of buffer implemented may be varied to meet the design criteria of a particular implementation. A voltage (e.g., VDD) may be applied to any one of the cells 102 a - 102 n . The voltage VDD may be presented from a VDD net (not shown) to any one of the cells 102 a - 102 n . The local tie up cell 120 a may be coupled to one of the cells 102 a - 102 n which provides the voltage VDD. In general, the local tie up cell 120 a may buffer the voltage VDD prior to the passing the voltage VDD to the transistors 122 a - 122 n . The voltage VDD may be received by the gate of the transistors 122 a - 122 n . A voltage (e.g., VSS) may be applied to any one of a particular number of cells 102 a - 102 n from a VCC net. The voltages VSS and VDD may be applied to one or more of the cells 102 a - 102 n . The number of cells 102 a - 102 n that may present the voltages VSS and VDD may be varied to meet the design criteria of a particular implementation.
[0018] The voltage VSS may be applied to any one of the cells 104 a - 104 n . The local tie down cell 140 a may be coupled to one of the cells 104 a - 104 n that provides the voltage VSS. The local tie down cell 140 a may buffer the voltage VSS prior to passing the voltage VSS to the transistors 142 a - 142 n . The voltage VSS may be received by the gate of the transistors 142 a - 142 n . The voltage VDD may also be applied to any one of the cells 104 a - 104 n . The local tie up cell 120 b may be coupled to one of the cells 104 a - 104 n that provides the voltage VDD. The local tie up cell 120 b may buffer the voltage VDD prior to passing the voltage VDD to the transistors 124 a - 124 n . The voltage VDD may be received by one of the gates of the transistors 124 a - 124 n . The voltages VSS and VDD may be applied to one or more of the cells 104 a - 104 n . The number of cells 104 a - 104 n that may present the voltages VDD and VSS may be varied to meet the design criteria of a particular implementation.
[0019] The voltage VSS may be applied to any one of a particular number of cells 106 a - 106 n . The local tie down cell 140 b may be coupled to one of the cells 106 a - 106 n that provides the voltage VSS. The local tie down cell 140 b may buffer the voltage VSS prior to passing the voltage VSS to the transistors 144 a - 144 n . The voltage VSS may be received by the gate of one of the transistors 144 a - 144 n . The voltage VDD may also be applied to one of the cells 106 a - 106 n . The local tie up cell 120 n may be coupled to one of the cells 106 a - 106 n that provides the voltage VDD. The local tie up cell 120 n may buffer the voltage VDD prior to passing the voltage VDD to the transistors 126 a - 126 n . The voltage VDD may be received by one of the gates of the transistors 126 a - 126 n . The voltages VSS and VDD may be applied to one or more of the cells 104 a - 104 n . The number of cells 104 a - 104 n that may present the voltages VDD and VSS may be varied to meet the design criteria of a particular implementation.
[0020] The voltage VSS may be applied to one of the cells 108 a - 108 n . The local tie down cell 140 n may be coupled to one of the cells 108 a - 108 n that provides the voltage VSS. The local tie down cell 140 n may buffer the voltage VSS prior to passing the voltage VSS to the transistors 146 a - 144 n . The voltage VSS may be received by one of the gates of the transistors 146 a - 146 n . The voltage VDD may be applied to any of the cells 108 a - 108 n . The voltages VSS and VDD may be applied to one or more number of cells 102 a - 102 n . The number of cells 102 a - 102 n that may present the voltages VDD and VSS may be varied to meet the design criteria of a particular implementation.
[0021] Referring to FIG. 3 , a block diagram of a circuit 300 illustrating ESD protection on local tie up nets is shown. The circuit 300 generally comprises a number of circuits 302 a - 302 n and a number of standard cell rows 308 a - 308 n . A number of circuits 302 a - 302 n may be implemented as localized tie up nets. The circuit 300 may include local tie down nets (not shown) The standard cell rows 308 a - 308 n may include power lines generally connected to a chip power mesh (not shown).
[0022] The tie up net 302 a generally comprises a local tie up cell 120 a ′ and a number of standard cells 122 a ′- 122 n ′. The local tie up cell 120 a ′ may be coupled to the standard cells 122 a ′- 122 n ′. The tie up net 302 n generally comprises a local tie up cell 120 n ′ and a number of standard cells 126 a ′- 126 n ′. The local tie up cell 120 n ′ may be coupled to the standard cells 126 a ′- 126 n′.
[0023] A power supply (not shown) may present a plurality of voltages (VSS_A-VSS_N) to the circuit 300 . A plurality of inputs 310 a - 310 n may receive the voltages VSS_A-VSS_N. A power supply (not shown) may present a plurality of voltages (VDD_A-VDD_N) to the circuit 300 . A plurality of inputs 312 a - 312 n may receive the voltages VDD_A-VDD_N.
[0024] The circuit 302 a may receive the voltage VDD_A on the input 312 a . The tie up cell 120 a ′ may receive the voltage VDD_A on the standard cell row 308 b . The circuit 302 n may receive the voltage VDD_N on the input 312 n . The local tie up cell 120 n ′ may receive the voltage VDD_N on the standard cell row 308 n.
[0025] Generally, each of the voltages VSS_A-VSS_N are not equal in value due to various IR (current and resistance) drops across the circuit 300 . Each of the voltages VDD_A-VDD_N are not equal in value due to various IR drops across the circuit 300 . The voltage VDD_A in the area of the local tie up net 302 a may be VDD_A+X, where X is a value given to compensate for the IR drop across the circuit 300 . The voltage VDD_N in the area of the tie up net 302 n may be VDD_N−Y, where Y is a value given to compensate for the IR drop across the circuit 300 . Generally, the tie up net 302 a may be separated from the tie up net 302 n by a predetermined distance. If the circuits 302 a and 302 n were implemented as tie down nets, the circuits 302 a and 302 n may be separated by a predetermined distance.
[0026] In one example, the circuit 302 a may be implemented as a tie up net and the circuit 302 n may be implemented as a local tie down net. The circuits 302 a and the circuit 302 n may be separated by a predetermined distance. The predetermined distance between the circuits 302 a and 302 n may be varied to meet the design criteria of a particular implementation. For example, the predetermined distance may be varied to meet the specification of a particular technology. The change in voltage may also be varied to meet the design criteria of a particular implementation.
[0027] Referring to FIG. 4 , a method 400 for providing ESD protection is shown. The method 400 generally comprises a state 402 , a state 404 , a state 406 , a state 408 , a state 410 , a state 412 and a decision state 414 . The state 402 generally comprises determining a pre-layout netlist from synthesis without any changes. The state 404 generally comprises performing floor-planning and standard cell placement. The state 406 generally comprises determining timing and post placement optimization. The pre-layout netlist generated in the state 402 may be implemented into the cell placement of the state 404 and into the post placement optimization of state 406 . The state 408 generally comprises implementing a new ESD optimization and tie up/tie down connection after the cell placement and the post optimization phase.
[0028] The new ESD optimization phase in the state 408 may perform an automatic insertion of the ESD protected tie up and/or tie down cells based on the placement of the logic cells. The gates of the transistors in a certain area may be connected to the local tie up and/or tie down cells (e.g., the ESD buffers). The method 400 may ensure that no other design rules are violated. The method 400 may also prevent large fan out nets in the design. A user may no longer need to be concerned with the placement of the standard cells and the connections to the local tie up cells and the local tie down cells.
[0029] The state 410 generally comprises implementing design rules and technology rules as input files. The state 410 generally comprises a substep 410 a and a substep 410 b . The substep 410 a generally comprises splitting the tie up nets and/or the tie down nets. The tie up nets and the tie down nets are split to provide ESD protection and to ensure silicon robustness. The substep 410 b generally comprises splitting the tie up nets and/or the tie down nets to relax congestion on the circuit 400 due to larger tie up nets and/or tie down nets. The state 412 generally comprises the end of the optimization. In the decision state 414 , if an engineering change order (ECO) is submitted, then the method 400 moves to step 408 . A new ESD optimization and tie up and tie down connection may be implemented, which may include the design changes requested in the ECO. If an ECO is not submitted, the method 400 is complete.
[0030] The method 400 may control different voltage values of the voltage VSS of the design due to IR drops. In general, the IR drop is a placement based effect because the IR drop is related to the distribution of the power mesh/supply. The method 400 may take different types of supply voltages into account. A designer may assign logic to 1′b0 or 1′b1. Generally, 1′b0 is a verilog syntax for a net tied to ground. The verilog syntax for a net tied to the voltage VDD is 1′b1. The ESD optimization phase in the state 408 may determine which ESD protected tie up and/or tie down domains are connected to the gate of the transistors.
[0031] The present invention may (i) eliminate high fanout nets implemented with the use of global tie up cells and global tie down cells, (ii) eliminate an ASIC designer's concerns with ESD protection of tied pins (iii) ensure the approach is correct by construction (iv) provide local tie up and local tie down cells instead of a global interconnect between local tie up and tie down cells to standard cells (v) eliminate IR drop (vi) ensure signal integrity and/or (vii) eliminate severe design closure issues.
[0032] The various signals of the present invention are generally “on” (e.g., a digital HIGH, or 1) or “off” (e.g., a digital LOW, or 0). However, the particular polarities of the on (e.g., asserted) and off (e.g., de-asserted) states of the signals may be adjusted (e.g., reversed) to meet the design criteria of a particular implementation. Additionally, inverters may be added to change a particular polarity of the signals.
[0033] While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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An apparatus comprising a plurality of input cells, two or more local tie up cells, and two or more local tie down cells. The plurality of input cells may be configured to provide (i) one or more gate voltage signals and (ii) one or more supply voltage signals. The two or more local tie up cells may be configured to provide electrostatic discharge (ESD) protection to one or more first standard cells. Each of the local tie up cells may be coupled to (i) the one or more first standard cells and (ii) each of the gate voltage signals. The two or more local tie down cells may be configured to provide ESD protection to one or more second standard cells. Each of the local tie down cells may be coupled to (i) the one or more second standard cells and (ii) each of the supply voltage signals.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a fluid reservoir for the purpose of reserving a liquid, such as brake oil, etc. for use in the hydraulic brake system of an automotive vehicle or the like.
2. Description of the Prior Art
The typical construction of a fluid reservoir for reserving the operating liquid such as brake oil, etc. generally known in art of the hydraulic brake system is such that there are provided a cap over the opening at the top end of the reservoir body and a diaphragm disposed in the inside of the cap in such a manner that the moisture, dust or the like is efficiently prevented from entering into the reservoir body by function of the diaphragm. Referring more specifically to such a typical construction of the reservoir, it is noted that the circumferential portion of the diaphragm is adapted to be secured rigidly in position by way of the cap, but with such construction of the diaphragm to be secured directly by using the cap member, it is inevitable that the circumferential portion of the diaphragm is likely to be twisted followingly with the turning motion of the cap, when so rotated. In the attempt to prevent such trend of twisting motion of the diaphragm from occurring, therefore, it is generally constructed that there is further provided a force ring around the circumferential portion of the diaphragm and a step formed on the inner circumferential surface of the cap for operative engagement with the force ring in such fashion that the diaphragm may be caused to be urged into resting position at its circumferential portion by slidingly securing the engagement step on the cap along the force ring of the diaphragm, accordingly.
With the employment of such force ring, it would naturally make a job intricate as it would require added procedures when installing and removing the cap for the reservoir, and also, there is a fear that it would occasionally be forgotten to put the force ring back to position for use.
In this respect, it has then been proposed that there is formed an annular groove in the lower face of the force ring, with which the circumferential portion of the diaphragm is formed to engage together so that these two members may be assembled as a unit, and that there are provided a plurality of projections in the outer circumferential surface of the force ring and also a spiral groove in the female threads formed in the inner circumferential surface of the cap in such a manner that the force ring may resiliently be deformed manually slightly in the radial way and then forced into threaded engagement with the spiral groove of the female threads of the cap so that it may freely rotate with respect to the cap, whereby these diaphragm and cap can now be handled as a unit in practice. (see the Japanese Utility Model Laid-Open Application No. 14,765/1981).
With such construction of the reservoir, however, as it is generally inevitable to have the force ring deformed manually slightly prior to installation onto the cap as mentioned above, and therefore, it would be very possible that the diaphragm run out of engagement at its circumferential portion with the spiral groove of the force ring, when so deformed manually, and then this would occasionally make an installation job of the reservoir inefficient, after all.
SUMMARY OF THE INVENTION
The present invention is therefore materialized to practice in view of such circumstances as noted above and is essentially directed to the provision of an improved fluid reservoir construction, which can afford an efficient installation of the cap of the reservoir in which the diaphragm can be fit loosely into rotatable engagement relationship with the inside of the cap without the necessity of deforming the force ring fit around the circumferential portion of the diaphragm prior to installation.
According to the gist of the present invention relating to the reservoir construction wherein the opening at the top end of the reservoir body of cylindrical shape is covered with a diaphragm, and wherein a force ring is mounted on the upper surface of the circumferential portion of the diaphragm so that the circumferential portion of the diaphragm is rigidly secured by using the cap through the force ring, there is provided, as briefly summarized, an improved reservoir construction which is characterized in that, the lower surface of the force ring is formed with an annular groove so as to have the circumferential edge of the diaphragm engaged snugly with the annular groove, and a flanged portion defined in the outer circumference of the force ring, the flanged portion being formed with male threads adapted to threadedly engage with female threads formed in the inner circumferential surface of the cap in such a manner that the flanged portion of the force ring can be placed to dwell loosely rotatably in the inside of the female threads.
By virtue of such an advantageous construction, it is assured that the flanged portion of the force ring can now be fit loosely into a rotatable engagement relationship with respect to the female threads of the cap without the necessity of deforming the force ring in the installation work. With such advantageous feature in contrast to the conventional force ring, there is no fear that the circumferential portion of the diaphragm would run out of engagement with the annular groove of the force ring at all, and consequently, it is practicably possible that the installation work of the reservoir may be made so efficiently, accordingly.
The other objects, principle, property and details of the present invention will, as well as advantages thereof, become more apparent from the following detailed description by way of a preferred embodiment of the invention, when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a longitudinal cross-sectional view showing the reservoir assembly;
FIG. 2 is a plan view showing generally the force ring; and
FIG. 3 is an enlarged fragmentary view showing, in cross section, the essential parts of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be explained by way of a preferred embodiment thereof as adapted in practice to the tandem type master brake cylinder in reference to the drawings attached herewith. Now, referring to FIG. 1 showing the reservoir 1 in side elevation, the reference numeral 2 designates the body of the reservoir of cylindrical shape, 3 designates a partition wall for separating the lower inside portion of the reservoir body 2 into a fore chamber 4 and a rear chamber 5, 6 designates a float equipped with a magnet 7, 8 a switch for detecting a current fluid level at which it is turned ON by function of the magnet 7, and 9 and 10 openings connected to port not shown of a brake master cylinder 11, respectively.
It is seen that there is formed male threads 14 in the upper end outer circumferential surface of the reservoir body 2, and female threads 16 of a cap 15 resting in threaded engagement with the male threads 14. There is disposed a rubber diaphragm 17 in position in the inside of the cap 15, which is adapted to hermetically close an upper end opening 18 of the reservoir body 2.
There is a force ring 20, which is formed integrally of a synthetic resin as generally shown in FIG. 2, fitted around the circumferential edge 19 of the diaphragm 17. As shown in detail in FIG. 3, there is formed an annular groove 21 in the lower surface of the force ring 20, into which annular groove there is press-fitted the circumferential edge 19 of the diaphragm 17.
In the inner wall 22 of the annular groove 21 at the radially outward position thereof, there is formed a ledge 23 of ring-like shape around the whole circumference of the inner wall 22 which serves as an engaging portion having the generally U-letter shape in cross section, and on the other hand, in the outer circumferential surface 24 of the circumferential edge 19 of the diaphragm 17, there is formed a recess of ring-like shape 25 along the entire circumference of the outer circumferential surface 24 serving as an engaging portion which can snugly fit with the ledge 23 noted above. By the mutual engagement between the ledge 23 and the recess 25, it is constructed that the force ring 20 does not run easily out of engagement with the circumferential edge 19 of the diaphragm 17, accordingly. In this manner, the mentioned engaging and engaged members can be put to be engaged with each other simply by forcing the circumferential edge of the diaphragm into engagement with the annular groove of the force ring, and as a consequence, the efficiency of the installation work of the reservoir can now be improved substantially. Also, as it is possible in practice to have the shapes of the annular groove of the force ring and the circumferential edge of the diaphragm so simple, the production cost of the metal molds for the force ring and the diaphragm can be cut short accordingly.
Also, there are provided a plurality of escaping holes at an equal interval along the upper circumferential wall 20a of the force ring 20, as shown in FIG. 2 and FIG. 3, which are designed to let the air, entrapped in the annular groove 21 during the fitting operation of the circumferential edge 19 of the diaphragm 17 into the annular groove 21 of the force ring 20, escaped by way of these escaping holes 26. Consequently, the press-fitting work of the circumferential edge 19 into the annular groove 21 can be conducted quite smoothly.
In the outer circumferential wall 27 of the force ring 20, there is formed a flanged portion 20b which extends integrally from the upper surface 20a, as shown in FIG. 2 and FIG. 3. The outer diameter of the flanged portion 20b is made generally equal to that of the male threads 14 of the reservoir body 2, and its cross-sectional shape is formed to be generally triangular similar to that of the male threads 14. Also, there is formed a single-turn thread 28 in the outer circumference of the flanged portion 20b as shown in FIG. 2, so that the single-turn thread 28, can engage threadedly with the female threads 16 of the cap 15.
On the other hand, there is formed a ring-shaped urging step 29 in the inner circumferential wall of the cap 15 as shown in FIG. 3, which is adapted to urge the upper wall surface 20a of the force ring 20 while keeping sliding contact therewith. Also, there is formed an inclined urging surface 31 extending in the circumferential direction in the outer circumferential corner of this urging step 29, which is adapted to urge the tapered portion 30 as formed in the upper surface of the flanged portion 20b of the force ring 20 while keeping like sliding contact therewith.
Furthermore, in the upper surface 20a of the force ring 20 as viewed in FIG. 2, there is formed a slotted groove 32 for vent extending in the radial direction and also as shown in FIG. 2, there is formed a similar slotted groove 33 for vent extending in the vertical directions in the female threads 16 of the cap 15. It is arranged that a space 34 defined between the cap 15 and the diaphragm 17 is open to the atmosphere by way of these slotted grooves 32, 33.
With the general construction of the reservoir 1 of the brake master cylinder 11 as fully explained hereinbefore, the procedures of installation work of the cap 15 and the diaphragm 17 onto the reservoir body 2 is as follows; firstly, fitting by compression the circumferential edge 19 of the diaphragm 17 into the force ring 20, thereafter engaging threadedly the single-turn thread 28 of the force ring 20 with the female threads 16 of the cap 15 by manually turning the diaphragm 17.
Next, by turning the diaphragm 17 by specified times, the flanged portion 20b of the force ring 20 is loosely fitted in position between the end 16a of the female threads 16 and the urging step 29. With such procedures, the diaphragm 17 is held in right position to the cap 15 by way of the force ring 20, thus making it possible to handle the cap 15, the diaphragm 17 and the force ring 20 as a unit.
As the force ring 20 is designed to be of screw-in type as explained hereinbefore, it is not necessary to apply an excessive force when installing the ring into the cap 15. In this respect, therefore, there is no apprehension that that the circumferential edge 19 of the diaphragm 17 would run out of engagement with the annular groove 21 of the force ring 20 owing to its deformation when installing, at all.
Next, the cap 15 with the diaphragm 17 installed therein as noted above is then put in position onto the opening 18 at the top end of the reservoir body 2, thereafter turning manually the cap 15 to have the female threads 16 thereof engaged threadedly with the male threads 14 of the reservoir body 2. Then, by turning the cap 15 several times as specified, the cap 15 may be secured in position to the reservoir body 2, thus completing the installation work of the cap 15.
At this moment, as the circumferential edge 19 of the diaphragm 17 is positively urged downwardly by function of the urging step 29 of the cap 15 by way of the force ring 20, there is obtained a due hermetic sealing state of the top end opening 18, urging the circumferential edge 19 against the upper end surface 2a of the reservoir body 2. In this installating operation, by virtue of the advantageous feature such that the urging step 29 of the cap 15 functions to urge the upper surface 20a of the force ring 20 while keeping the sliding contact relationship therewith, there is no fear of an undesired excessive force rendered in the circumferential direction upon the circumferential edge 19 of the diaphragm 17, thus preventing damages or improper sealing owing to possible twisting or the like condition of the circumferential edge 19 from occurring, accordingly.
Also, it is arranged advantageously such that the inclined urging surface 31 of the cap 15 urges increasingly the tapered portion 30 of the force ring 20 with a certain angular relationship in their mutual contact as the cap 15 is screwed-in, even if the diaphragm 17 or the force ring 20 would possibly be located out of center or in an eccentric position with respect to the top end opening 18 of the reservoir body 2, the force ring 20 would then be caused to shift in the radial way as being guided by the inclined urging surface due to its centering function with the tapered portion 30, thus providing the effect of automatic centering of the diaphragm 17, accordingly. With such an advantageous arrangement, therefore, there is no fear that there would be caused an improper sealing in the circumferential edge 19 owing to a possible misalignment or eccentricity in positioning of the diaphragm 17 at all.
It is seen that in the state that the cap 15 is completely secured in position as shown in FIG. 3, the lower end 27a of the outer circumferential wall 27 of the force ring 20 is held slightly away from the upper end surface 2a of the reservoir body 2. More specifically, with the lower end 27a of the outer circumferential wall 27 held with a small gap, it is possible to have the securing force of the cap 15 rendered fully effectively all around the circumferential edge 19 of the diaphragm 17, and then there may be ensured with a positive sealing effect from this securing force between the circumferential edge 19 and the upper end surface 2a of the reservoir body 2, accordingly.
While the present invention was fully explained hereinbefore by way of the preferred embodiment thereof, it is to be understood that the present invention is not intended to be restricted to the details of the specific construction shown in the preferred embodiment, but to the contrary, many changes and modifications may be made in the foregoing teaching without any restriction thereto and without departing from the spirit and scope of the invention. For instance, it is notable that while there is provided the tapered portion 30 specifically to the upper side of the flanged portion 20b only in the embodiment noted herein, it may naturally be formed extending toward the upper surface 20a of the force ring 20, as well. It is of course possible in practice to have the urging step 29 of the cap 15 extending in continuation from the inclined urging surface 31 in such modification.
While the ledge portion 23 of the force ring 20 is defined in the inner surface 22 on the outer diametral position of the annular groove 21 by way of the preferred embodiment of the invention, it is also possible that the same may as well be formed in the inner surface on the inner diametral position thereto. It is of course possible that another recess 1 be likewise formed in corresponding relationship in the circumferential edge 19 of the diaphragm 17, accordingly. While there is formed the ledge portion 23 in the annular groove 21 and the recessed portion 25 in the circumferential edge 19 of the diaphragm 17, respectively, according to the preferred embodiment of the invention, it is of course possible to have them formed in the other way round.
It is also to be understood that the appended claims are intended to cover all of such generic and specific features particular to the invention as disclosed herein and all statements relating to the scope of the invention, which as a matter of language might be said to fall thereunder.
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The present invention relates to a fluid reservoir unit designed for reserving a liquid such as brake oil and the like as applied in the field of hydraulic brake system, especially of such construction that there is provided a force ring adapted to engage in cooperation with the top surface of the circumferential edge of a diaphragm covering the opening at the top end of the reservoir body of cylindrical shape, the force ring being defined at its outer circumferential surface with a flanged portion having threads for the purpose that when installing the diaphragm and the force ring onto the cap to be threadedly engaged with the outer circumference of the top end of the reservoir body, the threads in the flanged portion is led to working position while engaging threadedly with the female threads defined in the inner circumferential surface of the cap, so that the flanged portion may be put to dwell loosely rotatably in the inside of the female threads.
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BACKGROUND OF THE INVENTION
This invention relates to a forced air heat transfer system of the type that circulates air throughout a building via ductwork that conducts the air around a heat exchanger to heat or cool the air. More particularly, the invention relates to a damper assembly for introducing fresh, outside air to the heat transfer system.
Recent research indicates that conventional forced air heating or air conditioning systems adversely affect the ion balance within the enclosure heated or cooled. Preferably, the negative and positive ions within the enclosure should be balanced, but the ductwork by means of which the heating or cooling air is distributed, as well as the incorporation of electronic air cleaning devices, results in a deficiency of negative ions and an overabundance of positive ions, or a deficiency in both kinds of ions. The use of synthetic, plastics materials within the enclosure also contributes to the ion imbalance or deficiency. Such an ion imbalance or deficiency has many disadvantageous effects, particularly on the health of the occupants of the enclosure. It has been demonstrated that the ion imbalance can be overcome, to a large extent, by the addition of fresh air to the heat exchanger of both heating and air conditioning systems. For further details on such research reference is made to Volumes I and II of Proceedings of International Conference on Ionization of the Air, Oct. 16 - 17, 1961, published by Franklin Institute, Philadelphia, Pennsylvania.
Apparatus for introducing fresh air to a heating system for a building are disclosed in U.S. Pat. Nos. 2,962,218, 2,009,643 and 3,204,870. Such apparatus includes a fresh air conduit in communication with outside fresh air and a damper or baffle plate swingably mounted in the conduit for adjusting the flow of air through the conduit. Although the conduits in which damper assemblies of this type normally are substantially horizontal, it is sometimes desirable due to limited space, for example, to mount such conduit vertically. To minimize the inventory and to minimize manufacturing and assembly costs, it is desirable to provide a damper assembly which can be mounted in either a vertical or horizontal conduit. Accordingly, it is an object of the present invention to provide a damper assembly of the type described including an air intake conduit which can be mounted in any selected one of a plurality of vertically or horizontally disposed positions.
A damper assembly constructed according to the present invention incorporates a counterbalance which is mounted on a damper or baffle plate that is movably mounted internally of a conduit for conducting fresh air to the heating system. The counterbalance is adjustably mounted on the baffle plate for movement to selected positions depending on the orientation of the conduit. The apparatus includes another adjustably mounted counterbalance connected to the damper or baffle plate but disposed exteriorly of the conduit for calibrating the counterbalancing system after installation of the damper assembly on the furnace. Accordingly, it is another object of the present invention to provide apparatus of the type described including a counterbalance mounted on the damper internally of the conduit and another counterbalance adjustably mounted exteriorly of the conduit to permit calibration of the counterbalancing system after installation.
Still another object of the present invention is to provide apparatus of the type described including a counterbalance which is adjustably mounted on the damper so as always to urge the damper to a conduit closing position regardless of the horizontal or vertical orientation of the fresh air conduit.
A still further object of the present invention is to provide apparatus of the type described including gauging means removably attached to the outside of the conduit for indicating the condition of filters or the like with which the furnace customarily is equipped.
Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
Apparatus for introducing fresh air to a forced air, ducted heat transfer system which distributes air throughout a building comprising a conduit which may be either vertically or horizontally oriented, for conducting fresh air from outside of a building to the heat transfer system, a damper movable within the conduit to control the flow of fresh air therethrough, and a counterweight adjustably mounted on the damper for movement to selected positions dependent on the orientation of the conduit.
The present invention may more readily be understood by reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a typical heating system incorporating apparatus constructed according to the present invention;
FIG. 2 is an enlarged, partly sectional, side elevational view illustrating ventilating apparatus constructed according to the present invention and illustrating its association with the furnace and the exterior wall of a building;
FIG. 3 is a still further enlarged, side elevational view of the ventilating apparatus, parts being broken away to illustrate more clearly the components inside the conduit;
FIG. 4 is an end view of the apparatus illustrated in FIG. 3; and
FIG. 5 is a still further enlarged view of the apparatus encircled in the chain line 5-5 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Apparatus constructed in accordance with the present invention is adapted for use in conjunction with a forced air heat transfer system which typically comprises a furnace, generally designated 10, that may be either gas or oil fired. The furnace 10 includes a hot air chamber 12 in which is mounted a heat exchanger 13, the hot air chamber being separated by a partition 14 from a cold air chamber 15 in which is mounted a conventional, motor driven, intermittently operated blower 16. Communicating with the cold air compartment 15 is a cold air return duct 17 through which cool air from inside a building is drawn by the blower 16 for delivery to the hot air compartment 12 via an opening formed in the partition 14 at the discharge end of the blower 16. In communication with the hot air compartment 12 is a hot air outlet duct 18 through which air warmed by the heat exchanger 13 is forced by the blower 16 for discharge to various rooms of the building, as is conventional. It should be understood, of course, that the heat exchanger 13 could comprise air cooling apparatus for cooling the air passing from the return duct 17 to the outlet duct 18.
Apparatus constructed according to the present invention comprises a damper assembly, generally designated 20, including a cylindrical conduit 22 of generally circular cross-section terminating at one end in a laterally extending, perimetrical mounting flange 24 for mounting the assembly on the cold air return duct 17 via screws 26 as illustrated in FIG. 2. An opening 27 may be formed in the cold air return duct 17 of such size as to correspond substantially to the cross-sectional area of the cylindrical conduit 22. The opposite ends of the conduit 22 are crimped or rolled as at 28 for strength. The free end of the conduit receives one end of a pipe 30, the opposite end of which receives a pipe 32 passing through a building wall 34 for communicating with the outside atmosphere. The outer end of the pipe 32 is covered by suitable screening material 36 and is shielded by a hood 38 to inhibit moisture and gusts of wind entering the fresh air conduit 30, 32.
Disposed within the conduit 22 is a rockable damper or baffle plate 40 which is mounted on a rotatable shaft 42 via clamping plates 44 that are secured to the damper plate 40 via screws 47 and 48, respectively. The shaft 42 also includes an offset portion 41 which is fixed to the damper by the plate 46. The shaft 42 is journaled in nylon bushings 50 that are received in openings formed in the side walls of the fresh air conduit 22, as particularly illustrated in FIG. 5, for rotation about an axis 41. Lock washers 52 fix the bushings in place. The damper plate 40 is generally of cylindrical configuration conforming generally to the internal configuration of the conduit 22 but having sufficient clearance to be easily rotated between the conduit closing position, illustrated in FIG. 3 in which it substantially prevents the flow of fresh air through the conduit 22, and the conduit opening position, illustrated in chain lines in FIG. 3 in which fresh air is permitted to flow to the cold air inlet duct 17.
The upstream side of the damper plate 40 is secured to the rockable damper shaft 42 adjacent the upper end of the damper plate 40 so that the damper plate 40 is eccentrically mounted and the force of gravity acts on the plate to urge it to move from the open position toward the closed position illustrated in FIG. 3 when the conduit 22 is horizontally oriented as illustrated in the drawings. When the conduit 22 is vertically oriented with the mounting flange 24 lowermost, the force of gravity acts on the plate to urge it to move toward the open position.
Eccentrically and adjustably mounted on the downstream side of the damper plate 40 is a counterweight 50 which is positioned as illustrated in solid lines in FIG. 3 when the conduit 22 is horizontally disposed so as to aid the force of gravity exerted on the damper plate 40 due to its eccentric mounting in urging the damper plate 40 from the open position to the closed position. The counterweight 50 can be adjusted to the position illustrated in chain lines in FIG. 3 when the conduit 22 is vertically disposed so as to counteract the force of gravity urging the damper plate 40 to the open position. An indicator slot 52 in the counterweight 50 provides the user with a quick visual indication of the orientation and position of the counterweight 50. In the position of the counterweight 50 illustrated in FIG. 3 the center of mass of the weight 50 is below the axis 41 of shaft 42 whereas in the position of the counterweight illustrated in chain lines in FIG. 3 it is above the axis 41. When the conduit 22 is mounted vertically, with the flange 24 lowermost, the eccentric mounting of the plate on the shaft 42 will cause the force of gravity to tend to swing the plate 40 to the open position. The counterweight 50 being disposed on the opposite side of the axis of rotation 41, will counterbalance the effect of gravity and tend to urge the baffle plate 40 to the closed position. Thus, in either adjusted position, the counterweight 50 will urge the baffle plate 40 to the closed position.
One end of the mounting shaft 42 is integrally joined to a convolute or spring-loop section 56 terminating in a rectilinear support rod 58. An external counterbalance 60 is adjustable along the length of the rod 58 and may be fixed in place by a set screw 62 in any one of a number of positions. When the conduit 22 is horizontally oriented, as illustrated in FIG. 3, the counterweight 50 and the counterbalance 60 are on opposite sides of the axis 41. The function of the counterbalance 60 is to provide a fine adjustment of the counterbalancing system after the damper assembly is installed. After installation the counterweight 50 is inaccessible and adjustment of the counterbalancing system must be effected through movement of the counterbalance 60 along the rod 58.
If the conduit 22 is horizontally oriented, the counterbalance 60 will be so positioned along the rod 58 as to overcome partially the gravitational forces acting on the damper plate 40, but the net force exerted by the counterbalance 60 should be less than the net force exerted by gravity on the plate 40 and counterweight 50 whereby the damper plate 50 is constantly urged toward the position in which it substantially closes the conduit 22. When the conduit 22 is vertically disposed, and the internal counterweight 50 is moved to the position illustrated in chain lines, the external counterbalance 60 is adjusted to a position in which, when the baffle 40 is open, the counterbalance 60 partially overcomes the force of counterweight 50 tending to close the baffle plate 40 and aids the gravitational force acting on the damper plate tending to open the plate. The external counterbalance 60 should be so positioned as to permit the counterbalance 60 to be disposed at a position on the same side of the axis of rotation 41 as the major portion of the damper plate 40 extends. The net gravitational force exerted on the external counterbalance 60 and the major portion of the damper plate tending to maintain the plate open should be less than the net gravitational force exerted on the counterweight 50 and the minor portion of the plate tending to maintain it closed.
A stop plate 66 is externally mounted on the side of the conduit 22 and includes a stop tab or projection 68 which is engaged by the counterbalance mounting rod 58 to interrupt the swinging movement of the damper plate 40 when the damper plate has swung to a position in which it is inclined at an angle A of 70° to a plane passing through the rotational axis 41. A marker, generally designated 70, is removably attached to the stop plate 66 via a magnet 71 and is movable to a position aligned with the rod 58 to indicate the internal position of the damper plate 40 when it is open. Air filters (not shown) may suitably be provided in the cold air return duct 17 and the conduit 22. When the filter system in the furnace 12 becomes clogged with dirt, the arm 58 will not swing to a position aligned with the marker 70, providing an indication to the user that the filter should be changed.
A resilient stop 72, constructed of rubber or other suitable material, is disposed on the inside bottom wall of the conduit 22 via a screw 73 for interrupting swinging movement of the plate 40 when the plate 40 is inclined at an angle B or 2° to 5° to a vertical plane passing through the axis 41. It is important that the plate be slightly vertically inclined in the closed position so that incoming gusts of draft air impinging on the lower portion of plate 40 will be at least partially deflected upwardly to increase the pressure at the upper end of the tube 22. This tends to prevent inadvertent opening or rocking of the damper plate under the influence of gusts of wind so as to prevent the damper from making objectionable noises.
It has been found that the damper assembly constructed according to the following dimensions is particularly effective in preventing the damper plate 40 from opening if air has not been removed from the house and the blower 16 is not operating but then immediately recovering to provide make-up air as necessary. Assuming that the baffle plate 40 has a longitudinal axis 43 and a radius R, the transverse rotational axis 41 is located a distance 51 equal to 0.28 R above the axis 43. The axis of the locating screw 48 mounting the counterweight 50 is located at a distance 52 equal to 0.39 R above the axis 43. The counterweight 50 for a 6 inch diameter damper plate 40 may be formed of steel and have a one inch outside diameter and be 1.375 inches in length. The distance 53 between the longitudinal axis of the support rod 58 and the axis 43 is 0.58 R.
The coil spring loop section 56 damps movement of the damper plate 40 from the closed position to the open position without imparting large shock loads to the rotational shaft bearings 50. The coil spring loop section 56 further permits a substantial mass 60 to be disposed on the support rod 58 which stabilizes the damper against drafts from being moved by outside wind gusts when the pipe is vertically disposed. An additional air shut-off valve 75 (FIG. 2) may be mounted in the pipe 30 to close the conduit 30 when the system is to be rendered inoperative for a lengthy period.
The apparatus is conditioned for operation by cutting an opening 27 in the wall of the cold air return duct 70. It will be assumed that the damper assembly is horizontally oriented with the flange 24 mounted on the wall via screws 26 as illustrated in FIGS. 1 and 2. An opening is cut in the building wall 34 for the reception of the tube 32. The conduits 32 and 22 are joined by a pipe 30 to permit outside air to flow to the inlet duct 17 via the screen 36 and the conduits 32, 30 and 22. The blower 16 is generally operated intermittently to draw air from within the building via duct 17 and discharge it past the heat exchanger 13 into the duct 18. The blower will intermittently operate, in response to operation of a thermostat, a sufficient length of time to maintain the temperature in the building substantially constant. When the blower 16 is operated, the air in the conduit 22 at the downstream side of the damper plate 44 is partially evacuated by the blower 16 to create a differential pressure across the plate 40. The pressure differential will cause the damper plate 40 to swing from its conduit closing position to its open position illustrated in chain line, thereby enabling fresh air to be drawn into the cold air return duct 17 via the pipes 30, 32. The fresh air delivered to the duct 17 will be mixed with air passing therethrough and partially warmed by the air in the duct that was withdrawn from the rooms of the building. All of such air will be circulated around the heat transfer apparatus 13 to be heated by the latter prior to its discharge through the discharge duct 18. When the damper plate 40 opens, the pressure tends to equalize somewhat but the air being drawn into the conduit 22, as well as the counterbalance 60 tends to hold it open. When the operation of blower 16 is interrupted, the pressure on the upstream and downstream sides of the baffle plate 40 will be equalized and the gravitational force exerted on the damper and the counterweight 50 will swing the damper plate 40 to the closed position thereby disabling air from passing through the conduit 22.
The disclosed embodiments are representative of the presently preferred forms of the invention, but is intended to be illustrative rather than definitive thereof. The invention is defined in the claims.
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Apparatus for introducing fresh, outside air to a forced air heating or cooling system of buildings comprising a conduit for conducting fresh air to the system, a damper movably mounted in the conduit for adjusting the flow of fresh air therein, and a counterweight adjustably mounted on the damper inside the conduit for movement to selected counterbalancing positions.
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This application is a divisional of copending U.S. patent application Ser. No. 08/295,027 filed on Aug. 25, 1994, which application is entirely incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of washing clothes and a washing machine. More particularly, the present invention relates to a washing method and a washing machine capable of performing the washing method wherein a dry-cleaning course for a washing object is performed by controlling a rotation speed of a rotary blade and water stream time and also a washing object made of delicate fabrics such as silk or wools can be washed clean without any damages.
2. Prior Arts
In general, in a fully automatic washing machine, washing the laundry is performed by sequentially performing washing, rinsing, draining and dewatering operations in accordance with predetermined programs which are installed therein. FIG. 1 is a block diagram showing a construction of a fully automatic washing machine. As shown in FIG. 1, the conventional fully automatic washing machine has a key array part 12 for generating washing order signals in accordance with a user's selection, a microcomputer (hereinafter, often referred to as "micom") 10 for generating control signals for performing various operations in accordance with the user's order signals, a driving part 16 for driving various parts pursuant to the control signals from micom 10 and a display part 14 for displaying the user's instructions and the operation status of the washing machine.
When washing the laundry by using the conventional fully automatic washing machine, firstly the user switches on the washing machine, selects a washing process which he wants, and then inputs this from key array part 12 so that the washing machine performs the washing process. Thereafter, the laundry is introduced into a washing tank and then a detergent is introduced into the washing tank in an amount suitable for the laundry. The detergent can be introduced into the washing tank manually or automatically by micom 10. At the bottom of the washing tank, a rotary blade for generating a water stream is provided. Washing water is supplied into the washing tank through a water introducing pipe while rotating the rotary blade at a low speed or at a stationary state of the rotary blade. With rotating the rotary blade at a low speed, water and the laundry can be mingled together before the washing process. When a predetermined amount of water suitable for the laundry is introduced into the washing tank, a sensor senses this and sends a washing start signal to micom 10. Then, micom 10 sends a water introducing stop signal to driving part 16, which closes a water introducing valve to stop the water introduction. In this way, a proper amount of water is introduced into the washing tank automatically.
When the supply of the water is completed, micom 10 sends a washing order signal to driving part 16, which drives a motor so that the rotary blade may rotate to generate the water stream during a predetermined time. Thus, the laundry is washed. At this time, the driving part drives the rotary blade to rotate right and left during a predetermined time to thereby generate a rotating water stream in the washing tank. Due to the rotating friction force of the rotating water stream, detergent detaches the stains or contaminants stuck to the laundry, i.e., the laundry is washed. The stains or contaminants remain in the washing tank in a colloid state with the mixed detergent.
When the washing process is completed, micom 10 sends a washing stop signal to driving part 10 to stop the rotary blade and to open a water drain valve. Then, the washing water in the washing tank is drained through a drain hose. When the water is completely drained, micom 10 senses it and closes the water drain valve.
Thereafter, through the water introducing pipe, a new washing water is introduced into the washing tank. The rotary blade is rotated in the same manner as in the washing process during a predetermined time to thereby accomplish rinsing of the laundry. When the predetermined time expires, the rotary blade stops and the water drain valve is opened again to drain the water which has rinsed the laundry through the drain hose. These water introducing--rotating--draining processes are repeated two or three times in general, to thereby separate stains and/or contaminants attached to the laundry from the laundry completely. This process is referred to as a rinsing process.
Next, a dewatering process is performed. When the washing water in the rinsing process is completely drained through the drain valve, micom 10 sends a dewatering signal to driving part 16 to rotate the washing tank which is combined with the rotary blade by a mechanical mechanism in one direction at a high speed during the predetermined time. The washing water absorbed in the laundry is dewatered by a centrifugal force generated by the above high speed rotation. In this manner, the washing of the laundry is completed.
In the above conventional fully automatic washing machines mentioned, the rotation speed of the rotary blade during the washing and rinsing processes and that of the washing tank during the dewatering process is previously determined at such a degree that the general laundry is not damaged. Accordingly, when washing the laundry made of a fabric which is thin and has a high shrinkage degree such silk or pure wool using the conventional washing machine, the centrifugal force generated by the rotation of the rotary blade during the washing and rinsing processes and the centrifugal force generated by the rotation of the washing tank during the dewatering process are so strong that the fabrics are extremely damaged by the rotary blade and the washing tank and become shrunk much. Therefore, when one wishes to wash the laundry made of these fabrics, he entrusts the laundry shop for washing the laundry where a particular detergent and solvent are suitably used for silks or wools. However, such a detergent and solvent is expensive and laundry charges include the labor cost, so the cost for the laundry becomes high. Further, in the laundry shop, they accumulate several laundries from different persons and wash them at one time. Therefore, someone may regard this as being unsanitary.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a washing method capable of washing the laundry made of a fabric which is thin and shrinkable such as silks, wools, etc., simply at home without damaging the delicate fabrics, thereby relieving the burden of the laundry charges and eliminating the prejudice of the unsanitation in relation to the laundry entrusted to the laundry shop so that one may wear the clothes with a clear and a comfortable mind.
Another object of the present invention is to provide a washing machine which is suitable for carrying out the above washing method.
To accomplish the above object of the present invention, there is provided a method for washing a washing object comprising the steps of:
introducing a detergent into a washing tank equipped with a rotary blade for generating a water stream;
introducing a first amount of water into the washing tank;
introducing water into the washing tank while generating a first water stream in the first amount of water by driving the rotary blade, so that the detergent is diluted in the first amount of water and that the washing tank is filled with a second amount of water suitable for washing the washing object;
introducing the washing object into the washing tank with the second amount of water; and
washing the washing object by rotating the rotary blade for generating a second water stream suitable.
After the washing step, a rinsing step of the washing object is performed by performing a rinsing process at least once. The rinsing process comprises the steps of:
a) draining a remaining water from the washing tank;
b) introducing a third amount of water suitable for rinsing the washing object into the washing tank; and
c) rinsing the washing object by generating a third water stream suitable for rinsing the washing object.
After the rinsing step, a remaining water is drained from the washing tank; and then a remaining water absorbed in the washing object is dewatered by rotating the washing tank.
In accordance with the above method, the washing object made of wool or silk can be washed. The rotation time of the rotary blade in the washing and rinsing steps is adjusted in accordance with the material of the washing object, so a water stream suitable for the washing object is generated.
In order to accomplish another object of the present invention, there is provided a washing machine for washing a washing object comprising:
a washing tank for containing a water, a washing object and a detergent;
a means for introducing a water into the washing tank;
a means for draining a water from the washing tank;
a rotary blade in the washing tank for generating a water stream;
a driving motor for transmitting a driving force to the washing tank and the rotary blade;
a driving part for operating the driving motor, the water introducing means and the water draining means;
a sensor for generating a first signal by sensing a first amount of water suitable for diluting a detergent, a second signal by sensing a second amount of water suitable for washing a washing object, and a third signal by sensing a completion of water draining;
a microcomputer for generating a water introducing signal for controlling the water introducing means which is transmitted to the driving part so that water may be introduced according to a user's order, a first rotation order signal for rotating the rotary blade in order to dilute the detergent which is transmitted to the driving part according to the first signal, a second rotation order signal for rotating the rotary blade to perform the steps of washing and rinsing the washing object which is transmitted to the driving part according to the second signal, a water drain signal for controlling the drain means in order to drain a water from the washing tank when a washing step or a rinsing step is finished which is transmitted to the driving part, and a washing or dewatering order signal for washing or dewatering the washing object according to the third signal.
Preferably, the washing machine includes a display part for displaying a general mode for performing a washing process for washing a washing object comprised of a cotton or a synthetic fiber, a silk mode for washing a washing object comprised of a silk and/or a dry mode for washing a washing object comprised of a wool according to a user's selection.
In accordance with the present invention, a rotating water stream which does not damage the washing object is generated in the washing and rinsing steps by considering the fabrics constituting the washing object. Therefore, a dry cleaning washing and silk washing courses can be simply performed at home without any damages to the laundry.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings in which:
FIG. 1 is a block diagram showing a construction of a fully automatic washing machine;
FIGS. 2A and 2B are a flow chart for schematically illustrating a washing method in accordance with one embodiment of the present invention and
FIG. 3 is a block diagram showing a construction of a washing machine according to one embodiment of the present invention for carrying out a method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be explained in details with reference to the accompanying drawing.
FIGS. 2A and 2B are a flow chart for schematically illustrating a washing method in accordance with one embodiment of the present invention and FIG. 3 is a block diagram showing a construction of a washing machine for carrying out a method of the present invention.
Referring to FIGS. 2A and 2B and 3, a washing method and a washing machine will be explained in detail as follows. As shown in FIG. 3, the washing machine according to one embodiment of the present invention has a washing tank 100 for receiving a detergent and the laundry as a washing object and performing a washing process for the laundry, a rotary blade provided at a bottom portion of washing tank for generating a water stream, a water introducing valve 120 for controlling the water introduction into washing tank 100, a water drain valve 130 for draining water from washing tank 100, a sensor 140 for sensing the water level and a load in washing tank 100, a motor 150 for driving rotary blade 110, a driving part 160 for driving motor 150, water introducing valve 120 and water drain valve 130, a key array part 170 for inputting a user's selection mode, a display part 180 for displaying the status of the washing machine and the user's selection mode, a speaker 190 for generating a buzzer sound and a micom 200 provided with program for receiving user's instructions from key array part 170 and then generating control signals for controlling driving part 160, display part 180 and speaker 190.
At first, the user prepares the laundry, considers whether he should perform a general course washing for washing a general washing object made of cotton, synthetic fabric, etc., dry cleaning course washing for washing a washing object made of a pure wool or a silk course washing for washing a washing object made of silk and then determines a washing mode of a washing machine in accordance with the kinds of laundry. Then, the power of the washing machine is switched on.
A detergent is introduced in an amount suitable for washing the laundry (S 1 ). At this time, water introducing valve 120 and water drain valve 130 are in a closed state. When performing a dry cleaning course washing or silk course washing, a detergent essentially consisting of lauryl alkyloxyethylene, alkanolamide, normal paraffins and limonene which are particularly suitable for the dry cleaning course and silk course washing (which is different from those for a general washing course and from those used in the laundry shop) is preferably used. The detergent is preferably used in an amount of 0.5 g per liter of washing water. After introducing the detergent into washing tank 100, a desired washing mode selected among a dry mode for performing the dry cleaning washing course and a silk mode for performing the silk washing course is inputted through key array part 170 (S 2 ). When any washing mode is not inputted until a predetermined period passes, micom 200 regards the washing mode as a general mode for performing a general washing course (S 3 ). In a case of a general washing course, after introducing washing water to a set water level (S 4 ), a general washing process comprised of a washing step (S 16 ), a rinsing step (S 17 ) and a dewatering step (S 18 ) is performed. This general washing process is the same as that performed in a conventional washing machine. At this time, the laundry is introduced into washing tank 100 before or after introducing the detergent.
When micom judges that the washing mode is a dry mode or a silk mode (S 3 ), sensor 140 senses the present water level of the washing water in washing tank 100. When the sensed water level does not reach a predetermined level (first level; for example about 40%-60% of the water level suitable for washing the washing object) suitable for diluting the detergent (that is, the water level is not enough for the dilution of the detergent) (S 5 ), micom 200 sends a water introducing order signal to driving part 160 to open water introducing valve 120 so that washing water is introduced into washing tank through a water introducing pipe (S 6 ). This is referred to as a first water introducing step. In the above description, the detergent has been introduced before the first water introducing stage. However, the detergent may be introduced into washing tank 100 during the first introducing step. The detergent is diluted with a first amount of washing water less than the amount of washing water suitable for performing the washing step of the washing object. In this manner, the washing ability of the detergent is improved.
When the sensed water level is higher than a predetermined water level suitable for diluting the detergent, micom 200 judges whether the sensed water level is a predetermined water level (a second water level) suitable for washing the washing object (S 7 ). The water level suitable for washing the washing object depends on the amount of the washing object. For example, when the amount of the washing object is not more than about 2 kg, the water level is determined such that the amount of the washing water in washing tank 100 is about 50 liters. When the amounts of the washing object are not more than about 4 kg and about 5 kg-9 kg, the water levels are determined such that the amounts of the washing water in washing tank 100 are about 80 liters and 93 liters, respectively. The concentration of the detergent in the washing water is about 0.5 g/liter. When the sensed water level is deficient in washing the washing object, micom 200 opens water introducing valve 120 through driving part 160 to continuously introduce water into washing tank 100. Simultaneously, micom 200 sends a rotation order signal to driving part 160 to thereby drive motor 150 (S 8 ). The driving force of motor 150 is transferred to rotary blade 110 in washing tank 100 so that rotatory blade 110 rotates to generate a water stream in the washing water in washing tank 100. Due to the water stream, the detergent is mixed with the washing water so that the detergent is diluted with the washing water before the washing step.
The washing water is continuously introduced into washing tank 100 and sensor 140 senses the water level and sends signals to micom 200. Within a predetermined time, sensor 140 senses a water lever enough for performing the washing step of the washing object. When micom 200 judges that the water level in washing tank 100 is suitable for performing the washing the laundry (S 7 ), micom 200 sends a water introducing stop order signal and a motor rotation stop order signal to driving part 160. Driving part 160 closes water introducing valve 120 in accordance with the water introducing stop order signal and stops motor 150 so that rotary blade 100 does not rotate any more (S 9 ).
Then, micom judges whether the washing mode is a dry mode or a silk mode (S 10 ). When the washing mode is dry mode, micom 200 sends a display signal to display part 180 so that display part 180 displays "dry" (S 11 ). When the washing mode is not a dry mode, that is, the washing mode is a silk mode, micom 200 send a display signal to display part 180 so that display part 180 displays "silk" (S 12 ). Then, the user sees the displayed mode and remembers the firstly determined mode so that the user may introduce an adequate washing object correctly into washing tank 100.
Then, micom 200 sends a buzzer sound generating signal to speaker 190 to generate a buzzer sound on speaker 190 (S 13 ). When the user hears the buzzer sound, he introduces the laundry into washing tank 100 and then pushes a start button in key array part 170. The start button generates a start signal which is transmitted to micom 200 to start a washing process. Within a predetermined time, for example, within one minute, when the start signal is not inputted in micom 200 from key array part 170, micom 200 sends a buzzer sound generating signal to speaker 190 again to generate another buzzer sound (S 15 ).
In accordance with the start signal, micom 200 sequentially sends a control signal for performing a washing step to driving part 160 to thereby control each system of the washing machine wholly. Motor 150 is driven via driving part 160. The driving force of motor 150 rotates rotary blade 100 to generate a water stream suitable for washing the laundry, to wash them (S 16 ).
When the washing object is comprised of a wool and therefore, the washing mode is a dry mode, micom 200 sends a control signal to driving part 160 so that rotary blade 110 may rotate right as in a first direction for about 2-4 seconds, be stationary for about 5-6 seconds, rotate left as in a second direction opposing to the first direction for about 2-4 seconds and then be stationary for about 5-6 seconds. This process including the above operations as one cycle is repeated continuously for about six minutes. Here, the ratio of water stream strength of the dry mode with respect to the general mode is about 0.24 to 0.34, preferably about 0.27 to 0.31.
When the washing object is comprised of a silk and therefore, the washing mode is a silk mode, micom 200 sends a control signal to driving part 160 so that rotary blade 110 may rotate right as in a first direction for about 0.3-0.5 seconds, be stationary for about 5-6 seconds, rotate left as in a second direction opposing to the first direction for about 0.3-0.5 seconds and then be stationary for about 5-6 seconds. This process including the above operations as one cycle is repeated continuously for about four minutes. Here, the ratio of water stream strength of the silk mode with respect to the general mode is about 0.06 to 0.11, preferably about 0.07 to 0.09.
When the washing step is completed, micom 200 sends a water drain order signal to driving part 160, which opens water drain valve 130 to drain the washing water from washing tank 100 through a drain hose. At this time, rotary blade 110 is in a stationary state.
When the water draining is completed, sensor 140 senses the water level and sends the sensed water level to micom 200. Micom 200 performs a rinsing step through driving part 160 (S 17 ). At first, micom 200 sends a water introducing order signal to driving part 160. Then, water drain valve 130 is closed and water introducing valve 120 is opened to thereby introduce a new washing water into washing tank 100 which is suitable for rinsing the washing object. When the water introduction is finished, water introducing valve 120 is closed and motor 150 is driven to generate a water stream suitable for rinsing the washing object.
The water stream necessary for the rinsing step is generated in the same manner as in the washing step. That is, when the washing mode is a dry mode, rotary blade 110 rotates right as in a first direction for about 2-4 seconds, is stationary for about 5-6 seconds, rotates left as in a second direction opposing to the first direction for about 2-4 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated continuously for about two minutes. When the washing mode is a silk mode, rotary blade 110 rotates right as in a first direction for about 0.3-0.5 seconds, is stationary for about 5-6 seconds, rotates left as in a second direction opposing to the first direction for about 0.3-0.5 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated continuously for about one to three minutes, preferably about two minutes. After generating the water steam for the rinsing step for a predetermined time, the rotation of rotary blade 110 is stopped and then water drain valve 130 is opened to separate contaminants suspended in the washing water from the washing object. This rinsing step is performed at least once, preferably twice so that contaminants remaining on the washing object are removed.
When the rinsing step is completed and all the washing water remaining in washing tank 100 is drained, micom 200 combines rotary blade 100 with washing tank 100 mechanically and then drives motor 150 to rotate washing tank at a high speed. Then, the water absorbed in the washing object is dewatered (S 18 ). While the rotation speed of washing tank 100 in a general mode is about 760 r.p.m., that in the dry or silk mode is about 100 to 150 r.p.m.
The above dewatering step in both dry and silk modes is performed by rotating washing tank 100 in a first direction for about 3-5 seconds, stilling washing tank 100 for about 5-6 seconds, repeating at least once, preferably about seven times a process comprising the steps of i)rotating washing tank 100 in a first direction for about 2-3 seconds and ii) stilling washing tank 100 for about 5-6 seconds, and then rotating washing tank 100 in a first direction for about 2-3 seconds.
When the dewatering step is completed to finish the washing of the washing object, micom 200 generates a buzzer sound via speaker 190 so that the user may note that.
The above washing method of the present invention can be automatically performed by using a washing machine according to the present invention.
Hereinafter, the present invention will be explained in more details with reference to the following embodiment.
Embodiment 1
The present embodiment illustrates a general washing method for washing a general washing object made of cottons or synthetic fabrics.
After introducing a detergent (S 1 ) and the laundry into washing tank 100, the power of the washing machine is switched on. Micom 200 waits for a signal for selecting a washing mode to be inputted. When any washing mode is not inputted until a predetermined period passes, micom 200 regards the washing mode as a general mode for performing a general washing course (S 3 ). Micom 200 sends a water introducing order signal to driving part 160 to open water introducing valve 120 so that washing water is introduced into washing tank through a water introducing pipe to a set level (S 4 ). During the water introducing step, micom 200 rotates rotary blade slightly so that the detergent is mixed uniformly before performing a washing step. In this manner, the washing ability of the detergent is improved.
Micom 200 senses via sensor 140 whether the sensed water level is a predetermined water level suitable for washing the washing object so that a suitable amount of water may be introduced into washing tank 100.
When the water introduction is finished, micom 200 sends a washing order signal to driving part 160 so that rotary blade 110 may rotate right and left. Due to the centrifugal force of rotary blade 110, the water stream in the washing water is generated to thereby wash the laundry by the rotation friction of the water stream (S 16 ). This is the same as in a general washing process in a conventional washing machine.
When the washing step is completed, water drain valve 130 is opened to drain the washing water from washing tank 100 through a drain horse. When the water draining is completed, water drain valve 130 is closed and micom 200 sends a rinsing order signal to driving part 160.
Then, water introducing valve 120 is opened to thereby introduce a new washing water into washing tank 100 which is suitable for rinsing the washing object. When the water introduction is finished, water introducing valve 120 is closed and rotary blade is rotated right and left in a predetermined time to generate a water stream suitable for rinsing the washing object. This rinsing step is performed twice so that contaminants remaining on the washing object are cleanly removed (S 17 ).
When the rinsing step is completed and all the washing water remaining in washing tank 100 is drained, a dewatering step is performed. In the dewatering step, with water drain valve 130 opened, micom 200 combines rotary blade 100 with washing tank 100 mechanically via driving part 160 and then drives motor 150 connected to driving part 160 to rotate washing tank 100 at a high speed. Then the water absorbed in the washing object is dewatered due to the centrifugal force of washing tank 100. Thus, the washing of the washing object is completed (S 18 ).
Embodiment 2
The present embodiment illustrates a dry cleaning washing method for washing a washing object made of a pure wool.
A detergent suitable for dry cleaning is introduced in an amount suitable for washing the laundry (S 1 ) and then a button for selecting a dry mode in key array part 170 is pushed (S 2 ). When micom 200 receives the signal for selecting the dry mode from key array part 170, a method for performing a dry cleaning washing course is performed to wash the laundry.
More particularly, in a selecting step of the washing mode, key array part 170 send a dry mode selection signal to micom 200 (S 3 ), which judges whether the water level reaches the first level (S 5 ) and sends a water introducing order signal to driving part 160 to open water introducing valve 120 (S 6 ). Then, washing water is introduced into washing tank 100 in a small amount through water introducing pipe.
When the suitable amount of water for diluting the detergent is introduced, micom 200 drives motor 150 via driving part 160 for a predetermined time, to thereby rotate rotary blade 110 at a low rotation speed. Due to the rotation of rotary blade 110, a water stream is generated to dilute the detergent. Simultaneously, a predetermined amount of water is sequentially introduced into washing tank 100 (S 8 ).
When the suitable amount of water (at this time, the concentration of the detergent is about 0.5 g/l) is introduced into washing tank (S 7 ) and the dilution of the detergent is completed, sensor 140 senses a water level enough for performing the washing step of the washing object and sends a signal to micom 200. Then, micom 200 sends a water introducing stop order signal and a motor rotation stop order signal to driving part 160 (S 9 ). Driving part 160 closes water introducing valve 120 in accordance with the water introducing stop order signal and stops motor 150 so that rotary blade 100 does not rotate any more. Also, micom 200 judges that the washing mode is a dry mode (S 10 ), and sends a display signal to display part 180 so that display part 180 displays "dry" (S 11 ) and sends a buzzer sound generating signal to speaker 190 to generate a buzzer sound on speaker 190 (S 13 ). When the user hears the buzzer sound, he introduces the laundry into washing tank 100 and then pushes a start button in key array part 170. Micom 200 judges whether the start signal is inputted from key array part 170 (S 14 ). When micom 200 senses the start signal, a signal for performing the washing step is transmitted to driving part 160 to start the dry cleaning washing course. Within one minute, when the start signal is not inputted in micom 200 from key array part 170, micom 200 sends a buzzer sound generating signal to speaker 190 again to generate another buzzer sound (S 15 ).
At the state that the washing object is in washing tank 100, when the start signal is applied, driving part 160 drives motor 150 so that rotary blade 110 rotates right and left for a predetermined time. More particularly, rotary blade 110 rotates in the right direction for about 2-4 seconds, is stationary for about 5-6 seconds, rotates in the left direction for about 2-4 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated for a predetermined time (for example, about six minutes) to wash the washing object (S 16 ).
When the washing step is completed, micom 200 sends a water drain order signal to driving part 160, which opens water drain valve 130 to drain the washing water from washing tank 100 through a drain horse.
When the water draining is completed, micom 200 sends a water introducing order signal to driving part 160. Then, water drain valve 130 is closed and water introducing valve 120 is opened to thereby introduce a new washing water into washing tank 100 which is suitable for rinsing the washing object. When the water introduction is finished, water introducing valve 120 is closed and motor 150 is driven to rotate rotary blade 110 for a predetermined time to generate a water stream suitable for rinsing the washing object (S 17 ).
The water stream necessary for the rinsing step is generated in the same manner as in the washing step. That is, rotary blade 110 rotates in the right direction for about 2-4 seconds, is stationary for about 5-6 seconds, rotates in the left direction for about 2-4 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated continuously for about two minutes.
This rinsing step is performed twice so that all the contaminants (stains and detergent) remaining on the washing object are removed.
When the rinsing step is completed, micom 200 sends a water drain order signal to driving part 160 to open water drain valve 130. Then the washing water remaining in washing tank 100 is drained, and a dewatering step starts. In the dewatering step, micom 200 combines rotary blade 100 with washing tank 100 mechanically and then drives motor 150 to rotates washing tank at a rotation speed of about 100 to 150 r.p.m. (S 18 ).
The dewatering step is performed by rotating washing tank 100 in the left or right for about 3-5 seconds, stilling washing tank 100 for about 5-6 seconds, repeating about seven times a process comprising the steps of i)rotating washing tank 100 in the left or right for about 2-3 seconds and ii)stilling washing tank 100 for about 5-6 seconds, and then rotating washing tank 100 in the left or right for about 1-3 seconds.
When the dewatering step is completed to finish the washing of the washing object, micom 200 generates a buzzer sound via speaker 190 so that the user may note that. This finishes the washing method for washing the washing object made of wool.
Embodiment 3
The present embodiment illustrate a washing method for washing a washing object made of a silk.
A detergent suitable for silk is introduced in an amount suitable for washing the laundry (S 1 ) and then a button for selecting a silk mode in key array part 170 is pushed (S 2 ). When micom 200 receives the signal for selecting the silk mode from key array part 170, a method for performing a silk washing course is performed to wash the laundry made of silk.
More particularly, in a selecting step of the washing mode, key array part 170 sends a silk mode selection signal to micom 200 (S 3 ), which judges whether the water level reaches the first level (S 5 ) and sends a water introducing order signal to driving part 160 to open water introducing valve 120. Then, washing water is introduced into washing tank 100 in a small amount through water introducing pipe (S 6 ).
When the suitable amount of water for diluting the detergent is introduced, micom 200 drives motor 150 via driving part 160 for a predetermined time, to thereby rotate rotary blade 110 at a low rotation speed. Due to the rotation of rotary blade 110, a water stream is generated to dilute the detergent (S 8 ). Simultaneously, a predetermined amount of water is sequentially introduced into washing tank 100.
When the suitable amount of water (at this time, the concentration of the detergent is about 0.5 g/l) is introduced into washing tank and the dilution of the detergent is completed, sensor 140 senses a water level enough for performing the washing step of the washing object and sends a signal to micom 200 (S 7 ). Then, micom 200 sends a water introducing stop order signal and a motor rotation stop order signal to driving part 160. Driving part 160 closes water introducing valve 120 in accordance with the water introducing stop order signal and stops motor 150 so that rotary blade 100 does not rotate any more (S 9 ). Also, micom 200 judges that the washing mode is a silk mode (S 10 ) and sends a display signal to display part 180 so that display part 180 displays "silk" (S 12 ) and sends a buzzer sound generating signal to speaker 190 to generate a buzzer sound on speaker 190 (S 13 ). When the user hears the buzzer sound, he introduces the laundry made of silk into washing tank 100 and then pushes a start button in key array part 170. Micom 200 judges whether the start signal is inputted from key array part 170. When micom 200 senses the start signal (S 14 ), a signal for performing the washing step is transmitted to driving part 160 to start the silk washing course. Within one minute, when the start signal is not inputted in micom 200 from key array part 170, micom 200 sends a buzzer sound generating signal to speaker 190 again to generate another buzzer sound (S 15 ).
At the state that the washing object is in washing tank 100, when the start signal is applied, driving part 160 drives motor 150 so that rotary blade 110 rotates right and left for a predetermined time. More particularly, rotary blade 110 rotates in the right direction for about 0.3-0.5 seconds, is stationary for about 5-6 seconds, rotates the left direction for about 0.3-0.5 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated for a predetermined time (for example, about four minutes) to wash the washing object (S 16 ).
The washing object made of silk does not sink into the washing water but floats at an upper portion of the washing water. In the conventional washing machine, the rotating water stream is generated regardless of the kinds of the fabrics of the washing objects. In this case, when the rotating water is generated for a long time, the washing object sinks due to the rotating water stream to come in contact with rotary blade 110 or with the bottom portion of washing tank 100. Therefore, the washing object is damaged. However, in the present embodiment, rotary blade is rotated for about 0.3 to 0.5 seconds. Then, the washing object sinks to the lower portion of the washing water and is washed due to the rotation friction force. However, since the water stream is generated for a short time, the washing object does not come in contact with rotary blade 110 or the bottom of washing tank 100 although the washing object sinks into the washing water. Therefore, the washing object is not damaged.
After rotating rotary blade 110 for about 0.3-0.5 seconds, rotary blade 110 is stationary for about 5-6 seconds. At this time, the pressure generated by the rotating water stream is reduced and the washing object which has sunk due to the rotating water stream rises to the surfaces of the washing water.
At this state, rotary blade 110 rotates in the opposing direction to generate a rotating water stream again. Then, the washing object sinks again and is washed due to the rotating friction force of the water stream.
When the washing step is completed, micom 200 sends a water drain order signal to driving part 160, which opens water drain valve 130 to drain the washing water from washing tank 100 through a drain hose.
when the water draining is completed, micom 200 sends a water introducing order signal to driving part 160. Then, water drain valve 130 is closed and water introducing valve 120 is opened to thereby introduce a new washing water into washing tank 100 which is suitable for rinsing the washing object. When the water introduction is finished, water introducing valve 120 is closed and motor 150 is driven to rotate rotary blade 110 for a predetermined time to generate a water stream suitable for rinsing the washing object. The water stream necessary for the rinsing step is generated in the same manner as in the washing step. That is, rotary blade 110 rotates in the right direction for about 0.3-0.5 seconds, is stationary for about 5-6 seconds, rotates in the left direction for about 0.3-0.5 seconds and then is stationary for about 5-6 seconds, which as one cycle is repeated continuously for about two minutes (S 17 ).
This rinsing step is performed twice so that all the contaminants (stains and detergent) remaining on the washing object are removed.
When the rinsing step is completed, micom 200 sends a water drain order signal to driving part 160 to open water drain valve 130. Then the washing water remaining in washing tank 100 is drained, and a dewatering step starts.
In the dewatering step, micom 200 combines rotary blade 100 with washing tank 100 mechanically and then drives motor 150 to rotate washing tank at a rotation speed of about 100 to 150 r.p.m.
The dewatering step is performed by rotating washing tank 100 in the left or right for about 3-5 seconds, stilling washing tank 100 for about 5-6 seconds, repeating about seven times a process comprising the steps of i)rotating washing tank 100 in the left or right for about 2-3 seconds and ii)stilling washing tank 100 for about 5-6 seconds, and then rotating washing tank 100 in the left or right for about 1-3 seconds (S 18 )
When the dewatering step is completed to finish the washing of the washing object, micom 200 generate a buzzer sound via speaker 190 so that the user may note that. This finishes the washing method for washing the washing object made of silk.
In accordance with a method described in embodiment 1, a washing object made of cottons or a synthetic fiber has been washed. As a washing machine, DWF-9290RD (trade name by Daewoo Electronics Co. Ltd.) wherein the method of the present invention is embodied was used. As a detergent, a standard detergent for investigating the washing capability of a washing machine was used. The detergent was used in an amount of 2 g per liter of water.
Additionally, using a conventional washing machine wherein the conventional washing method is embodied, a conventional general washing method has been carried out under the same conditions. The washability and dewatering have been measured against the washing objects which had been washed by using a washing machine of the present invention and a conventional washing machine. The results are shown in table 1 as below.
TABLE 1______________________________________ Embodiment 1 Conventional Method______________________________________washability 113 100dewatering 102 100______________________________________
As can be seen from table 1, it can be noted that the washability of the washing object according to the present invention is superior to that of a conventional method, while the dewatering degrees are similar with each other.
In accordance with the methods described in embodiments 2 and 3, washing objects made of a wool and a silk has been washed. AS a washing machine, DWF-9290RD (trade name by Daewoo Electronics Co. Ltd., Korea) wherein the method of the present invention is embodied was used. As a detergent, Dryten (trade name by Hichem Co., Korea) was used. The detergent was used in an amount of 0.5 g per liter of water.
Additionally, using a conventional washing machine which is used in a laundry shop wherein a conventional washing method is embodied, a conventional detergent for washing the objects made of a wool and a silk and a conventional solvent comprised of perchloroethylene, a dry cleaning of the washing object has been carried out. The shrinkage and the fabric damage have been measured against the washing objects which had been washed by the method of the present invention and a conventional dry cleaning method.
The measuring methods are as follows.
1) After washing test pieces of fabrics (silk and wool) as a washing object four times, the lengths of the test pieces have been measured. The shrinkage was calculated by the following equation (1). ##EQU1##
2) After washing test pieces of fabrics (silk and wool) as a washing object twenty times, the weights of the test pieces have been measured. The damage degree was calculated by the following equation (2). ##EQU2##
The measured shrinkage and damage degrees are shown in table 2 as below.
TABLE 2______________________________________ Embodi- Embodi- Conventional Conventional ment 2 ment 3 (wool) (silk)______________________________________shrinkage(%)1) 1.09 1.51 1.33 2.732) 0.81 0.37 0.65 1.42damage (%) 0.58 0.45 3.58 3.58______________________________________ Note. 1) measured in a lengthwise direction of the test fabric pieces 2) measured in a crosswise direction of the test fabric pieces
As can be seen from table 2 above, when performing a washing method of the present invention for wool and silk, the shrinkage and damage are similar with those in the conventional method in a laundry shop. This indicates that washing a washing object made of wool or silk can be easily performed according to the method of the present invention.
In accordance with the present invention, washing a washing object made of pure wool or silk can be easily performed at home without any damages to the washing object. Therefore, economic costs which may occur by entrusting the laundry to the laundry shop may be reduced. Further, the impression that the laundry is unsanitary since many washing objects from the different persons are washed simultaneously in the laundry shop, may be avoided. Therefore, one may wear clothes with a clear and comfortable mind.
While the present invention has been particularly shown and described with reference to particular embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be effected therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A washing machine is disclosed which is suitable for use in the home and is capable of washing laundry consisting of fabrics which are thin and shrinkable such as silks, wools, etc., without damaging the delicate fabrics. The washing machine has a washing tank into which is introduced water, detergent and the laundry to be washed. A rotary blade is positioned within the washing tank. The tank is provided with a sensor which senses a first amount of water within the tank suitable to dilute the detergent, a second sensor for sensing the amount of water in the tank suitable for washing and rinsing the laundry and a third sensor for sensing when the water has been drained from the tank. A microcomputer receives the signals from the respective sensors and, in turn, transmits signals to a driving part 1) for controlling the amount of water to be introduced into the washing tank, 2) for rotating the rotary blade in order to dilute the detergent, 3) for rotating the rotary blade to perform the steps of washing and rinsing and 4) for draining the water from the washing tank.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to farm implements and, more particularly, to a method and apparatus for purging distribution channels for an air seeder of a farm implement.
[0002] Agricultural or farm implements that apply seed, fertilizer, or other particulate (granular) matter to a surface (“farm field”) typically have one or more central hoppers or tanks that are loaded with the particulate matter. The hoppers have or are associated with a metering device, which is typically a rotating element, that meters the particulate matter from the hoppers into a set of distribution channels, such as conduits, hoses, etc., that are flow coupled to the individual row units, or seed boxes associated with the individual row units. In many implementations, a blower system provides a turbulent air stream into which the particulate matter is entrained to pass the particulate matter through the distribution channels and ultimately to the individual row units. Such air seeders can take many forms and use various configurations to apportion the correct amount of particulate matter evenly throughout the distribution channels so that the particulate matter is deposited onto the farm field in a uniform and consistent manner.
[0003] One type of air seeder uses a large conduit to convey all the metered product to a first hollow distributor or manifold at which the particulate product is divided into a number of secondary streams evenly using evenly sized and spaced outlet ports. The secondary streams are fed to secondary headers, with each secondary header providing additional division and distribution of the secondary streams before the air/product streams are fed to the individual row units.
[0004] Another type of air seeder uses a metering roller that is segmented into a number of sections, with each section of the metering roller communicating with a dedicated set of secondary headers. With this type of air seeder, the product is mechanically metered and separated into different streams or runs and each stream is fed to a secondary header that provides additional division and distribution of the air/product streams before being fed to the individual row units.
[0005] A third type of air seeder avoids the use of secondary headers and the downstream division that such secondary headers provide. These air seeders use a metering roller that is large enough to feed product to each of the row units directly.
[0006] Regardless of the type of air seeder used, due to the increasing cost of seed and fertilizer, the agronomic disadvantage and waste associated with redundant application of seed and fertilizer, and the increasing size of seed drills, efforts have been made to selectively shut off the flow of product to the secondary headers which allows the seed drill to traverse previously seeded land without necessarily reapplying seed or fertilizer while the seed drill is used to apply particulate matter to nearby unseeded land. For air seeders having segmented or direct feed metering rollers, sectional control can be achieved by preventing the flow of product to the metering roller. When starving the roller by mechanically stopping the flow of product by using a gate or similar structure or by not rotating the roller, the roller cannot meter product downstream.
[0007] It will thus be appreciated that achieving sectional control is relatively straightforward for air seeders having segmented or direct feed metering rollers. However, for an air seeder that uses a distribution manifold and several downstream secondary headers to distribute particulate matter to the individual row units, sectional control is considerably more difficult. That is, if air flow is stopped to one of the outlet ports of the main header or manifold, the downstream channel may become plugged by the residual product thereby causing an issue when the air flow through the stopped outlet port resumes. If the channel becomes plugged, the application devices that are fed by the plugged channel will not be able to apply product to the field and will result in inconsistent and undesirable application of the seed and/or fertilizer.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method and system for sectional control of an air seeding system that uses a main header or distribution manifold to distribute product, such as seed or fertilizer, to a plurality of secondary headers that likewise distribute the product for delivery to application devices, such as row units, or the seed boxes for the row units. The present invention enables sectional control for such an air seeding system by providing an apparatus and method for purging a channel of residual product when air flow to the channel through the header is stopped. In one implementation, the invention provides a plenum of air that provides a purging air flow to a distribution channel that has been shut off from a product air flow. A two position valve is used to selectively flow couple the channel to the primary product air flow and to the purging air flow. In one implementation, the blower that is used to provide the air flow for delivery product is also used to provide a volume of air to the plenum that can be used to purge the closed channel of residual product.
[0009] Therefore, in accordance with one aspect of the invention, an apparatus for a product distribution system of a farm implement is comprised of a header having an inlet and a plurality of outlets. The inlet is configured to receive product entrained in an air flow and the plurality of outlets are configured to pass respective portions of the product. A plenum having a volume of air and selectively in fluid communication with the plurality of outlets of the header is provided and is configured to provide a purging air flow to one or more of the plurality of outlets when in fluid communication with the one or more of the plurality of outlets.
[0010] In accordance with another aspect of the invention, a product distribution system for a farm implement includes a distribution manifold having a fluid inlet and a plurality of outlets, an entrained fluid flow containing particulate matter entrained in air, and a purging fluid flow free of the particulate matter to which at least one of the plurality of outlets is automatically exposed to when the at least one of the plurality of outlets is fluidly isolated from the entrained fluid flow.
[0011] The invention is also embodied in a method of purging a product distribution system of a farm implement. According to one aspect of the invention, the method includes passing entrained product through a manifold for subsequent distribution to a plurality of secondary headers for application of the entrained product onto a farm field. When desired for sectional control, the method includes selectively preventing air flow entrained with product to one of the secondary headers and simultaneously therewith, exposing the one secondary header to an air flow absent of entrained product to substantially purge the product placement devices connected to the one secondary header of product.
[0012] It will therefore be appreciated that one object of the invention is to provide a sectional control for a product metering system of a farm implement.
[0013] It is another object of the invention to provide a method and apparatus for purging a closed distribution channel of a production distribution system of a farm implement.
[0014] Other objects, features, aspects, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout.
[0016] In the drawings:
[0017] FIG. 1 is a pictorial view of a farm implement incorporating the principles of the present invention;
[0018] FIG. 2 is a schematic view of the product distribution system of the farm implement of FIG. 1 ;
[0019] FIG. 3 is an isometric view of a main header and plenum of the product distribution system of FIG. 2 ;
[0020] FIG. 4 is a top section view of the main header and plenum of FIG. 3 taken along line 4 - 4 of FIG. 3 ;
[0021] FIG. 5 is a section view of the main header and plenum taken along line 5 - 5 of FIG. 3 ; and
[0022] FIG. 6 is a section view of the main header and plenum similar to the view shown in FIG. 5 but with exit ports of the main header fluidly exposed to a purging air flow according to one aspect of the invention.
DETAILED DESCRIPTION
[0023] Turning now to FIGS. 1 and 2 , an air seeder 10 includes an air hoe drill 12 coupled to a towing tractor 14 in a conventional manner. As known in the art, an air cart 16 is coupled to the air hoe drill 12 and in the illustrated embodiment is towed behind the air hoe drill 12 . As also known in the art, the air cart 16 has a large hopper 18 that holds a quantity of particulate matter, e.g., seed and/or fertilizer, and a metering unit 20 that meters the particulate matter from the hopper 18 to the air hoe drill 12 . The size of the hopper 18 may vary, but in one embodiment, the hopper 18 is sized to hold 580 bushels of particulate matter. One exemplary air cart is a Precision Air cart which is commercially available from CNH America, LLC.
[0024] In addition to being mechanically linked with the air hoe drill 12 , the air cart 16 and the air hoe drill 12 are interconnected by an air/product hose 22 and an air hose 24 . Air is supplied to both hoses 22 , 24 by a blower assembly 25 generally mounted adjacent the front of the hopper 18 and adjacent the metering unit 20 . Alternately, the blower assembly 25 may be mounted rearward of the hopper or adjacent a side of the hopper. As known in the art, the blower creates a turbulent air flow that forces the particulate matter metered by metering unit 20 into and along air/product hose 22 . The particulate matter is entrained in the air flow created by the blower and communicated from the air cart 16 through hose 22 to a main header or manifold 26 that is mounted to and supported by the air hoe drill 12 . In the illustrated embodiment, the main header 26 is vertically oriented but it is understood that other orientations are possible.
[0025] The main header 26 is a hollow conduit fluidly coupled in a conventional manner to hose 22 so that the product/air mixture P passed through hose 22 is delivered to the main header 26 and, more particularly, to a set of outlet or exit ports 28 formed in the main header 26 . The exit ports are equiradially spaced about the upper end of the main header 26 and the openings of the exit ports 28 are equally sized.
[0026] In operation, the product/air mixture is led to the main header 26 and distributed evenly by the main header 26 to a set of primary conduits or hoses 30 that are flow coupled to the outlet ports 28 . The primary conduits 30 are flow coupled to a set of secondary headers 32 . The secondary headers 32 are similar to the main header 26 in that each secondary header 32 has a set of outlets 34 , with each outlet flow coupled to a secondary conduit 36 . Each secondary conduit 36 passes its portion of the air/product mixture to a row unit 38 which is configured in a conventional manner to deposit the particulate matter onto the seeding surface S.
[0027] To provide sectional control but also prevent clogging of the conduits downstream of the main header 26 , the present invention provides, in combination, a plenum 40 and a valve arrangement 42 , as shown in FIGS. 4 through 6 . The plenum 40 is mounted adjacently beneath the main header 26 and includes an air inlet 44 that is flow coupled to the air hose 24 . In this regard, the plenum 40 is fed air from the same blower assembly that provides the forced air for passing particulate matter through hose 22 .
[0028] In the illustrated example, the valve arrangement 42 includes valves 46 a, 46 b, 46 c, and 46 d and each is configured to selectively expose a respective main header exit port to either the product/air mixture supplied to the main header 26 by hose 22 or to the volume of air contained in the plenum 40 that is fed air via hose 24 . in one implementation, each valve has a gate 48 that is movable between a first position, shown in FIG. 5 , in which the exit port is in fluid communication with the air/product flow P and a second position, shown in FIG. 6 , in which the exit port is in fluid communication with the plenum 40 . It is contemplated that the valves could be activated in a known or to be developed manner, such as by a linear or rotary actuator, generally shown at 47 . Moreover, while a gate 48 is shown, it is understood that any known or to be developed mechanism could be used to selectively expose the exit port to the air/product mixture and the plenum of air. In this regard, when a valve is moved from the first or “open” position to the second or “closed” position, the exit port associated with that valve when will be closed off to the supply of particulate matter in the entrained air flow, as shown in FIG. 6 . As such, the secondary header flow coupled to that exit port will not be supplied product and the row units fed from that secondary header will not be fed product. However, to prevent clogging of the secondary header, the primary conduit that feeds the secondary header, and the secondary conduits, when the valve is moved to the second position, the exit port is exposed to the plenum of air A which functions to purge the downstream components of any particulate matter. When the valve is in the closed position, air only is fed to the row units associated with the closed main header exit port. Thus, the row units will not deposit product thereby enabling the implement operator to selectively control the application of particulate matter onto the seeding surface. This sectional control is believed to be particularly advantageous in avoiding the reapplication of particulate matter to a previously seeded or fertilized area. In another embodiment, the valve arrangement includes tandem pairs of butterfly valves. Other valve types could also be used.
[0029] It will be appreciated that the main header described herein may take a form different from that shown and described and thus the present invention is not limited to the specific main header design shown in the figures. Additionally, while the plenum has been described as being mounted beneath the main header, it is understood that other mounting arrangements could be used. It is also understood that other mechanisms could be used to selectively expose outlet ports of the main header to a purging volume of air. Further, it is contemplated that the present invention could be used with one or more of the secondary headers.
[0030] Additionally, in a preferred embodiment, the speed or the displacement of the metering assembly is adjusted when any of the exit ports of the main header is closed to the product/air mixture. Adjusting operation of the metering assembly is preferred so that open ports do not receive excess particulate matter when any of the other ports are closed. It is contemplated that a controller (not shown) could receive feedback with respect to the number of closed exit ports and adjust operation of the metering assembly automatically. For example, if twenty percent of the total number of exit ports of the main header is closed to the air/product mixture, the metering assembly is slowed by twenty percent.
[0031] Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes will become apparent from the appended claims.
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A method and system enables sectional control for an air seeding system of a farm implement by exposing a main header, or selected ports of the main header, to a purging air flow when product flow through the selected ports is stopped. A plenum of air is fluidly coupled to the main header and provides a purging air flow to any exit port of the main header that has been shut off from product flow. Valves are used to selectively flow couple the exit ports of the main header to the product flow and to the purging air flow.
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CLAIM OF PRIORITY
[0001] This application claims priority to U.S. Provisional Application No. 61/868,393, which is entitled “Five-Level Four-Switch DC-AC Converter,” and was filed on Aug. 21, 2013, the entire contents of which are hereby incorporated by reference herein.
TECHNICAL FIELD
[0002] The present description generally relates to electrical power conversion systems including systems that convert direct current (DC) voltages to alternating current (AC) voltages.
BACKGROUND
[0003] Inverter circuits are known to the art for the conversion of a DC voltage to an output AC voltage. Inverters that convert a DC source to an AC voltage with multiple output levels are of interest to a wide range of applications, including low-power applications. Existing inverter circuits that are configured to generate multiple output levels often require a large number of switching transistors and other components including, but not limited to, capacitors and transformers to generate an AC voltage from a DC input source. FIG. 5 depicts examples of prior art converters that generate a five-level voltage for a single-phase output. The number of levels per number of switches (nL/nS) for the prior art configurations are given by 5/8 and 5/6. An improved inverter circuit that generates multi-level AC output voltages in an efficient manner would be beneficial to improve quality of the output voltage and efficiency of the inverter circuit.
SUMMARY
[0004] A single-phase DC-AC converter is configured to generate an AC output voltage with five levels at the output converter side. An illustrative embodiment of the converter that is depicted in FIG. 1 includes an optimized relationship between the number of levels per number of switches: nL/nS=5/4. Besides the nL/nS, the converter also includes a reduced number of semiconductor devices while maintaining a high number of levels at the output converter side, only requires one DC source without any need to balance the capacitor voltages, and operates with high efficiency.
[0005] In one embodiment a power converter generates an AC output voltage from a DC voltage. The power converter includes a first switching device with a first terminal electrically connected to a first terminal of a split-wound coupled inductor and with a second terminal configured to be connected to a direct current (DC) voltage source, a second switching device with a first terminal electrically connected to a second terminal of the split-wound coupled inductor and with a second terminal configured to be connected to the direct current (DC) voltage source, a third switching device with a first terminal electrically connected to the second terminal of the first switching device and with a second terminal configured to be connected to a load, a fourth switching device with a first terminal electrically connected to the second terminal of the second switching device and with a second terminal configured to be connected to the load, and a controller operatively connected to the first switching device, second switching device, third switching device, and fourth switching device. The controller is configured to operate the first switching device, second switching device, third switching device, and fourth switching device to generate an alternating current (AC) output voltage that is supplied to the load through the second terminals of the third switching device and the fourth switching device and through a third terminal of the split-wound coupled inductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic diagram of a converter circuit that generates an AC output voltage with five levels using four switching elements.
[0007] FIG. 2 is a set of schematic diagrams that depict a portion of the circuit of FIG. 1 in different operating modes.
[0008] FIG. 3 is a schematic diagram depicting pulse with modulation (PWM) controls for operating switching elements in the circuit of FIG. 1 and FIG. 2 .
[0009] FIG. 4 is a set of graphs depicting simulated and measured results for DC to AC inversion using the circuit of FIG. 1 and FIG. 2 .
[0010] FIG. 5 is a set of schematic diagrams for prior art inverter circuits.
DETAILED DESCRIPTION
[0011] For a general understanding of the environment for the system and method disclosed herein as well as the details for the system and method, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements.
[0012] Referring to FIG. 1 , a converter circuit 100 includes four switching power devices (S 1a , S 2a , S 1b , and S 2b ), two diodes (D 1 and D 2 ) and one split-wound coupled inductor (L 1 ). The switching device S 1a has a first terminal that is connected to a first terminal a 1 in the split-wound coupled inductor L 1 and a second terminal connected to a DC voltage source V dc . The switching device S 2a has a first terminal that is connected to a second terminal a 2 in the split-wound coupled inductor L 1 and a second terminal connected to the DC voltage source V dc . The third switching device S 1b has a first terminal that is connected to the second terminal of the first switching device S 1a and a second terminal that is connected to a load V l . The fourth switching device S 2b has a first terminal that is connected to the second terminal of the second switching device S 2a and a second terminal that is connected to the load υ l . The split-wound coupled inductor L i has a third terminal a that is between the windings connected to the terminals a1 and a2. The third terminal a is connected to the load υ l . The diode D 1 includes a cathode that is connected to the first terminal of the first switching device S 1a and an anode that is connected to the DC voltage source V dc . The diode D 2 includes an anode that is connected to the first terminal of the second switching device S 2a and a cathode that is connected to the DC voltage source V dc .
[0013] In one embodiment the switching power devices S 1a , are controlled power transistors, such as metal oxide field effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs) and bipolar junction transistors (BJTs). In the description below, the state of the switches is represented by a binary variable, where S j =0 means an open switch and S j =1 means a closed switch (with j=1a, 2a, 1b and 2b). As described in more detail below, the switching devices S 1a , S 2a , S 1b , and S 2b are closed and opened using pulse width modulation (PWM) control signals to enable the circuit 100 to generate an AC output voltage from the DC voltage that is supplied by the DC source V dc . FIG. 1 depicts a PWM controller 150 that is operatively connected to the switching devices S 1a , S 2a , S 1b , and S 2b . In an embodiment where the switching devices S 1a , S 2a , S 1b , and S 2b are transistors, the PWM controller 150 generates signals that control the base or gate of the transistors to switch the transistors on and off.
[0014] FIG. 2 depicts different configurations of the switching devices S 1a and S 2a from the circuit 100 of FIG. 1 . The circuit configuration 204 depicts a continuous conduction mode through the coupled-windings L 1 . The circuit configuration 208 depicts a configuration where the switching devices S 1a and S 2a are both open (0-0). The circuit configuration 212 depicts a configuration where the switching device S 1a is open and the switching device and S 2a is closed (0-1). The circuit configuration 216 depicts a configuration where the switching device S 1a is closed and the switching device and S 2a is open (1-0). The circuit configuration 220 depicts a configuration where the switching devices S 1a and S 2a are both closed (1-1).
[0015] In the circuit configurations of FIG. 1 and FIG. 2 , the voltages υ a10 and υ a20 (voltages from the nodes a1 and a2 to zero) can be expressed as a function of the state of the switching devices with the following equations:
[0000] υ a10 =S 1a V dc
[0000] υ a20 =(1 −S 2a ) V dc
[0000] Similarly, the voltage υ b0 is the voltage from node b to zero and is expressed with the following equation: υ b0 =S 1b V dc , where S 1b =1−S 2b , where the switches S 1b and S 2b are operate in a complementary configuration to avoid a short circuit of the DC source.
[0016] In the circuit 100 , the voltage υ a0 is provided by the following equation:
[0000]
v
a
0
=
1
2
(
v
a
10
+
v
a
20
)
[0017] The load voltage υ l , which is the AC output voltage that is delivered to a load, is determined using υ a0 and υ b0 using the following equation:
[0000] υ l =υ a0 −υ b0 .
[0018] Table 1 lists different voltages of the converter circuit when the switching devices are in different states. The AC voltage that is generated at the converter output has five different levels (V dc , V dc /2, 0, −V dc /2, −V dc ).
[0000]
TABLE 1
Load Voltage as a Function of Switching State
S 1a
S 2a
S 1b
S 2b
v a10
v a20
v a0
v b0
v ind
v l
0
0
0
1
0
V dc
V dc /2
0
−V dc
V dc /2
0
0
1
0
0
V dc
V dc /2
V dc
−V dc
−V dc /2
0
1
0
1
0
0
0
0
0
0
0
1
1
0
0
0
0
V dc
0
−V dc
1
0
0
1
V dc
V dc
V dc
0
0
V dc
1
0
1
0
V dc
V dc
V dc
V dc
0
0
1
1
0
1
V dc
0
V dc /2
0
V dc
V dc /2
1
1
1
0
V dc
0
V dc /2
V dc
V dc
−V dc /2
[0019] In the circuit 100 , the split-wound coupled inductor L 1 is operated in a continuous conduction mode. The voltage level υ ind in the split-wound coupled inductor L 1 is provided by the following equation:
[0000] υ ind =υ a10 −V a20 .
[0020] As depicted in Table 1, the modulation parameters for operating the switching device S 1b are defined with the following rules: (i) S 1b =1 if υ l *<0 and S 1b =0 if υ l *≧0. The leg b in the circuit 100 operates at the frequency of the output AC load (e.g. 50 Hz or 60 Hz for many electrical grids), and the comparatively low frequency of the switching leg b reduces the switching losses in the circuit 100 .
[0021] During operation of the circuit 100 , the signals that control the operation of the switching devices S 1a , S 2a , S 1b , and S 2b produce an average load voltage υ l * and average inductor voltage υ ind * are characterized by the following instantaneous time equations:
[0000]
v
l
*
=
S
1
a
V
dc
2
+
(
1
-
S
2
a
)
V
dc
2
-
S
1
b
V
dc
v
ind
*
=
S
1
a
V
dc
-
(
1
-
S
2
a
)
V
dc
[0022] The previous equations are instantaneous time equations that describe the states of the switching devices S 1a and S 2a at single point in time. To control the circuit over time, a controller operates the switching devices using a pulse width modulation (PWM) control scheme in which each of the switching devices S 1a , S 1b , S 2a , S 2b are switched between closed and opened states with duty cycles of d 1a , d 2a , d 1b , and d 2b , respectively. As described above, the PWM cycles for the transistors S 1b and S 2b are complementary where S 1b is closed whenever S 2b is opened, and vice-versa. The duty cycles for each of the switching devices are described in the following equations:
[0000]
d
1
a
=
1
T
s
∫
t
t
+
T
s
S
1
a
(
t
)
t
d
2
a
=
1
T
s
∫
t
t
+
T
s
S
2
a
(
t
)
t
d
1
b
=
1
T
s
∫
t
t
+
T
s
S
1
b
(
t
)
t
d
2
b
=
1
T
s
∫
t
t
+
T
s
S
2
b
(
t
)
t
=
1
-
d
1
b
[0000] The following equations describe the average load voltage υ l * and average inductance voltage υ ind * in conjunction with the duty cycles:
[0000]
2
v
l
*
V
dc
=
d
1
a
+
1
-
d
2
a
-
2
d
1
b
v
ind
*
V
dc
=
d
1
a
+
d
2
a
-
1
[0000] The terms d 1a and d 2a from the preceding equations are expressed in the following equations:
[0000]
d
1
a
=
v
ind
*
+
2
v
l
*
2
V
dc
+
S
1
b
d
2
a
=
v
ind
*
+
2
v
l
*
2
V
dc
+
(
1
-
S
1
b
)
[0023] In the circuit 100 , the controller 150 is operatively connected to the power switching devices S 1a , S 2a , S 1b , and S 2b to switch the devices on (closed switch) and off (opened switch) into the states that are depicted in Table 1. In one embodiment, the controller 150 generates the PWM signals that control the base or gate of the power transistors S 1a , S 2a , S 1b , and S 2b to switch the transistors on and off FIG. 3 depicts schematic diagrams 304 and 308 of circuits that are implemented in the controller 150 to generate the PWM control signals. The control circuits 304 and 308 generate PWM control signals with duty cycles that correspond to the equations listed above for d 1a , d 2a , d 1b , and d 2b . The controller 150 implements the functionality that is depicted in the schematic circuits 304 and 308 using, for example, discrete analog and digital circuit components, or as stored program instructions that are executed by a microcontroller or other appropriate digital processor.
[0024] FIG. 4 depicts a graph 402 of simulated results including a simulated AC output voltage waveform 404 and output current waveform 408 . The graph 420 depicts measured output waveforms from an embodiment of the circuit 100 including a measured AC output voltage waveform 424 and measured AC output waveform 428 . The measured AC output waveform 428 is formed in a sinusoidal AC output waveform at the predetermined AC output voltage frequency with the five discrete output voltage levels that are described above in Table 1. In the illustrative example of FIG. 4 , the DC voltage level is 400V, and the measured AC output voltage swings between +400V and −400V with the sinusoidal output waveform at the predetermined AC waveform frequency. As depicted in FIG. 4 , the output voltage of the AC voltage has five voltage levels from the positive peak voltage amplitude to the negative peak voltage amplitude.
[0025] While the embodiments have been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. The reader should understand that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the scope of the claims presented below are desired to be protected.
|
A single-phase DC-AC converter generates an AC voltage with five levels at the output converter side by using four controlled power switches. The converter has a relationship between the number of levels per number of switches (nL/nS) of five to four. The converter reduces the number of semiconductor devices required to generate a high number of levels at the output converter side, requires only one DC source to generate an AC output, and operates with high efficiency.
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BACKGROUND OF THE INVENTION
[0001] A common indoor problem is undesired insects, such as Asian lady bugs, houseflies, flies, fruit flies, gnats, stink bugs, and the like. Undesired insects may cause contamination of food, allergic reactions in humans, and general annoyance. Many procedures and devices have been produced to capture or remove such undesired insects from within households, store, restaurants, and other indoor areas. However, insects that are caught in such traps (e.g. adhesives that are hung from ceilings to capture a passing insect) are in full view, which may be undesirable.
[0002] It is known in the art that many insects, including domestic pests such as house flies, are attracted to light sources. In the case of house flies, the insects often end up congregating at the strongest light source, i.e. exterior-facing windows. Prior inventions have attempted to capitalize on this fact, such as adhesive devices that are placed on windows. However, insects caught on such adhesives are in full view, which may be aesthetically unpleasant and undesirable. Some insects traps have been designed to have a box or decorative element that surrounds the insect trapping means to keep captured insects out of view, but this box or decorative element also decreases the amount of light surrounding the insect trapping means, potentially decreasing the attraction of the insect towards the insect trapping area and decreasing the effectiveness of the trap. Some other insect traps have been designed to include a light source which attracts insects towards an insect trap, but this increases the size, cost, and complexity of the insect trap.
[0003] The prior art teaches the use of at least two orthogonally-rotated polarizing filters to control the passage of light through both windows and thus obscure the view of objects located behind both filters. There is no prior art that teaches using polarized light to capture houseflies. It was discovered by the inventor that an object, such as the body of a housefly, which is located between two parallel, orthogonally-rotated, plane-polarizing light filters is substantially obscured from external view, a novel effect not taught or suggested by the prior art. Further experimentation demonstrated that a trap which is substantially transparent from an insect's plane-on point of view but which is opaque to a human's face-on point of view is superior to a trap which is opaque to both human and insect, which was an unexpected benefit from the method.
[0004] It is now apparent that the prior art lacks an insect trap that effectively utilizes ambient light to attract insects while substantially hiding captured insects from public view. This invention provides such an insect trap.
BRIEF SUMMARY OF THE INVENTION
[0005] One object of the present invention is to provide a device and method for trapping flies that overcomes problems not addressed by the prior art. Another object of the invention is to provide an insect trap that is inexpensive and easy to manufacture, is compact for efficient storage and shipping, is simple to use, utilizes ambient light as an attractant, and which can be disposed of once full without exposing the user to the insect capturing means or captured insects.
[0006] The invention described herein is a trap containing at least two parallel, planar, transparent faces, each face configured to polarize transmitted light into a single plane. The faces are oriented such that the light polarization planes are at right angles. When the trap is attached substantially flush to a window, positively phototactic insects upon the window perceive the trap faces as transparent and are thus induced to crawl in to the trap. However, light is prevented from passing through both faces, substantially obscuring the view of trapped insects inside to a casual human observer.
[0007] In the instant invention, the word “insect” is defined as it is used in the US Patent and Trademark Class Definition for Class 43 Subclass 107, that is, it is used to mean “not only true insects all of which are Hexapods, or six-legged, but creatures, often confounded with insects, belonging to the classes known as ‘Arachnida’ and ‘Myriapoda’, examples of the former class being scorpions, spiders, and mites and of the latter being centipedes and millipedes.”
[0008] In the instant invention, the word “window” is broadly defined as a substantially transparent portion of a continuous face, which may encompass a portion up to 100% of said face. This definition includes the common definition of “window” that refers to a transparent structural feature within an otherwise opaque wall of a building or vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 depicts the propagation of light as it passes sequentially through two plane-polarizing windows which polarize light at 90° to each other.
[0010] FIG. 2 depicts one embodiment of the insect trap of the invention, with internal spacing elements and a plurality of openings.
[0011] FIG. 3 depicts a second embodiment of the insect trap, with marginal spacing elements and a single opening, in folded configuration.
[0012] FIG. 4 depicts the second embodiment of the insect trap of the invention, in an unfolded configuration.
[0013] FIG. 5 depicts a third embodiment of the insect trap, with marginal spacing elements and a plurality of openings.
[0014] FIG. 6 depicts a cylindrical embodiment of the insect trap.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The preferred embodiment of the invention as shown in the accompanying drawings will now be described in detail. The following description of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.
[0016] It is well known how to polarize light such that it propagates in a single plane. FIG. 1 depicts the path of light waves as they pass through two opposing, orthogonally oriented polarizing filters. The light waves are depicted in a Cartesian coordinate system with an X-axis, Y-axis, and Z-axis. Waves of non-polarized light 2 incident on a first polarizing layer 4 , which is configured to polarize light in a single plane (as depicted by parallel shading lines 6 ), are filtered such that only light waves propagating in an X-Z plane 8 are transmitted. A second polarizing layer 10 , which is configured to polarize light in a single plane (as depicted by parallel shading lines 12 ), has been oriented 90 degrees offset to the first layer 4 . When the X-Z polarized light waves 8 encounter the second polarizing layer 10 , none of the X-Z polarized light waves 8 are permitted through, resulting in a substantially darkened region 16 where the two polarizing layers 4 , 10 overlap. Conversely, waves of non-polarized light 2 incident on the second polarizing layer 10 are polarized into an X-Y plane 14 and are unable to pass through the first, X-Z polarizing layer 4 resulting in a substantially darkened region 16 . In this and subsequent drawings, parallel shading lines on a face are used to represent the polarization angle of transmitted light waves.
[0017] As shown in FIG. 2 , one preferred embodiment of the insect trap includes a first light polarizing layer 4 configured to polarize light in a first specific plane 6 , and a second light polarizing layer 10 configured to polarize light in a second specific plane 12 , the second plane 12 being at substantially right angles to the first plane 6 , resulting in a substantially obscured region 16 where the two faces overlap. The insect trap further includes a plurality of openings 20 , created by an internal spacing element 22 that ensures that the two polarizing layers 4 , 10 remain separated. The plurality of openings 20 allow insects to approaching the trap from multiple directions to enter and become ensnared by the insect trapping means 24 . The insect trapping means 24 preferably traps common household insects including but not limited to Asian lady bugs, box elder bugs, brown marmorated stink bugs, cluster flies, cone bugs, filth flies, fruit flies, fungus gnats, house flies, June beetles, moths, yellow jackets, and wasps. The insect-trapping means 24 is preferably a pressure-sensitive adhesive that functions to trap insects as they pass within close proximity or land on the adhesive. The insect trapping means 24 may alternately include protrusions that snag onto a crawling, flying, or otherwise passing insect. The insect trapping means 24 is preferably translucent and/or transparent to allow light to come in through the wall that it is coupled to. The insect trapping means 24 may also include a colorant that tints the light passing through the adhesive to a more attractive color, or may also include an ultraviolet pigment, which may be more attractive to insects, thus luring the insect towards the insect trapping material 24 . A securing means 26 , in this embodiment a removable, pressure-sensitive adhesive, is employed to secure the insect trap to a substrate such as a window. The securing means 26 is preferably an adhesive that allows the container to sit flush against the substrate. Alternatively, the securing means 26 could be a hook, for example an “S” hook that hooks onto both the insect trap and a substrate such as a windowsill. The securing means 26 is preferably non-permanent, allowing relatively easy removal or replacement of the insect trap, for example when the user wishes to replace a used trap with a new trap. However, the securing means 26 may be of any other suitable type.
[0018] An alternate preferred embodiment of the insect trap is shown in FIG. 3 . A first polarizing layer 4 , configured to polarize light in a specific plane 6 and a second polarizing layer 10 configured to polarize light in a second specific plane 12 are oriented such that the two planes of light 6 , 10 are at substantially right angles, resulting in a significantly obscured region 16 where the two polarizing layers 4 , 10 overlap. The insect trap further includes a single opening 20 or space between the two layers whereby insects may enter the trap and become ensnared by the insect trapping means 24 . In this embodiment, the insect trapping means 24 is a pressure-sensitive adhesive, coupled to the inside face of the polarizing layers 4 , 10 . The spacing element 22 is marginal to the two polarizing layers 4 , 10 , resulting in a single opening 20 . A securing means 26 by which the insect trap may be secured to a substrate is also illustrated.
[0019] FIG. 4 depicts an unfolded configuration of the insect trap pictured in FIG. 3 which is constructed out of a single sheet of polarizing material. The sheet is preferably a material that is foldable but maintains a certain level of stiffness to maintain the shape of the container in the folded mode, for example, a thin sheet of polypropylene containing a polarizing means. The insect trap is cut out from a single sheet of polarizing material and scored along fold lines 40 as shown. An insect trapping means 24 such as an adhesive is applied to one side and is covered by a release paper 42 for ease of storage, transport, and handling. Once an individual (for example, a store merchant or the end user) decides to use the insect trap, the release paper 42 is removed. The sheet is then folded along the score lines 40 to form the insect trap as pictured in FIG. 3 . The center of the original sheet becomes a first polarizing layer 4 which polarizes incident light in one plane 6 , while the two distal segments join to form a second polarizing layer 10 , subsequently polarizing incident light at a second plane 12 rotated 90° from the first plane 6 . The two regions between the center segment and the distal segments are used as the spacing element 22 in this embodiment. The larger of the distal segments 44 may overlap the opposing distal segment in such a way that the insect trapping means 24 is also used to hold the segments together to form a continuous layer 10 . Alternately, the sheet may include overlapping portions that are tabs which are inserted into slits to maintain the sheet in the folded mode. However, any other means or method may be used to maintain the sheet in the folded mode.
[0020] Another embodiment of the insect trap is shown in FIG. 5 . The first polarizing layer 4 , configured to polarize light in a first plane 6 is coupled to a frame 50 . The second polarizing layer 10 , which is configured to polarize light in a second plane 12 is also coupled to a frame 50 . The two polarizing layers 4 , 10 are held parallel by the spacing elements 22 in order to create a significantly obscured region 16 where the two layers 4 , 10 overlap. In this embodiment, the spacing elements 22 are marginal, creating multiple openings 20 . Optionally, at least one spacing element 20 , depicted on the bottom in this figure, may extend the entire length of one side of the polarizing layers 4 , 10 , to allow for single-sheet assembly of the frames 50 and spacing elements 22 . In one configuration, the interior surface of the polarizing layers 4 , 10 are secured to exterior of the frames 50 by an adhesive which also serves as an insect trapping means. However, any appropriate means of assembly may be used. In another configuration, the exterior surface of the polarizing layers 4 , 10 may be secured to the interior of the frames by any appropriate means, such as a hot melt adhesive. The insect trapping means would then be coated on the internal faces of the polarizing layers 4 , 10 separately. The insect trap of this embodiment may be secured to a window by any appropriate means.
[0021] A fourth embodiment of the insect trap is shown in FIG. 6 . In this embodiment, the first polarizing layer 4 , configured to polarize light in a first plane 6 is formed in an open cylindrical shape. A second, flat polarizing layer 10 , configured to polarize light in a second plane 12 , can be inserted inside the cylindrical first polarizing layer 4 such that a substantially obscured region 16 is produced when it is viewed at an angle roughly perpendicular to the plane of the second polarizing layer 10 . The second polarizing angle may be wide enough to fully bisect the openings 20 of the cylindrical first layer 110 , but that is not necessary. An insect trapping means 24 such as a pressure sensitive adhesive may be applied on one or both sides of the flat second layer 10 , as depicted. Optionally, the insect trapping means 24 may additionally be applied to the internal surface of the cylindrical first layer 4 . A trap of this embodiment may additionally consist of a hanging element or a stand, which would allow it to be secured somewhere other than in a window, such as hanging from a ceiling tile, joist, or beam, or standing on a table or shelf.
[0022] It should be clear to one of average skill in the art that minor variations or additions to the preferred embodiment fall within the scope of the invention as presented. For example, the insect trap may include more than one pair of opposing polarizing filters. The opposing polarizing layers 4 , 10 , which are configured to polarize light in a specific plane, may be formed entirely from a polarizing material or may be formed from a polarizing material layered on the exterior of another, optically neutral, substantially transparent material including but not limited to glass, polycarbonate, polypropylene, polyethylene, or other suitable polymeric materials. An example of such a polarizing material is produced by Sanritz Corporation of Japan, where 99.9% of light that passes through a first polarizing layer and then to a second polarizing layer oriented at a 90 degree offset from the first polarizing layer is blocked. However, any other suitable type of polarizing material may be used. The insect trap may be composed of a flexible material, alternately it may be composed of a rigid material that is formed in the shaped of the container, for example, a molded plastic or formed glass. However, the insect trap may be formed using any other suitable material or means. In another variation, the insect trapping means 24 may be incorporated into a separate removable element to allow for reuse of the insect trap body. The insect trapping means 24 may be something besides an adhesive; for example, the insect trap of FIG. 3 could be rotated 45° clockwise from the portrayed position and filled with a liquid trapping medium such as soapy water. Or the insect trapping means 24 may be simply the shape of the entrance holes 20 ; Donahue (U.S. Pat. No. 5,392,560) for example, teaches using conical entrance holes to prevent insect exit from the trapping region of an insect trap. Another possible variation is to add color or patterns to the insect trapping means in order to more narrowly target attractiveness to a single species of insect. The insect trapping means 24 may also include a lure material, for example a pheromone that attracts insects, to further lure insects or alternately to lure only specific insects into the insect trap.
[0023] Without limiting the scope of the invention as outlined in the claims, this section illustrates the primary features of the best mode of the invention for better understanding by the reader and to enable anyone skilled in the art to make and use this invention. However it will be readily apparent to anyone skilled in the art that omissions, modifications, substitutions, and changes in the form or details of the device, its appearance, or its operation may be made without departing from the spirit and scope of the invention. This section has provided examples of variant embodiments which may be employed that fall within the spirit and scope of the claims. Accordingly, the invention should not be limited by the details herein illustrated.
EXAMPLE I
[0024] Prototypes of the embodiment depicted in FIG. 3 were compared to a commercially available trap of similar shape (Fly Motel® Window Trap, Black Flag Brands LLC, New York Mills, N.Y.; also described in Acevedo U.S. Pat. No. 5,649,385) in a replicated cage bioassay. Two traps of each type were placed in a 25 cm wide×25 cm high×75 cm long acrylic box with a screen on one end. All traps were secured in a bottom corner of a long wall, with the trap opening facing towards the center of the box. Similar traps were placed in opposing corners to minimize possible positional effects due to minor variations in external light. Two replicate cages were set up. Approximately 75 flies (Musca domestica, Rincon-Vitova Insectaries, Ventura, Calif.), 1-2 days old and mixed sexes, were released into each cage every day for three days. Traps were not rotated between positions. A single count of flies captured in each trap was performed 24 hours after the final release. Approximately 5% of flies were not captured by any trap. The results are given in Table I.
[0000]
TABLE I
MEAN TOTAL
FLY COUNT
TRAP
Average
SD
FIG. 3 embodiment
82.0
28.1
Trap of Acevedo
8.5
4.1
[0025] The nearly 10-fold increase in average fly catches clearly demonstrates the superior performance provided by the present invention. However, there was concern that a lack of rotation emphasized unforeseen positional effects, so the test was repeated with rotation of trap positions between repetitions.
EXAMPLE II
[0026] Prototypes of the embodiment depicted in FIG. 2 were compared to a commercially available trap of similar shape (Fly Motel® Window Trap, Black Flag Brands LLC, New York Mills, N.Y.; also known as the trap of Acevedo, U.S. Pat. No. 5,649,385) in a replicated cage bioassay. Two traps of each type were placed in a 25 cm wide×25 cm high×75 cm long acrylic box with a screen on one end. All traps were secured in a bottom corner of a long wall. Similar traps were placed in opposing corners to minimize possible positional effects due to minor variations in external light. Two replicate cages were set up. Approximately 40 flies (Musca domestica, Rincon-Vitova Insectaries, Ventura, Calif.), 1-2 days old and mixed sexes, were released into each cage every day for four days. The number of flies caught in each trap was counted daily before releasing the next set. Traps were rotated between positions daily to compensate for the positional effects observed previously. Approximately 12% of flies were not captured by any trap. The results are given in Table II.
[0000]
TABLE II
FLIES
PER DAY
PER TRAP
TRAP
Average
SD
FIG. 2 embodiment
12.4
12.4
Trap of Acevedo
5.8
5.4
Uncaught
4.8
5.9
[0027] The superior performance provided by the present invention is reinforced by the two-fold increase in average fly catches. High variance in the average fly counts of both traps was due to an uneven number of flies released across days, not due to variable performance. Even with high variance, the difference in average trap catches was statistically significant (p=0.048).
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An insect trap for multiple species of pest insects, especially flying insects that are an indoor nuisance. The trap contains at least two parallel, planar, transparent faces, each face configured to polarize transmitted light into a single plane. The faces are oriented such that the light polarization planes are at substantially right angles. When the trap is attached substantially flush to a window, phototactic insects against the window perceive the trap faces as transparent and are thus induced to crawl in to the trap. However, light is prevented from passing through both faces, substantially obscuring the view of trapped insects inside to a casual human observer.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/440,560, filed May 16, 2003, which is a continuation application of U.S. patent application Ser. No. 09/943,805, filed Aug. 30, 2001, now U.S. Pat. No. 6,591,123, which claims the benefit of U.S. Provisional Application Ser. No. 60/299,616, filed Aug. 31, 2000, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to oximetry sensors and, in particular, pulse oximetry sensors which include coded information relating to characteristics of the sensor.
[0003] Pulse oximetry is typically used to measure various blood flow characteristics including, but not limited to, the blood-oxygen saturation of hemoglobin in arterial blood, the volume of individual blood pulsations supplying the tissue, and the rate of blood pulsations corresponding to each heartbeat of a patient. Measurement of these characteristics has been accomplished by use of a non-invasive sensor which passes light through a portion of the patient's tissue where blood perfuses the tissue, and photoelectrically senses the absorption of light in such tissue. The amount of light absorbed is then used to calculate the amount of blood constituent being measured.
[0004] The light passed through the tissue is selected to be of one or more wavelengths that are absorbed by the blood in an amount representative of the amount of the blood constituent present in the blood. The amount of transmitted light passed through the tissue will vary in accordance with the changing amount of blood constituent in the tissue and the related light absorption. For measuring blood oxygen level, such sensors have been provided with light sources and photodetectors that are adapted to operate at two different wavelengths, in accordance with known techniques for measuring blood oxygen saturation.
[0005] Nellcor U.S. Pat. No. 5,645,059, the disclosure of which is hereby incorporated herein by reference, teaches coding information in sensor memory used to provide pulse modulated signal, to indicate the type of sensor (finger, nose), the wavelength of a second LED, the number of LEDs, the numerical correction terms to the standard curves, and an identifier of the manufacturer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a block diagram of a pulse oximeter system in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The present techniques provide a memory chip for use in an oximeter sensor, or an associated adapter or connector circuit. The memory chip allows the storing of different data to provide enhanced capabilities for the oximeter sensor. In addition to providing unique data to store in such a memory, the techniques include unique uses of data stored in such a memory. The data stored in the memory chip includes information relating to use of the oximeter sensor. For example, the memory chip may encode a sensor model identification that can be displayed on a display screen when the sensor is connected to an oximeter monitor. The memory may also encode a range of operating parameters such as light levels over which the sensor can function or a maximum drive current. The operating parameters are read by a controller circuit which uses the data read from the memory chip to control the functioning of the pulse oximetry system.
Part I
[0008] FIG. 1 is a block diagram of a pulse oximeter system incorporating a calibration memory element 56 according to the invention. In one embodiment, memory element 56 is a two-lead semiconductor digital memory chip. The calibration element is part of the sensor 50 which also includes red and infrared LEDs 52 as in the prior art, along with a detector 54 . If desired, LEDs 52 may be replaced with other light emitting elements such as lasers.
[0009] The oximeter includes read circuit 60 , drive circuit 66 , look-up tables 62 and 63 , controller 64 , amplifier 72 , filter 74 , and analog-to-digital converter 76 . Read circuit 60 is provided for reading multiple coded values across the two leads 51 , 53 connected to calibration element 56 . One value is provided to a look-up table 62 to determine appropriate wavelength dependent coefficients for the oxygen saturation calculation, as in the prior art. The other value(s) are then provided to another look up table(s) 63 which provides input (e.g., coefficients) to other calculations performed by controller 64 . These additional calculations may enhance the performance and/or safety of the system. Controller 64 provides signals to a drive circuit 66 , to control the amount of drive current provided to LEDs 52 .
[0010] As in the prior art, detector 54 is connected through an amplifier 72 and a filter 74 to an A/D converter 76 . This forms a feedback path used by controller 64 to adjust the drive current to optimize the intensity range of the signal received. For proper operation the signal must be within the analog range of the circuits employed. The signal should also be well within the range of A/D converter 76 (e.g., one rule that may be applied is to adjust LED drives and amplifier gains so that both red and IR signals fall between 40% and 80% of full scale reading of converter 76 ). This utilizes correct and independent settings for both the red and infrared LEDs. The current techniques allow for another feedback path which may alter the LED settings based on other sensor characteristics contained in the coding of the calibration element 56 , which is discussed in further detail below.
[0011] Memory 56 may, for example, be implemented as a random access memory (RAM), a FLASH memory, a programmable read only memory (PROM), an electrically erasable PROM, a similar programmable and/or erasable memory, any kind of erasable memory, a write once memory, or other memory technologies capable of write operations. Various types of data useful to a pulse oximetry system can be stored in memory 56 . For example, data indicating a sensor model identification code corresponding to a particular sensor model can be encoded in memory 56 . Also, an action can be encoded into memory element 56 indicating an action to be performing by the oximeter monitor in response to reading the sensor model identification code.
[0012] For example, an identification code in the form of text indicating the specific model of sensor can be digitally encoded into memory 56 and read by the oximeter monitor when the sensor is connected to the oximeter. An action indicating that the sensor model text is to be displayed by the oximeter monitor on a display screen can also be encoded in memory 56 . The identification code can be displayed in human readable form on a display screen connected to the pulse oximeter monitor. The identification code allows the oximeter instrument to display a text string indicating what sensor model is being used, e.g. “Nellcor OXISENSOR I1 D-25,” “Adult Digit Sensor,” or “Agilent N-25.”
[0013] Alternately, display text for a plurality of specific models of pulse oximeter sensors can be stored in a lookup table coupled in parallel with lookup tables 62 and 63 in the pulse oximeter monitor. The pulse oximeter monitor reads a sensor code from memory 56 when the sensor 50 is connected to the oximeter. The sensor identification code stored in memory 56 is used to locate display text stored in a lookup table that corresponds to a specific sensor model. The oximeter can display the display text for the specific sensor model on a display screen for viewing.
[0014] The present techniques may eliminate the printing of a model name and number on the sensor itself. Even when model names and numbers are printed on a sensor, the text may become illegible after several uses. Displaying text that corresponds to a specific sensor model can be highly useful for users of pulse oximetry sensors. For example, it may be important to identify a sensor model so that instructions relating to a particular sensor model in the manufacturer's handbook can be identified. In addition, it may be desirable to identify a sensor model name or identification number when corresponding with the manufacturer.
[0015] Digitally encoded data indicating a sensor model type in memory 56 or in a lookup table may be used to determine whether a sensor model is compatible with a particular pulse oximeter monitor. For example, memory 56 may contain a code indicating a sensor model type that is read by controller 64 . Memory 56 can also encode an action indicating that controller 64 is to compare the code from memory 56 with a list of codes in a lookup table (or other oximeter monitor memory device) to determine if the sensor is compatible. If controller 64 successfully matches the code read from the sensor, the display text indicating the sensor model type is displayed on the display screen. If controller 64 does not recognize the code, an error message may be displayed on the display screen indicating that the oximeter monitor does not recognize the sensor, and the oximeter may refuse to operate until the sensor is replaced.
[0016] A code can be stored in the sensor memory 56 identifying the sensor manufacturer. An action indicating a use for the code by the oximeter can also be stored in memory 56 . The code is read by controller 64 and is used for the purpose indicated by the action. The action may, for example, indicate that the code in memory 56 is to be used to indicate operability with oximeter monitors of other manufacturers. Controller 64 can recognize certain codes as indicating compatible oximeter sensors. If the oximeter monitor does not recognize the code, then controller 64 can display an error message on a display screen indicating that the sensor is not compatible, and/or controller 64 can shut down circuitry in the oximeter monitor that senses signals from the sensor until the sensor is replaced with a compatible sensor.
[0017] Other information may also be encoded into memory 56 , read by the 17 monitor, and displayed for user reference. For example, language codes or country codes can be stored in memory 56 , read, and displayed to the user. The user can select a language or country code so that messages are displayed, such as error messages, in the selected language or a language corresponding to the selected country. Messages may also be encoded into memory 56 . For example, safety messages relating to the proper use of the sensor can be encoded in memory 56 and displayed on a display screen in human readable form.
[0018] It is often desirable to upgrade the algorithms that are used by the oximeter to determine blood oxygen saturation levels, pulse rates, pulse amplitude, blood pressure, and other patient data as technology progresses and the operating parameters (such as filter coefficients) are refined. Because oximeter sensors are typically much less expensive to replace than oximeter monitor instruments, it is desirable to encode data corresponding to the updated algorithms in the sensors rather than in the oximeter monitors.
[0019] One method for performing these updates is by encoding revisions to the algorithms used for calculating the patient parameters in memory within the oximeter monitor, while encoding updated software code or tuning coefficients in sensor memory 56 . The updated code or coefficients correspond to updated algorithms that are read by the oximeter monitor so that the updated algorithms can be applied to the standard algorithms preprogrammed into the oximeter. For example, a line of software code in an algorithm used by the oximeter monitor can be replaced by a updated line of code stored in memory 56 .
[0020] Controller 64 can read the updated code or coefficients from memory 56 and apply the updated algorithms to signals received from detector 54 to determine accurate blood oxygen saturation levels, pulse rates, pulse amplitudes, perfusion data, blood pressure, and other patient data. The updated algorithms can also be used to allow only supported features to be used. In one embodiment, once updated, the new code or coefficients become permanently stored in the oximeter monitor, along with a new algorithm revision number, and are utilized for all future sensor use until later updated.
[0021] Encoding a sensor model identification code could also be used to accommodate sensor-specific operating parameters such as LED drive currents or “sensor off” characteristics (as an alternative to programming the value of drive current or “off” characteristics themselves). Under normal operating conditions, photosignals coming from the sensor LEDs generally fall within a certain range. When a sensor is removed from a patient, or falls off on it's own, the photosignal usually changes. This is particularly true for the reusable clip-style sensor, because in their normal disconnected state, the LEDs shine directly onto the photodetector unimpeded by, for example, tissue. By programming a “threshold photocurrent” into memory chip 56 , reliable detection of a “sensor is off the patient” condition can be accomplished. In this example, exceeding a certain detected threshold light level is an indication that the sensor is not on a finger or other site.
[0022] For certain other sensors, a low light level may be indicative of the sensor being off. An adhesive sensor, for example, lays flat when in it's natural state—little LED light may reach the detector. Encoding an expected range of light levels for the specific model of sensor being used into memory 56 allows enhanced detection of when the sensor is improperly placed or has been removed. When controller 64 senses that the light level output detected by photodetector 54 has fallen below or exceeded the expected range of light levels encoded into memory 56 , the oximeter monitor can display an “sensor off” message on a display screen indicating to the medical personnel that the sensor is not in an operable position and that valid data cannot be detected (i.e., a sensor off condition). The oximeter monitor can also emit an alarm signal until the light level detected by photodetector 54 reaches the expected range.
[0023] If desired, expected ranges of light levels (or other parameters such as pulse size) that are specific to a particular patient may be encoded and saved into memory 56 by the clinical through the oximeter. The oximeter compares the expected range for the parameters encoded into memory 56 with data received from the photodetector to determine a sensor off condition each time the sensor is used until the range data is overwritten with new data. This is advantageous because light levels, pulse sizes, and other parameters detected by the photodetector can vary significantly from patient to patient.
[0024] Existing pulse oximeter sensors determine whether a sensor is off the patient, or not in good contact by using a number of metrics. Those metrics include pulse size, pulse variability, IR/Red correlation, light level variability, pulse shape, and pulse regularity. Not only the light level, but any of these other values could vary depending on the type of sensor, the characteristics of an individual patient, and the location on the body where the sensor is to be applied. Thus, sensor memory 56 could encode information about the expected variation in any of these metrics for the particular sensor type or model or a particular patient, and these metrics may be used in determining if a sensor is off from any combination of these or other metrics as an indication that the sensor is off the patient.
[0025] For example, pulses could be typically weaker on the forehead compared to the finger. Memory device 56 of an oximeter sensor designed for use on the forehead of a patient can be encoded with a range of pulse sizes as well as a range of light levels that are expected from that particular oximeter sensor model. If desired, memory 56 can encode a range of numbers based upon light level and pulse size (and other parameters). For example, memory 56 can encode a range of numbers representing the expected range of pulse size times light level received from detector 54 for a specific sensor model.
[0026] Controller 64 reads and decodes the pulse size, light level range, and other data encoded in memory 56 . Controller 64 then compares the expected pulse size and light level range data with the information received from detector 54 . When the pulse size and/or light level data received from detector 54 exceeds or falls below the expected range data encoded in memory 56 , the oximeter monitor displays an output message, e.g., a warning of a poor signal, on the display screen indicating that the sensor is not operable or emits an alarm signal. Further details of a Method and Circuit for Indicating Quality and Accuracy of Physiological Measurements are discussed in U.S. patent application Ser. No. 09/545,170, filed Apr. 6, 2000 to Porges, et al., which is incorporated by reference herein in its entirety.
[0027] Running LEDs 52 at a high drive current results in more light output from the LEDs, thus improving the signal-to-noise ratio of the blood oxygen saturation signal from detector 54 , but comes at a cost of causing additional heat dissipation (i.e., the LEDs run “hotter”). As current flows through the sensor LEDs, the LED emits heat (i.e., the LED power=LED drive current times the voltage drop across the LED). The majority of the energy output by the LEDs is dissipated as heat, and the smaller portion of the energy output by the LEDs is emitted as light. This heat typically causes the temperature of the skin under the sensor to rise by an amount that that depends on the heat dissipation properties of the sensor. Current safety regulations and guidelines limit the temperature of the skin contacting portions of the sensor to remain at or below 41° C. Sensors that do a poor job of directing the heat away from the skin contacting surface, should use a lower LED drive current. Sensors with good thermal management can utilize higher drive currents without risk to the patient.
[0028] Accordingly, by encoding the maximum safe LED drive current into the sensor itself, the oximeter instrument can utilize the highest safe drive current for the sensor being used to attain the greatest amount of LED light without risk of injury. The maximum safe drive current allowed to achieve a skin temperature at or below a maximum level can be determined in advance through testing for a given oximeter sensor model. That maximum drive current can be encoded into memory 56 and read by controller 64 when the sensor is connected to the oximeter monitor. Controller 64 then communicates with drive circuit 66 to drive LEDs 52 at or near the maximum drive current value read from memory 56 , but to prevent circuit 66 from driving LEDs 52 with a current that exceeds the maximum drive current.
Part II
[0029] Embodiments of the present technique include the following:
[0030] Sensor Model ID
[0031] Encoded text of the specific model of sensor would allow the instrument to display a text string indicating what sensor is being used, e.g. “Nellcor OXISENSOR II D-25” or “Adult Digit Sensor” or “Agilent N-25”. Alternately, a sensor code could be stored that points to a lookup table of display text. Encoding sensor model ID could also be used to accommodate sensor-specific operating parameters such as LED drive currents or “sensor off” characteristics (as an alternative to programming the value of drive current or “off” characteristics themselves).
[0032] Sensor Model—Specific Information
[0033] Coefficients for Taylor's Series Calibration Curves
[0034] The sensor may store a general polynomial curve. Other families of polynomials, such as Tchebyschev polynomials, could be used as well. This may also pertain to other calibration information, such as temperature calibration and force transducer calibration. This allows new sensor types (such as a sensor with an offset emitter and detector).
[0035] Sensor Adjustment/Re-Application Light Levels
[0036] Sensor Off Light Levels
[0037] Under normal operating conditions, photosignals coming from the sensor LEDs generally fall within a certain range. When a sensor is removed from a patient, or falls off on its own, the photosignal usually changes. This is particularly true for the reusable clip-style sensor, since in their normal disconnected state, the LEDs shine directly onto the photodetector unimpeded by, for example, tissue. By programming a “threshold photocurrent” into the memory chip, reliable detection of a “sensor is off the patient” condition can be accomplished (in this example, exceeding a certain detected light level is a sure sign the sensor is not on a finger or other opposed site). For certain other sensors, a low light level may be indicative of the sensor being off (an adhesive sensor, for example, lays flat when in its natural state, so little LED light may reach the detector). Encoding an expected range of light levels for the specific model of sensor being used allows enhanced detection of when the sensor is improperly placed or has been removed.
[0038] Temperature at Which to Switch to STORM Algorithm
[0039] The STORM algorithm here refers to the sensors designed to be used where “motion provides the signal”, i.e., the cardiac pulse need not be present or discernible in order for the oximeter to provide SpO 2 values. Instead, the red and IR waveforms resulting from the motion itself are used for determining the arterial saturation. This feature is possible for tissue beds that are well “arterialized” (a large supply of arterial blood relative to the metabolic needs of the tissue) resulting in a small aterio-venous saturation difference, as well as other signal characteristics that are not germane to this discussion. It has been observed that the necessary degree of arterialization correlates well to being “well perfused” at the tissue site, which itself correlates well to the tissue bed being warm. Thus by monitoring the temperature of the skin at the sensor site, and by knowing a value of temperature (programmed into the memory chip) at which the “motion-is-signal” algorithm can be utilized for the specific sensor design being used, improved reading accuracy through motion can be better accomplished.
[0040] Additional Information on Use of Pins
[0041] Contact Switch—Sensor Off
[0042] Similar to the contact electrodes of the Nellcor FS-14 fetal sensor, an extrinsic probe of skin contact can be used to indicate whether the sensor is in adequate contact to the patient. This extrinsic probe could be accomplished, for example, through an impedance measurement across two electrodes, a force or pressure switch that is sensitive to whether adequate force or pressure is present in the sensor placement, or through other means. Dedicated sensor connector pins, or pin-sharing, could be used to accomplish this additional measure of sensor-patient contact.
[0043] Chemical Sensor for EtO Cycles
[0044] An electro-chemical or thermal device that senses and stores to memory the number of exposures (zero, once, or potentially more than once or the actual number) to sterilization cycles could be used to capture the history of the sensor. Excessive exposure to sterilization cycles degrades a number of components in the sensor, and can affect its performance. A sensor exceeding a certain number of exposures could cause a display to indicate the sensor needs to be replaced.
[0045] Sensor Expiration
[0046] This need not be a separate device, but the memory could contain a date after which time the sterilization can no longer be certified as being effective. Sterilization can be sensed and the date recorded automatically by the sensor itself.
[0047] Sensor Expiration Date/Sensor Parking: Meter
[0048] At the time of manufacture, the expiration date of the sensor may be written into the memory chip. The memory-enabled instrument would then do something with this knowledge (e.g., indicate “expired sensor”, or refuse to function if expired). Alternately, the elapsed time of sensor usage could be tracked in the memory chip (written to it by the instrument) and the sensor would “expire” after a memory programmed maximum (greater for reusable sensors than for single-use sensors).
[0049] Auto Shut-Off
[0050] After sensor expiration, the instrument may refuse to function with this sensor and would indicate that a fresh sensor is needed. Furthermore, the sensor could be disabled by running a high current through it, or by other means.
[0051] Warranty Date
[0052] Similar to the expiration date, the date of expiration of the sensor warranty could be written into the memory chip (e.g., 2, or 6, or 12, etc. months from the date of 10 manufacture or the date of first use). The instrument would give some indication of this as appropriate.
[0053] Patient Specific Information (Written to Sensor from Monitor)
[0054] Trending and/or data logging of patient monitoring parameters may be stored in the memory of the memory chip. As the patient and sensor travel from ward-to-ward of the hospital, and consequently plug into different oximeters, the patient-specific data could be displayed as it is contained in the patient's dedicated sensor. Examples of the type of data are given below:
[0055] Trending
[0056] Low High Sat
[0057] The lowest and/or highest SpO 2 value during the monitored time, or the lowest/highest values over the past specified monitoring time (e.g., 2 hours, 1 day, etc.)
[0058] Duration of Monitoring
[0059] How long has the patient been monitored by the pulse oximeter? (elapsed time counter).
[0060] Beginning and End of Monitoring
[0061] Clock time of when the monitor was turned on and off.
[0062] Pre-set Alarm Limits
[0063] The alarm limits used with this patient become written to the memory chip by the instrument. This allows patient-specific alarm values to be set and memorized so that as the patient moves from monitor-to monitor (the sensor staying with the patient), the appropriate alarm limits need not be reset each time on the new monitor. Instead, this only needs to happen once, or whenever the clinician adjusts alarm limits.
[0064] Changeable Key
[0065] Data encryption utilizes private and/or public keys to scramble the data written to the memory chip and later decipher the data so that only authorized devices are supported. To further prevent the use with a monitor that is not certified to provide correct results, the sensor manufacturing system could periodically change the private and/or public keys. The change in the key could be communicated to the instrument via the memory chip in encrypted form. The purpose of this feature is to elevate the level of security in the memory system.
[0066] Monitor Code Upgrades From Modem or Sensor
[0067] Distributing code updates in memory. Whenever an oximeter notes that a code update field is present in the sensor, it would check whether the proposed update had previously been installed, and (if not) whether any indicated prerequisites were present (e.g. a code patch might not function properly in the absence of a previously-circulated patch). If appropriate conditions are met, the code upgrade would be installed. If prerequisites are missing, a message would be displayed to the user, telling him how to obtain the prerequisites (e.g. call Nellcor).
[0068] Black Box Encoder (patient history, serial number of box. etc.)
[0069] Use the memory as a general-purpose carrier of patient data, covering not just oximetry but a lot of other information about the patient.
[0070] Optical Efficiency Correction
[0071] If it is desirable to know where a particular patient lies in COP space, it is useful to know the inherent brightness of LEDs, sensitivity of detector, and anything else about the particular sensor assembly (e.g. bandage color and alignment) that will affect the amount of light which the sensor receives. Given that information, a measure of the patient's optical transmissivity may be computed for each LED wavelength, which depends almost entirely on the properties of the patient. Signal to noise ratio of the oximeter is probably determined by the size of the detected signal, not by the transmissivity of the patient alone. This could take advantage of DC transmissivity of the tissue to improve the accuracy of pulse oximetry.
[0072] Another reason for recording LED and detector parameters in the sensor memory is to provide a basis for later research on the drift of these parameters due to various environmental conditions which the sensor experiences. Parameters of interest include not only LED power and detector sensitivity, but also LED wavelengths, FWHM, and secondary emission level.
[0073] Pigment Adjustment Feature
[0074] For some types of sensors, the accuracy of the sensor may be different for patients with different skin color. The sensitivity of accuracy to skin color may depend on sensor model. The sensor might contain a sensitivity index, indicating how large an adjustment in readings should be made as a function of skin color. Skin color might be obtained by user entry of the data (e.g. menu selection). Another option would be for the sensor to measure skin color. One way to achieve the latter option would be to provide transmission sensors with auxiliary detector for “reflected” light. In combination with the optical efficiency information noted above, the signal levels reported by the auxiliary detector would sense to what extent the patient's skin was affecting red and IR pathlengths differently, and hence to what extent readings needed to be corrected.
[0075] Accelerometer on Chip
[0076] This might be used in a scheme in which the memory chip was on the bandage, not in the connector. This combines a MEMS accelerometer with any of several different chips that might usefully be placed in the sensor head, local digitizing chip, preamp chip, memory chip.
[0077] Accelerometer data may be used to warn of the presence of motion (in which case special algorithms may be called into play or oximetry may be suspended), or actually to help correct for motion (to the extent to which we can produce algorithms which can predict physio-optic effects of known motion).
[0078] Optical Shunt
[0079] The amount of optical shunting could be measured for each sensor, or family of sensors. The value would be stored in the sensory memory for the monitor to read and use to adjust the processing coefficients.
[0080] Monitor Chip Temperature
[0081] The temperature of a red LED, in particular, affects its principal wavelength, which affects calibration. For one class of LEDs, the wavelength shifts by about 0.14 nm/C. The memory chip might contain circuitry capable of monitoring a thermistor or thermocouple, or the memory chip could be mounted in proximity to the LED (e.g. under it), so that it could sense directly the temperature of the LED, and provide a calibration correction accordingly.
[0082] Monitor Ambient Temperature
[0083] This might be used, e.g., in overseeing the operation of a warmed ear sensor. There is a thermal cutout in the control system of the WES, that causes operation to terminate if the sensor goes over a certain temperature. This is a component for protecting the patient against burns. If the reason for a high sensor temperature is that the environment is warm, it could be quite acceptable to continue oximetry, even though warmer operation would be shut down. In the absence of knowledge about environmental temperature, a high temperature reading might have to be assumed to mean that something was wrong with the sensor, in which case all operation might have to cease. An environmental temperature sensor in the plug could help to tell which rule to apply. Again, the memory chip could record the calibration of whatever device was used for thermometry.
[0084] A passive component on the memory chip could be the thermometric sensor, and a resistance or voltage measuring device in the instrument could read out that sensor. Thus, ambient temperature sensing might not require that large changes be made in the memory chip.
[0085] Temperature Amplifier/Detector
[0086] In illuminating the skin for the purpose of making oxygen saturation measurements, some heat is generated by the LED emitters. Tests have been done to establish the maximum safe current for the LED drive which will assure that the skin temperature stays within a safe value for the worst case sensor/patient conditions. This means that in all cases the sensor will be operated at cooler than the maximum temperature but in most cases well below the maximum temperature.
[0087] To establish the optimum signal for the measurement, it is desirable to drive the LEDs with higher current than is imposed by the above limitations. The temperature amplifier/detector would allow the LEDs to be driven to a level that still results in a safe temperature by monitoring the temperature, yet in many cases allow more drive current, and therefore higher signals, which could give better readings.
[0088] The inexpensive thermistor devices that could be used in this application are characterized to allow the measurement to be accurate. These characterization values could be stored in the sensor where the thermistor is located. While in operation, the oximeter would be able to read the characterization values from the sensor, measure the resistance of the thermistor, and calculate accurately the temperature of the skin surface where the thermistor is located. This would keep the patient safe from burns and still provide the best signal available.
[0089] RCAL Resistance Built into Chip
[0090] In legacy oximetry sensors there is a resistor which is selected and installed in the sensor connector, to correspond to the wavelength of the red LED. The wavelength difference from LED to LED has an impact on the calibration of the saturation measurement, if not compensated for. The oximeter will read the value of resistance and adjust its calculation accordingly.
[0091] When adding the memory chip, memory compatible oximeters will be able to obtain the necessary calibration coefficients from the memory chip but the legacy instruments will still need a calibration resistor value. If the resistance were built-in to the chip and trimmed or selected at manufacture then only one device would need to be installed in the sensor connector. That would reduce the overall cost, yet keep the sensor compatible with both the legacy instruments and the new memory compatible instruments.
[0092] Secondary Emission Measurement
[0093] The oximeter is measuring the relative transmission of the red and infrared light through the tissue. LEDs have a characteristic called secondary emission which is indicative of the amount of light, at wavelengths other than the primary wavelength, that is being emitted. This characteristic will change the calibration of the device if not compensated for. It is possible to make an oximeter that will function within calibration if the secondary emission is known and compensated for. If the LED were characterized during manufacture and then the secondary emission values entered into the memory chip, the oximeter would be able to read those values and compensate for them so that the sensor was used properly. This would increase the range of LEDs that could be used for oximetry, reduce cost and provide better calibration across a wider range of LED emitters.
[0094] Patient ID (Potentially as Tracking Device, Archiving Patient History, etc.)
[0095] Currently sensors are placed on patients at one hospital site and stay with the patient from hospital site-to-site. It would be helpful to have the patient ID carried along in the sensor so that the record keeping, which occurs at each site, would be able to link the recorded information with the patient. Without patient ID, the tracking has to be done manually. With trend information being stored in the sensor it also would be desirable to have the patient ID included so that as the patient went from location to location, the new location's staff could verify old information and be assured that it correlated with the patient they were receiving.
[0096] Encode Contact Resistance (e.g. for Oxicliq)
[0097] When making measurements of the resistance that is placed in the sensor for calibration information purposes, one of the factors that can influence that measurement is the contact resistance of the connectors that are between the oximeter and the resistor itself. In order to compensate for connectors that are significant in their impact on the measure, one could encode the contact resistance of the connector and subtract that algorithmically from the measured resistance to get a more accurate measurement of the resistance of the calibration resistor. This would enhance the accuracy with which the resistance measurement is made and, therefore, make the instrument less prone to inaccuracies in saturation calculation and display.
[0098] Measure Capacitance to Balance Common Mode Rejection
[0099] One of the interfering noise sources that plagues oximetry is that of common mode noise. This can come from the surrounding electrical environment. Other instruments, lighters, drills etc. can produce electrical fields that can couple into the cable between the patient and the oximeter. Once coupled-in, they can make measurements more difficult, less accurate, or not possible, depending on the severity of the noise. To help reduce this common mode noise, differential amplifiers are used for amplifying the signal from the sensor. These amplifiers amplify only the difference between two signal wires. Thus, if the common mode signal is coupled exactly the same into both wires, the amplifier will not amplify it because the same signal is present on both wires.
[0100] If the two wires have different coupling to their electrical environment, then they will present different signals, and the difference will be amplified as if it were a signal. One component that influences this coupling is the capacitance of the lines to the outside world. This is affected by the manufacture of the cable, materials, twists in the wire, etc. If one measured the cables during manufacture and then stored that information in the memory chip, it could be read when the oximeter is operating. Once the capacitances for the two wires to the shield are known, the instrument could be provided with a tunable capacitance device that would then balance the two lines again and make the noise coupling to the lines better matched. This would reduce the amount of susceptibility to the external noise that got coupled into the patient cable. Reduced noise results in better measurements or the ability to make measurements at all on some patients.
[0101] Fiber-Optic Infrared Wavelength Shift
[0102] The relative wavelengths of the red and infrared light that is used to make the measurement in oximetry are important to know so that calibration can be maintained. In traditional LED oximetry, the LED sources are at the skin so that whatever wavelength is emitted is what is sensed by the photodiode that receives the light. The red LED is the only one that we need to characterize for accurate saturation measurements to be realized. The saturation is less sensitive to the IR wavelength as long as it stays fixed in the acceptable range that has been specified for the IR LEDs.
[0103] When using plastic fibers for transmission of the light, there is a wavelength dependent absorption caused by the fiber. This has the effect of altering the apparent center wavelength of the IR source, which can affect calibration of the unit. By characterizing the fiber for its shift, one could then provide the proper compensation in the algorithm that calculated the saturation. This would restore the accuracy that would otherwise be lost in fiber transmission of the light.
[0104] Inform Monitor of Extra LEDs
[0105] There are limitations on the number and type of blood constituents that can be sensed using the two conventional LED wavelengths of the oximeter. The accuracy of the oximetry measurement can also be improved by using different wavelengths at different saturation ranges. An analysis unit could be developed that would utilize either or both of these features. To do this, it would be able to drive additional LEDs. The additional LEDs could be driven along with the traditional ones or separately. The oximeter (or additional constituent measurement unit) would provide the capability to calculate values for these other wavelengths, and the sensor would provide the additional information to allow the oximeter to make that calculation. These could be stored in the memory.
[0106] Active Ambient Light Measurement
[0107] One of the problems with oximetry sensors is the interference caused by ambient light in the environment. This can be made worse when a sensor comes loose or when the ambient light is extremely high in value. By characterizing the sensor, one could know what level of ambient light could be expected or tolerated, and give a warning to the user when the level has been exceeded. This would give them the opportunity to adjust the sensor, the light, or both to affect an improvement in the performance of the oximeter.
[0108] Active Pressure Adjustment for Modulation Enhancement
[0109] The stronger the pulsatile signal, the better the chances are of measuring the saturation accurately. One way to enhance the modulation percentage is to apply pressure in the range of the median pulsatile pressure. If this were implemented, one could use relatively low cost transducers and supply calibration coefficients in the memory to allow accurate pressure readings to be made. The memory could also contain the pressure settings and/or expected modulation enhancement capability to determine effectiveness of the pressure enhancement.
[0110] Measure Perfusion
[0111] The amount of perfusion affects the amount of modulation, and thus the AC signal. This affects both the percentage of modulation vs. the DC amount, and the absolute size of the modulation. The measured modulation, or other measurement of perfusion, can be stored in memory for trending or setting limits on acceptable perfusion before movement or other adjustment of the sensor is required.
[0112] Keep Track of Last Time Sensor Moved or Disconnected
[0113] The time of movement or disconnecting of the sensor could be written into the memory. Disconnecting can be detected from the interruption of the signal to the monitor. Moving can be detected by a sensor off detection, and a subsequent sensor on detection. Alternately, aggressive movement could be detected and interpreted as moving of the sensor, or a combination with a sensor off detection could be used.
[0114] Identify Private Label Sensors
[0115] A code can be stored in the sensor memory identifying the sensor manufacturer. This code can be read and used to indicate operability with monitors of other manufacturers, or to indicate any conversion algorithm that may be needed for a signal from a sensor to be used by a monitor from a different manufacturer. The code can also be used to allow only supported features to be used.
[0116] Measure Sensor Wetness
[0117] A moisture sensor or impedance sensor can detect the amount of wetness of the sensor. This can be used for different purposes and can be stored in the sensor memory for trending or monitoring. To determine sensor malfunction, the sensor can be disabled if the wetness exceeds a threshold, which could be stored in the sensor memory. Some sensors may not provide for isolation of the patient from the electronics for excessive wetness. The maximum allowable wetness could be stored in the sensor memory.
[0118] Sensor Isolation Indicator
[0119] The sensor memory could identify that the sensor provides isolation, so wetness is not a concern. Alternately, it could indicate that isolation is not provided by the sensor, or a limited amount of isolation is provided.
[0120] Low Power Mode Identifier (Sensor Tells Oximeter to Sleep or Wake Up)
[0121] A portable battery-powered monitor can power down when the saturation is at a good level, and the patient is stable. Minimal circuitry in the sensor could be used to do sufficient processing to tell the monitor when to wake up.
[0122] Battery to Run Digital Chip
[0123] A battery can be included in the sensor for a wireless connection to a monitor. Alternately, a battery could be used to continue to send data when the monitor is powered down.
[0124] Motion Generator (“Thumper”)
[0125] The sensor can include a cuff (which inflates and deflates) or other mechanical mechanism for inducting motion to get a signal or for inducing pulsitile blood flow to improve the signal.
[0126] Sensor Force Indicator (e.g., too Tight)
[0127] A transducer can measure the amount of force on the sensor. This can be compared to a maximum value stored in the sensor memory to determine if the sensor is on too tight. The tightness can also be recorded and monitored. For example, a patient could swell, and this could be determined from the trend information and provided as information to a clinician on a display.
[0128] Force Transducer Calibration to Get Pressure
[0129] A calibration value can be stored in the sensor memory for converting a force measurement into a pressure measurement. A force transducer can then be used to measure pressure.
[0130] Number of Wavelengths
[0131] The sensor memory can store an indication of the number of wavelengths used in the sensor, and could store the wavelengths themselves.
[0132] Drive Information
[0133] The sensor memory can store information about when to drive which LEDs. They could all be driven at once, or a subset could be driven, for example.
[0134] Display for Additional Wavelengths
[0135] The memory can store information about what parameters are to be analyzed and displayed when the extra wavelengths are used. Oxygen saturation may be displayed when 2 wavelengths are used, while additional information could be displayed when an extra wavelength or more are used (Hct, COHb, etc.).
[0136] Recycling times
[0137] Each time a sensor is recycled (sterilized and reconstructed), a number in the sensor memory can be incremented. This can be used to prevent operation of the sensor if it has been recycled more than the allowed number of times (e.g., 3 times).
[0138] While the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments and equivalents falling within the scope of the claims.
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Embodiments of the present invention include systems and methods that relate to a sensor with memory. Specifically, one embodiment includes a sensor, comprising a light emitting element configured to emit light, a light detecting element configured to detect the light, and a memory storing data corresponding to algorithms used by an oximeter monitor, the memory providing access to the oximeter monitor to read the data.
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BACKGROUND OF THE INVENTION
Modern high speed sophisticated looms induce bending stresses in the conventional long reed spanning the lay beam of the loom, as a result of which stresses the reed may not remain straight during the operation of the loom, thereby causing serious problems.
The objective of the present invention is to solve this problem of reed bending in high speed looms by strengthening the top extrusion cap of the reed to better resist bending without adding additional weight to the top extrusion cap. As a result of the strengthening of the top extrusion cap of the reed without the addition of weight to the cap, inertia forces acting on the top extrusion cap in high speed looms are not increased and therefore the problem of bending is effectively solved.
In accordance with the present invention, the top extrusion cap of the reed is formed of aluminum to minimize weight and the cap is shortened in the direction extending radially of the lay beam rocker shaft and lay swords. To compensate for this shortening of the top extrusion cap, longitudinal stiffening ribs are provided along the opposite side walls of the top extrusion cap which effectively resist bending of the cap and reed without adding additional weight to the structure.
Other features and advantages of the invention will become apparent to those skilled in the art during the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a loom lay beam and associate equipped with an improved reed according to the present invention.
FIG. 2 is a transverse vertical section taken through a standard reed according to the prior art.
FIG. 3 is a similar section taken on line 3--3 of FIG. 1.
FIG. 4 is a fragmentary perspective view of the improved reed according to the present invention.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, a conventional loom includes a lay beam 10 having shuttle boxes 11 mounted on its opposite ends, the lay beam being carried by swords 12 which are swingable in unison on a rocker shaft axis 13 parallel to the lay beam 10. A reed 14 forming the subject matter of the present invention spans the lay beam 10 between the shuttle boxes 11 and is held in a longitudinal groove 15 of the lay beam offset from corresponding sides of the shuttle boxes. A reed cap 16 mounted on and moving with the lay beam structure has a groove 17 receiving the top of the reed 14 in accordance with conventional practice.
In the prior art typified by FIG. 2 of the drawings, a reed 14' contains a multiplicity of closely spaced parallel flat wires 18 whose top and bottom end portions 19 and 20 are received in top and bottom extrusion caps 21 and 22 which may be formed of aluminum or steel, in some cases. The use of steel particularly for the top cap 21 is not desirable on any modern high speed loom because of the weight of steel and the resulting increase in inertial forces generated by this weight.
In the prior art construction, even where the top extrusion cap 21 is formed of aluminum to reduce its weight and inertia on a high speed loom, a serious problem arises due to the tendency of the long reed to bend as a result of stresses induced by the high speed motion of the modern loom. If the top cap 21 is formed of steel, it may remain straight during operation but the aforementioned additional weight and inertia problem is still present. Thus, a dilemma is presented in connection with the prior art standard reed and it is this dilemma which the present invention seeks to overcome or solve in accordance with its main objective.
Referring to FIGS. 3 and 4 of the drawings showing the improved reed 14, the flat wires 23 of the reed 14 have their end portions 24 and 25 held in top and bottom extrusion caps 26 and 27, both formed of aluminum. The bottom extrusion cap 27 is substantially conventional and comprises a flat rectangular cross section channel member whose cavity may be filled with epoxy 28 or the like to anchor the wire end portions 25 firmly. In accordance with common practice, the wire end portions are maintained spaced by a coil spring 29 extending along the top of the bottom extrusion cap 27 and also being embedded in epoxy 30 to form a rigid structure.
In accordance with this invention, the two side walls 31 of the top aluminum extrusion cap 26 are foreshortened on the longitudinal axes of the wires 23 which extend radially of the rocker shaft axis 13. This foreshortening reduces the weight of the top extrusion cap. To strengthen the top cap against bending during operation of the high speed loom, two continuous parallel longitudinal strengthening ribs 32 are provided on the exteriors of the side walls 31 substantially at the center of the top extrusion cap 26 with respect to its axis along the wires 23. These ribs 32 enable the top extrusion cap to resist bending in the planes occupied by the side walls 31 during high speed loom operation, and the provision of the ribs 32 does not increase the weight of the top aluminum extrusion cap 26, which weighs no more than the prior art cap 21, but is a great deal more resistant to bending.
The end extensions 31 of the wires 23 are anchored in the top extrusion cap 26 by epoxy or the like and a top coil spring 33 is utilized to maintain the proper spacing of the wires 23 at their tops. The spring 33 is also embedded in epoxy 34.
The foreshortened and rigidified top extrusion cap 26 may engage in the existing groove 17 of the loom reed cap 16, FIG. 3, while the strengthening ribs 32 abut the lower face of the cap 16. In new installations, the groove 17 can be made shallower so that there will be no cavity at the end wall 35 of the top extrusion cap 26.
It may be seen that the improved top extrusion cap allows the use of a light metal, such as aluminum in lieu of steel, to lessen weight and inertia. The resulting loss of bending strength along the length of the reed is regained by providing the ribs 32 and the presence of these ribs does not increase the overall weight of the top extrusion cap. Therefore, the invention solves the dilemma of the prior art in a very simple, economical and practical manner.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
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The top extrusion cap for a reed used in high speed looms is strengthened to resist bending without adding additional weight to the extrusion cap by the addition of longitudinal stiffening ribs to the opposite sides of the top extrusion cap.
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PRIORITY
[0001] The present patent application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 60/484,081; filed on Jun. 30, 2003, titled “Method for Coating Substrates.” The full disclosure of U.S. Provisional Patent Application Ser. No. 60/484,081 is incorporated herein by reference.
RELATED APPLICATIONS
[0002] This application is related to the following filed U.S. Applications, which are incorporated by reference herein:
U.S. patent application Ser. No. 10/074,706; filed on Feb. 13, 2002, titled “Method and Apparatus for Localized Liquid Treatment of the Surface of a Substrate,” and U.S. patent application Ser. No.09/998,889; filed on Nov. 1, 2001, titled “Method and Apparatus for Removing a Liquid from a Surface.”
FIELD
[0005] The present invention relates generally to forming a thin film, which is also called a coating, on a substrate.
BACKGROUND
[0006] Coatings may be prepared in the gas phase (using chemical vapor deposition or physical vapor deposition—See, e.g., Silicon Processing for the VLSI Era, S. Wolf and R. Tauber, Lattice Press Calif., USA, 2000—Chapters 6 and 11) or in the liquid phase. When a coating is prepared in the liquid phase, the coating liquid used in the process may contain a variety of components, such as binders, solvents, and additives. (See, e.g., Modern Coating and Drying Technology, E. Cohen and E. Gutoff, Wiley VCH, 1992, pp 1, which is hereby incorporated by reference in its entirety.) The coating liquid may also be identical in composition as the final coated film, such as in case of molten materials.
[0007] Various methods exist for applying the coating liquid to the substrate, including dip coating, rod coating, knife coating, blade coating, air knife coating, gravure coating, roll coating, slot coating, slide coating, curtain coating, Langmuir Blodgett coating, spray coating, spin coating, and the like. (See, e.g., Modern Coating and Drying Technology, E. Cohen and E. Gutoff, Wiley VCH, 1992, pp 6-10.) In many of these methods (but not all), the substrate is brought into contact with the coating liquid and a relative motion between the substrate and the coating liquid is induced.
[0008] These liquid coating processes rely on a balance between: a viscous force; a body force, such as centrifugal force, gravity, and/or friction (depending on the particular configuration); pressure of (gaseous) ambient air, gas and/or vapor; and surface tension. The magnitude of these forces influences a thickness of the liquid film left behind (see FIG. 1 ).
[0009] An example of a liquid coating process includes pulling substrates (such as plates, foil, or wire) through a bath of molten coating material (where the substrate, wire, or foil material has typically a higher melting point than the coating substance). Other examples include wire coating with polymers, metal coating with Zn film from molten Zn baths, dip coating, and the like.
[0010] Various methods exist to control the coating film thickness. Some of the methods that are used to control the coating film thickness include the use of “air knives,” metering blades, knives, metering rolls, and gravure rolls. (See, e.g., Modern Coating and Drving Technology, E. Cohen and E. Gutoff, Wiley VCH, 1992, pp 2-3.) Examples include the following. Air knives consist of slit-shaped nozzles through which pressurized gas (or air) is blown at high speed. The impact of the gas stream on the liquid surface reduces the thickness of the film left behind, through the impact force. An inherent side effect of these air knives is that they typically involve strong flows of gases which may lead to additional contamination from the air flow and strong evaporation effects, leading to additional contamination (due to enhanced solvent evaporation). Metering blades (also known as “doctor blades”) or knives reduce the film thickness through scraping away excess liquid from the substrate. Metering rolls and gravure rolls determine the amount of coating liquid that is delivered to the moving substrate.
[0011] Ramdane and Quéré report in “Thickening factor in Marangoni coating” (Langmuir 1997) on solutions containing surfactants that create a Marangoni flow, which thicken the film when pulling a solid out of solution. However, this method is not applicable for reducing the film thickness to be comparable to a film thickness resulting from pulling a solid out of pure liquid.
[0012] Fanton et al. teach in “Thickness and shape of films driven by Marangoni flow” (Langmuir 1996) that the film thickness is dependent on a surface tension gradient, which can be induced by a temperature gradient. However, this method is not applicable for all kinds of substrates.
SUMMARY
[0013] A method for depositing a coating layer on at least part of a surface of a substrate is disclosed. The method includes supplying a coating substance to the at least a part of the surface of the substrate, subjecting the substrate to a relative movement with respect to a source of the coating substance, and modifying the surface tension of the coating substance. The modifying of the surface tension of the coating substance is performed locally and at least a part of the time while subjecting the substrate to the movement, which influences the thickness of the coating layer.
[0014] The coating layer may be a continuous layer or a non-continuous layer. Supplying a coating substance to at least a part of the surface includes contacting the at least part of the surface of the substrate with at least part of the coating substance. Subsequently, the contacted surface is then subjected to a surface tension modification process. In particular, a three-phase region (see definition below) is subjected to the surface tension modification process.
[0015] Influencing the thickness of the coating layer includes increasing or decreasing the thickness within a range of predetermined values. Influencing the thickness of the coating layer also includes adjusting the thickness to a predetermined value or a range of predetermined values. Preferably, adjusting the thickness is understood as increasing or decreasing the thickness of the deposited coating layer.
[0016] Modifying the surface tension creates a surface tension gradient in the deposited coating substance. In particular, modifying the surface tension includes increasing or decreasing the surface tension of the deposited coating substance, in such a way that there are at least two points in the coating substance exhibiting a different surface tension.
[0017] Modifying the surface tension may be performed using an external device. The modification the surface tension influences the surface tension of the deposited coated substance. The external device is a device that is not part of the coating substance. Additionally, the external device may be a device delivering a physical quantity affecting the surface tension of the deposited coating substance. More particularly, the external device may be a device delivering a surface tension affecting substance. Additionally or alternatively, the external device may be a device delivering heat or any other means to locally affect the temperature distribution of the coating substance.
[0018] The surface tension affecting substance may be in the form of a liquid, a solid, a vapor, a mist, or a gas. In one example, the external device locally delivers a surface tension lowering gas, such as isopropyl alcohol (when delivered to aqueous liquids), which decreases the thickness of the deposited coating layer. Alternatively, a surface tension increasing substance may be used to increase the coating layer thickness.
[0019] A device delivering heat or any other means to locally affect the temperature distribution of the coating substance may locally adjust the temperature, depending on the desired thickness of the deposited coating layer. In particular, the temperature controlling device heats the deposited coating liquid (creating a local lowering of the surface tension), which decreases the thickness of the coating liquid. Heating may be performed by means of incident electromagnetic radiation, infra-red light, radiation, or other appropriate method.
[0020] In one example, the method of depositing a coating layer on at least a part of a surface of a substrate includes chemically or physically modifying the deposited coating layer to form a coating layer. Modifying the deposited coating layer may be performed by thermal treating (thereby obtaining evaporation of solvent), subjecting to a predetermined ambient (e.g., oxidizing ambient, and the like), crystallisation, and/or recrystallization.
[0021] The deposited coating layer may have a thickness below 10 micrometer, below 5 micrometer, below 1 micrometer, below 500 nm, below 100 nm, or below 10 nm. Preferably, the deposited coating layer has a thickness below 100 nm. The deposited coating layer can be a continuous layer or a non-continuous layer.
[0022] The coating substance may be molten material (such as a metal), sol gel solution, or any film precursor brought into the liquid state by means of melting, dissolution, or any other physical or chemical modification which may require the use of additional products or species (such as chelating agents, complexing agents, counterions, and the like).
[0023] The movement is a relative movement between the substrate and a source of the coating substance, delivering the coating substance. The movement may be a rotational or a linear movement, or a combination of both rotational and linear movements.
[0024] The coating layer made by the method for depositing a coating layer on at least part of a surface of a substrate may be used in integrated circuit fabrication processes.
[0025] These as well as other aspects and advantages will become apparent to those of ordinary skill in the art by reading the following detailed description, with reference where appropriate to the accompanying drawings. Further, it is understood that this summary is merely an example and is not intended to limit the scope of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Presently preferred embodiments are described below in conjunction with the appended drawing figures, wherein like reference numerals refer to like elements in the various figures, and wherein:
[0027] FIG. 1 is a diagram of a typical case of coating a substrate surface with a liquid;
[0028] FIG. 2 is a block diagram of a method for coating a substrate according to an example;
[0029] FIG. 3 is a scanning electron microscopy image of a coating layer prepared from a 0.7 M (BiLa) 4 Ti 3 O 12 solution by spin-coating;
[0030] FIG. 4 is a scanning electron microscopy image of a coating layer prepared from a 0.7 M (BiLa) 4 Ti 3 O 12 solution by dip-coating; and
[0031] FIG. 5 is a scanning electron microscopy image of a coating layer prepared from a 0.7 M (BiLa) 4 Ti 3 O 12 solution according to the method depicted in FIG. 2 .
DETAILED DESCRIPTION
[0032] As used throughout this specification, the term “coating” may be defined as “the replacement of air with a new material on a surface of a substrate.” (See, e.g., Modern Coating and Drving Technology, E. Cohen and E. Gutoff, Wiley VCH, 1992, Foreword.) The arrangement of the new material on the surface of the substrate can be in the form of a uniform film or can be in the form of a regular or irregular pattern. The term “substrate” can refer to a solid piece of material of various geometries (e.g., plate, wire, ribbon, tape, tube, sheet).
[0033] The purpose of applying such a coating layer can vary, depending on the particular application, but generally two basic types can be distinguished. (See, e.g., Modern Coating and Drying Technology, E. Cohen and E. Gutoff, Wiley VCH, 1992, pp4-5.) A first category contains coatings that are sold as final product, such as paints, photographic films, X-ray films, plates for printing, containers for food packaging, magnetic storage media, optical disks, adhesive tape, wallpaper, and so on. In a second category, the coating forms an integral part of a particular application or forms an intermediate product in the production process, such as photoresists, coatings for interconnecting components on circuit boards, adhesive coatings during a fabrication process, various layers deposited during the fabrication of a micro-electronic circuit or sensor, and so on.
[0034] The following description refers to a coating liquid. It is understood however that the description can be applied to other coating substances such as a vapor, a molten metal, a sol-gel solution, a mist, a gas, a finely dispersed solid, and combinations thereof.
[0035] A surface tension modifying process is used to influence the thickness of the coating layer that is deposited. The surface tension modifying process creates a surface tension gradient in the deposited coating layer (also called coating film). The application of the use of surface tension gradients to influence the coating film thickness is also illustrated on FIG. 1 (for the particular case where the surface tension gradient results in a reduction in coating film thickness).
[0036] The surface tension of a substance such as, but not limited hereto, a liquid depends on many physical properties from which temperature and concentration of a tension-active component are particularly suited to generate a difference in local surface tension. (See, e.g., T. Molenkamp, PhD thesis, 1998, “Marangoni Convection, Mass Transfer and Microgravity”, Rijksuniversiteit Groningen, The Netherlands.) The surface tension gradient is preferably generated in a three-phase contact area.
[0037] The three-phase contact area may be defined as the region where the substrate, coating substance, and gas phase (this can be the ambient gas phase, e.g. air) meet each other and which is characterized by an increase in liquid film thickness (measured perpendicularly to the substrate) when moving towards the region from where the coating liquid is being delivered (e.g. the recipient). The surface tension gradient is generated such that the direction of the surface tension gradient assists in reducing or increasing the thickness of the coating layer.
[0038] The three phase contact region is defined by the particular properties of the embodiments that are used in the coating process, as well as by the properties of the coating liquid, ambient gas phase, and surface properties of the substrate, which can be adequately tailored by a person skilled in the art. Preferably, the surface tension gradient is generated by means of a source that is externally positioned with respect to the substrate and the coating liquid (e.g., delivery of a soluble tensio-active component, external heat source, and the like).
[0039] In the embodiment of the temperature induced surface tension gradients, it is well known that the surface tension of a liquid generally decreases with temperature (P. W. Atkins, Physical Chemistry, and A. W. Adamson “Physical Chemistry of Surfaces”, fifth edition, 1990, John Wiley & Sons, inc., New York). This means that if the external heat source (or heat sink) results in a temperature gradient, having the highest temperature in the part of the three phase region nearest the substrate, a flow in the coating liquid is created, resulting in a reduced film thickness of the coated layer (as compared to a comparable embodiment that does not comprise the external source). Alternatively, a temperature gradient in the opposite direction, i.e. having the lowest temperature in the part of the three phase region nearest the -substrate, may result in an increased thickness of the coated film (as compared to a comparable embodiment that does not comprise the external source).
[0040] In a similar manner, the external source may also deliver through the gas phase a component having a surface tension differing from the surface tension of the coating liquid (and at least partly soluble in it), which upon contact with the liquid at the three phase region, induces a surface tension gradient at the surface of the liquid (e.g., by having tensio-active properties in combination with a non-zero solubility in the coating liquid).
[0041] For an external species with a surface tension lower than the coating liquid, the resulting surface tension gradient is a result of the gradient in local concentrations of the external species, which in turn is the result of the difference in local thickness of the coating liquid in the three phase region. Under these conditions, the coating film thickness may be reduced with respect to a similar embodiment not comprising a system suitable for delivering an external tensio-active component. Alternatively, obtaining a thicker film may be achieved by delivering an external component whose surface tension is higher than the coating liquid.
[0042] After deposition of the coating film, an additional step may be required for the purpose of improving the film properties, such as a thermal curing step, a heat treatment step to drive out (at least part of) the additives present in the coating film, a recrystallization step to transform the film into the appropriate crystallographic phase, and the like.
[0043] The method for coating substrates allows obtaining a significant reduction in film thickness compared to a state-of-the-art method. Additionally, when the coating liquid comprises a solvent that is removed during the post-treatment step, the method results in less contamination from undesired trace impurities present in the substrate material. Moreover, a lower purity of the solvent is required, which provides a more cost effective solution. As a result, for a given thickness, a more concentrated coating liquid can be used, requiring less evaporation of solvent in the post-treatment step, which reduces the amount of contamination originating from the evaporation process.
[0044] Furthermore, the method results in less risk of cracking or other structural defect formation related to the transformation to a solid by evaporation of a solvent, since for the same thickness of final film, less total amount of liquid (and thus less solvent) can be used. As an illustration of this, note the crack formation in the dip-coated sample (See, FIG. 4 ), which is absent in the sample coated according to the method described with reference to FIG. 2 (See, FIG. 5 ).
[0045] FIG. 2 is a block diagram of a method 200 for coating a substrate. At block 202 , a coating liquid is supplied to at least a part of the surface of the substrate. The substrate comprises preferably a solid material and the coating liquid comprises the species to be deposited. The species to be deposited may be transformed into the liquid state prior to deposition. The substrate and coating liquid may be chosen so that under ambient conditions good wetting properties of the coating liquid are obtained on the substrate. Good wetting properties may be characterized by a contact angle between a liquid and a substrate that is less than 90 degrees, and preferably less than 45 degrees. Preferably, the contact angle between the coating liquid and the substrate is less than 35 degrees.
[0046] At block 204 , the substrate is subjected to movement. The movement may be understood as a relative movement of the surface of the substrate with respect to the source of the liquid. A list of non-limiting examples is provided as follows.
[0047] In one example, a vessel contains the coating liquid. The substrate is immersed in the vessel and withdrawn through the free surface that is formed under the influence of a body force, such as gravity, at a speed between 0.1 mm/s and 10 m/s, and preferably in the range between 0.1 mm/s and 10 mm/s.
[0048] Another example includes a recipient containing the coating liquid through which a substrate having at least one dimension significantly larger than the dimensions of the recipient is pulled (such as a wire, tape, and the like) at a speed between 0.1 mm/s and 10 ms/, and preferably in the range between 0.1 mm/s and 10 mm/s.
[0049] Another example includes a delivery system that is capable of delivering the coating fluid onto the surface of the substrate under conditions in which a continuous and distinct perimeter is formed at the interface of the contact between the coating fluid, the substrate surface, and the ambient gas phase. This perimeter forms the onset of the three phase contact region. By inducing a relative motion between the surface of the substrate and the delivery system, the perimeter moves over the surface of the substrate that is to be coated.
[0050] The delivery system may include nozzles delivering an uninterrupted flow of the coating liquid onto the surface of the substrate. A perimeter may be formed at the contact area, where the flow of the coating liquid being delivered onto the surface of the substrate intersects with the surface of the substrate. Depending on the geometrical configuration of such a nozzle system, the shape of the perimeter may be circular, prolonged (e.g., for slit shaped nozzles), or any other shape.
[0051] In another example, the delivery of the liquid may occur by means of a device in close contact with the surface of the substrate that provides additional functionality to the process. An example of such a device is a brush or a sponge. The brush or sponge has a relative motion with respect to the surface of the substrate and is capable of delivering the coating liquid to the surface of the substrate. The brush or sponge delivers the coating liquid at substantially the same time a mechanical interaction is taking place between the surface of the substrate and the material comprising the brush or sponge. In this manner, the brush or sponge may precondition or pre-clean the surface of the substrate prior to the coating process.
[0052] At block 206 , at least part of the surface of the substrate is subjected to a surface tension modifying process. This process results in a surface tension gradient being generated in the three phase contact region. The surface tension gradient may be generated by using a difference in temperature, a concentration of surface active species, or another means capable of inducing a surface tension gradient.
[0053] The physical property responsible for the difference in surface tension is induced by the delivery of an appropriate physical quantity. For example, for a thermally induced Marangoni effect, the physical quantity comprises heat or any other means to affect the temperature distribution. As another example, for a concentration induced Marangoni effect, the physical quantity comprises a concentration of a surface active compound.
[0054] The physical quantity is delivered by an appropriate device that is not initially part of the substrate or part of the coating liquid. An example of an appropriate device for the temperature induced Marangoni effect is a device that delivers a flow of heat, such as electromagnetic radiation of a wavelength that is suitable to be adsorbed by the liquid or the substrate. Another example of an appropriate device for the temperature induced Marangoni effect is a device that delivers a flow of fluid at a temperature different from the temperature of the coating liquid in the three-phase region. The flow of fluid may change the temperature distribution of the coating liquid in the three phase contact region by means of physical contact between the coating liquid and the fluid at a different temperature.
[0055] An example of an appropriate device for the concentration induced Marangoni effect is a device that delivers a flow of a soluble component having a non-zero solubility in the coating liquid and resulting in a variation of the surface tension upon dissolving in the coating liquid. Especially strong Marangoni effects may be obtained when the coating liquid has a high surface tension, preferably above 50 mN/m and more preferably close to 72 mN/m. The coating liquid may have a high surface tension when water is the primary constituent of the coating liquid; other components in the coating liquid, such as additives, do not have a drastic effect on the surface tension of the liquid; and the surface tension reducing component is an organic molecule with a surface tension lower than 50 nM/m, preferably between 10 and 30 mN/m. The surface tension reducing component may be an alcohol, a carboxylic acid, an alkane, an alkene, or a ketone having a non-zero solubility in water.
[0056] The surface tension reducing component may be delivered to the three phase contact region by using an inert carrier fluid. Preferably, the inert carrier fluid consists of air or nitrogen gas into which the tensio-active component is entrained. The surface tension reducing component may be chosen so that the surface tension reducing component has a preference to be in the liquid phase, has a vapor pressure high enough at the operating temperatures, and a solubility in the carrier gas such that the surface tension reducing component can be entrained with the carrier gas by bringing the two components into physical contact. The two components may be brought into physical contact by means of a device known to a person skilled in the art, such as a bubbler system. Such a bubbler system acts as to separate the flow of the inert carrier fluid into smaller flows (typically thermodynamically encountered as bubbles), which enhances the area of contact between the phases of the surface tension reducing component and the inert carrier fluid, resulting in an increased mass transfer.
[0057] The surface tension reduction is induced in the three phase region in the following way. For thinner films the surface tension reduction is induced in such a way that the largest surface tension exists in the liquid source. For thicker films the surface tension reduction is induced in such a way that the largest surface tension exists on the substrate side (i.e., not on the liquid side).
[0058] Subsequent process steps may be performed after the surface tension modifying process of the at least part of the surface of the substrate. For some applications, the deposited coating layer can fulfill requirements with no further treatment. However, if a solid film is desired, the deposited liquid coating layer may be transformed into the solid state by a post-treatment process step, such as baking, solidification, and evaporation of volatile carrier material. Additionally, subsequent process steps may be performed when an objective of the coating is to obtain a thin film that has a particular functionality within a given structure from which the coating process forms a dedicated part of the fabrication process.
EXAMPLE 1
[0059] A first example of the application of this invention relates to the reduction of the coating thickness of a molten metal, such as Zn, which is used as anodic corrosion protection material in steel wires and other products composed of metal. This is a common case in industrial applications where the purpose is to reduce consumption of fairly expensive Zn in corrosion protection coating.
[0060] The wire is pulled through a bath of molten Zn. The wire is heated at the point where the wire is withdrawn from the melt. At this point where the substrate, liquid source, and the air coincide is the three-phase region. Heating may be performed in various ways, such as using additional radiative heat sources, inductive heating, or by applying a voltage to the system such that a current flows through the three-phase region. A surface tension gradient is created over the molten Zn surface that results in a flow of liquid Zn along the surface from the three-phase region with low surface tension (i.e. from the wire) towards the higher surface tension (i.e. towards the melt in the bath). Thus a thinner Zn film is obtained. Additionally, the Zn will remain as a liquid for a longer time, allowing more time for the Zn to “drip down” resulting in a lower thickness.
EXAMPLE 2
[0061] In a second example the purpose is to increase the thickness of the coating of Zn onto steel wire. The wire is pulled through a bath of molten Zn. At the point where the wire is withdrawn from the melt, the wire is cooled. This cooling may be done in various ways. For example, the wire may be cooled by using cooling gas or liquid flows, or by contacting cooled solid surfaces (e.g. wheels). A surface tension gradient is created over the molten Zn surface that results in a flow of liquid Zn along the surface from the region with low surface tension (i.e. from the melt in the bath) towards the higher surface tension (i.e. towards the wire). In this way a thicker coating is obtained. Additionally, the Zn will remain as a liquid for a shorter time leaving less time for the Zn to “drip down” resulting in an enhanced thickness.
EXAMPLE 3
[0062] In a third example, the application is to deposit a thin layer of a ferro-electric material onto a flat substrate from an aqueous solution in which the ferro-electric material is present in the form of an appropriate precursor, in a volume concentration Co, which is preferably in the range between 10 −6 M to 10M, and more appropriately in the range 0.1-5M. Preferably, the concentration is between 0.1 and 1M.
[0063] In tests, the precursor solution has been prepared for a (BiLa) 4 Ti 3 O 12 or “BLT” layer in a concentration of 0.7M. The flat substrate consisted of a piece of polished bare Si material which was thoroughly cleaned and covered with a protective oxide layer (e.g., obtained by rinsing in ozonated ultrapure water).
[0064] The substrate is vertically withdrawn from the solution at a speed on the order of 5 mm/s. The surface tension gradient is induced by blowing an appropriate volatile, soluble tension-active component (such as IsoPropyl Alcohol—IPA) onto the three-phase region through a slit-shaped nozzle in a flow on the order of 0.5 SLM per cm width in a concentration on the order of approximately 4 volume %. The latter is obtained by bubbling an inert carrier gas (in this case nitrogen), through liquid IPA at room temperature.
[0065] By means of comparison, the same precursor film is coated onto the same substrate by means of spin-coating at 3000 rotations per minute. This can be considered as being representative of a state-of-the-art process, as it would be preferred by a person skilled in the art. Additionally, the same precursor solution is also coated onto the same substrate by means of dip-coating. In the latter, the substrate is withdrawn vertically from a recipient containing the precursor solution at the same withdrawal speed as the tests described above.
[0066] After the coating process, the coated film is cured by a heat treatment consisting of 1 minute at 160 degrees Celsius, 4 minutes at 260 degrees Celsius, and 2 minutes at 650 degrees Celsius. After these heat treatment steps, the films are analysed by spectroscopic ellipsometry (SE) at an angle of 75.09 degrees with respect to the surface normal and a wavelength range between 300-850 nm and by Rutherford Backscattering (RBS).
[0067] From the spectroscopic ellipsometry data, the real and imaginary part of the refractive index of the film was determined. A Sellmeier (2) model assuming 1 homogenous film on the silicon substrate was fitted to these results in order to extract a value for the film thickness. From the RBS results, a thickness was extracted by fitting the energy spectrum to a simulated spectrum containing Bi, Ti, La, and O.
[0068] The results of both measurements are summarized in Table 1, containing the fitted thickness for the three conditions based on spectroscopic ellipsometry and RBS, as well as the fitted atomic compositions based on RBS results. Finally, the surfaces of the various samples were inspected by Scanning Electron Microscopy. The results (for a 5000 times magnification) are represented in FIGS. 3, 4 , and 5 .
TABLE 1 Thickness Composition Spectroscopic RBS RBS RBS RBS RBS ellipsometry Thickness Atom Atom Atom Atom Method Thickness (nm) (nm) % Bi % Ti % La % O Spin-coat 61 +/− 0.002 60 14.5 16.1 4.8 64.5 Dip-coat 157.3 +/− 0.072 300 15.0 15.0 3.7 66.4 This 5.8 +/− 0.01 6 15.0 15.0 3.7 66.4 invention
[0069] It should be understood that the illustrated embodiments are exemplary only and should not be taken as limiting the scope of the present invention. The claims should not be read as limited to the described order or element unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
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A method for depositing a coating layer on at least a part of a surface of a substrate is described. The method includes supplying a coating substance to at least part of a surface of a substrate. The substrate is subjected to a relative movement with respect to a source of the coating substance. The surface tension of the coating substance is modified, at least locally, at least part of the time while the at least part of the substrate is subjected to the movement. A thickness of the coating layer is influenced by modifying the surface tension of the coating substance.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a substrate for an organic light-emitting device, a method of fabricating the same and an organic light-emitting device including the same, and more particularly, a substrate for an organic light-emitting device which not only improves light extraction efficiency but also has superior productivity and fabrication efficiency, a method of fabricating the same and an organic light-emitting device including the same.
[0003] 2. Description of Related Art
[0004] In general, light-emitting devices can be generally divided into organic light-emitting devices in which a light-emitting layer is formed from an organic matter and inorganic light-emitting devices in which a light-emitting layer is formed from an inorganic matter. An organic-light-emitting diode used in organic light-emitting devices is a self-emitting element which generates light using energy emitted from excitons that are generated through the recombination of electrons injected through a cathode and holes injected through an anode. Such organic light-emitting devices have a variety of advantages, such as, low-voltage driving, self-emission, a wide viewing angle, a high resolution, natural color reproduction and rapid response.
[0005] Recently, active studies are underway in order to apply organic light-emitting devices to a variety of devices, such as portable information devices, cameras, watches, office equipment, information display windows of vehicles, televisions (TVs), displays, or illumination systems.
[0006] Approaches for improving the luminous efficiency of organic light-emitting devices include an approach of improving the luminous efficiency of a material that constitutes a light-emitting layer and an approach of improving the light extraction efficiency at which light generated from the light-emitting layer is extracted.
[0007] The light extraction efficiency depends on the refractive indices of the layers which form an organic light-emitting device. In a typical organic light-emitting device, when a ray of light generated from the light-emitting layer is emitted at an angle greater than a critical angle, the ray of light is totally reflected at the interface between a higher-refractivity layer which could be a transparent electrode layer and a lower-refractivity layer which could be a substrate. This consequently lowers the light extraction efficiency, thereby lowering the overall luminous efficiency of the organic light-emitting device, which is problematic.
[0008] More specifically, only about 20% of light generated from an organic light-emitting diode is emitted to the outside and about 80% of the light is lost by a waveguide effect originating from the difference in the refractive index between a glass substrate and an organic light-emitting diode which includes an anode, a hole injection layer, a hole transport layer, an emissive layer, an electron transport layer and an electron injection layer, as well as by the total internal reflection originating from the difference in the refractive index between the glass substrate and the air. Here, the refractive index of the internal organic light-emitting layer ranges from 1.7 to 1.8, whereas the refractive index of indium tin oxide (ITO) which is generally used for the anode is about 1.9. Since the two layers have a very small thickness ranging from 200 to 400 nm and the refractive index of the glass used for the glass substrate is about 1.5, a planar waveguide is thereby formed inside the organic light-emitting device. It is calculated that the ratio of the light lost in the internal waveguide mode due to the above-described reason is about 45%. In addition, since the refractive index of the glass substrate is about 1.5 and the refractive index of the ambient air is 1.0, when the light is directed outward from the inside of the glass substrate, a ray of the light having an angle of incidence greater than a critical angle is totally reflected and is trapped inside the glass substrate. The ratio of the trapped light is about 35%. Therefore, only about 20% of the generated light is emitted to the outside.
[0009] In order to overcome this, a variety of methods for improving light extraction efficiency has been studied. For example, a planarization layer having an intermediate refractive index, as an antireflection film, is provided between a glass substrate and a light-emitting structure, or a partition wall in which white particulates or transparent particulates is dispersed in polymer, as an optical waveguide, is provided on a substrate, the refractive index of the transparent particulates being different from that of the polymer.
[0010] A typical technology for light extraction is to coat a substrate with a light-scattering layer including scattering particles. That is, metal oxide particles are contained in a matrix to act as scattering particles, whereby a light scattering effect can be expected at the boundaries between the metal oxide particles and the matrix and from the difference in the refractive index therebetween.
[0011] The light-scattering layer is fabricated typically by a wet coating method, such as spin coating or bar coating. However, the wet coating causes some problems.
[0012] It is difficult to uniformly disperse the metal oxide particles in the matrix by the wet coating method. According to the characteristics of the wet coating, the volume of the liquid matrix decreases by ⅕ to 1/20 during the baking process. Then, some of the metal oxide particles remaining in the matrix protrude from the surface of the matrix when the volume of the matrix decreases, thereby increasing the surface roughness of the matrix. This consequently has an adverse effect on the characteristics of the organic light-emitting device.
[0013] In addition, in the related art, after fabrication of a light extraction layer in which the scattering particles are disposed inside the matrix by the above-mentioned wet coating method, a planarization layer which reduces the surface roughness of the matrix layer is disposed on the matrix for the reliability of an organic light-emitting device. Afterwards, a transparent electrode, an organic light-emitting layer and a metal electrode are sequentially deposited on the resultant structure by a dry process.
[0014] Since the deposition process for the light extraction layer and the deposition process for the organic light-emitting diode are carried out by different processes in the related art, some handling is required between the two processes. This handling between the processes causes a problem to the organic light-emitting device, the efficiency of which is significantly sensitive to a minute defect.
[0015] The information disclosed in the Background of the Invention section is provided only for better understanding of the background of the invention and should not be taken as an acknowledgment or any form of suggestion that this information forms a prior art that would already be known to a person skilled in the art.
RELATED ART DOCUMENT
[0016] Patent Document 1: Korean Patent Application Publication No. 10-2012-0038214 (Apr. 23, 2012)
BRIEF SUMMARY OF THE INVENTION
[0017] Various aspects of the present invention provide a substrate for an organic light-emitting device which not only improves light extraction efficiency but also has superior productivity and fabrication efficiency, a method of fabricating the same and an organic light-emitting device including the same.
[0018] In an aspect of the present invention, provided is a substrate for an organic light-emitting device which is disposed on one surface of the organic light-emitting device through which light from the organic light-emitting device is emitted. The substrate includes: a base substrate; a light-scattering layer disposed on the base substrate, the light-scattering layer including a number of light-scattering particles; and a transparent conductive film disposed on the light-scattering layer. A metal oxide that forms the transparent conductive film fills all or parts of a number of pores between the number of light-scattering particles.
[0019] According to an embodiment of the present invention, the transparent conductive film may serve as a transparent electrode of the organic light-emitting device.
[0020] The transparent conductive film may be formed from ZnO to which a dopant is added.
[0021] The light-scattering particles may be formed from at least one selected from the group consisting of ZnO, SiO 2 and TiO 2 .
[0022] The diameters of the light-scattering particles may range from 50 to 500 nm.
[0023] In another aspect of the present invention, provided is a method of fabricating a substrate for an organic light-emitting device which is disposed on one surface of the organic light-emitting device through which light from the organic light-emitting device is emitted. The method includes a first dry deposition step of forming a light-scattering layer by depositing light-scattering particles on a base substrate by dry deposition; and a second dry deposition step of forming a transparent conductive film by depositing a conductive metal oxide on the light-scattering layer by dry deposition.
[0024] According to an embodiment of the present invention, at the first dry deposition step, the light-scattering particles may be deposited on the base substrate using a precursor and an oxidizer, the precursor being selected from the group consisting of a ZnO precursor of diethyl zinc (DEZ), a SiO 2 precursor of tetraethyl orthosilicate (TEOS) and a TiO 2 precursor of titanium isoproxide (TTIP).
[0025] At the first dry deposition step, the oxidizer may be at least one of vapor of H 2 O and ozone.
[0026] At the first dry deposition step, a deposition temperature may be controlled to be in the range from 300 to 500° C.
[0027] In addition, at the second dry deposition step, the conductive metal oxide may be deposited on the light-scattering layer using an organic solvent of hydrocarbon, a ZnO precursor of diethyl zinc or dimethyl zinc and an oxidizer, the ZnO precursor being diluted in the organic solvent.
[0028] At the second dry deposition step, the oxidizer may be at least one of vapor of H 2 O and ethanol.
[0029] At the second dry deposition step, a deposition temperature may be controlled to be in the range from 250 to 550° C.
[0030] The second dry deposition step may include adding a dopant to the metal oxide.
[0031] The dry deposition may be chemical vapor deposition (CVD).
[0032] The chemical vapor deposition may be atmospheric pressure chemical vapor deposition (APCVD).
[0033] The first dry deposition step and the second dry deposition step may be continuously carried out in-line on a conveyor belt.
[0034] In a further aspect of the present invention, provided is an organic light-emitting device that includes: a base substrate; a light-scattering layer disposed on the base substrate, the light-scattering layer including a number of light-scattering particles; an anode disposed on the light-scattering layer, the anode being formed from a transparent conductive film; an organic light-emitting layer disposed on the anode; and a cathode disposed on the organic light-emitting layer. A metal oxide that forms the transparent conductive film fills all or parts of a number of pores between the number of light-scattering particles.
[0035] According to embodiments of the present invention, since light-scattering particles and a transparent conductive film (TCO) are continuously deposited in-line on a base substrate in a dry deposition process, it is possible to improve productivity and efficiency in the fabrication of a substrate for an organic light-emitting device. In particular, since the transparent conductive film which serves as the anode of the organic light-emitting device is formed at the step of fabricating the substrate, it is possible to simplify future diode fabrication processes.
[0036] In addition, since the light-scattering particles form a layer in front of the organic light-emitting diode, it is possible to improve the light extraction efficiency of the organic light-emitting device.
[0037] Furthermore, the light-scattering particles can be uniformly dispersed on the base substrate by atmospheric pressure chemical vapor deposition (APCVD).
[0038] In addition, since the light-scattering particles are bonded to the base substrate via the transparent conductive film deposited by APCVD, it is possible to achieve structural stability.
[0039] Furthermore, since the transparent conductive film serves as both a matrix layer for the light-scattering particles and the electrode of the organic light-emitting device, it is possible to dispense with the related-art planarization layer disposed on one surface of the organic light-emitting device that is in contact with the transparent electrode, thereby simplifying the fabrication process. Since the planarization layer is omitted, the light-scattering particles are disposed closer to the organic light-emitting layer of the organic light-emitting device, whereby the ability of the light-scattering particles to improve light extraction efficiency can be further enhanced.
[0040] The methods and apparatuses of the present invention have other features and advantages which will be apparent from, or are set forth in greater detail in the accompanying drawings, which are incorporated herein, and in the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a cross-sectional view showing a substrate for an organic light-emitting device according to an exemplary embodiment of the present invention, the substrate being disposed on one surface of an organic light-emitting device through which light from the organic light-emitting device is emitted;
[0042] FIG. 2 is a schematic view showing the processes of a method of fabricating the substrate for the organic light-emitting device according;
[0043] FIG. 3 is electron microscopy pictures showing light-scattering layers; and
[0044] FIG. 4 is electron microscopy pictures showing transparent conductive layers.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Reference will now be made in detail to a substrate for an organic light-emitting device, a method of fabricating the same and an organic light-emitting device including the same according to the present invention, embodiments of which are illustrated in the accompanying drawings and described below, so that a person skilled in the art to which the present invention relates can easily put the present invention into practice.
[0046] Throughout this document, reference should be made to the drawings, in which the same reference numerals and signs are used throughout the different drawings to designate the same or similar components. In the following description of the present invention, detailed descriptions of known functions and components incorporated herein will be omitted when they may make the subject matter of the present invention unclear.
[0047] As shown in FIG. 1 , a substrate 100 for an organic light-emitting device according to an exemplary embodiment is disposed on one surface of an organic light-emitting device through which light from the organic light-emitting device is emitted in order to improve the light extraction efficiency of the organic light-emitting device. The substrate 100 for the organic light-emitting device includes a base substrate 110 , a light-scattering layer 120 and a transparent conductive film 130 .
[0048] Although not specifically shown, the organic light-emitting diode 10 has a multilayer structure in which an anode, an organic light-emitting layer and a cathode are sandwiched between the base substrate 110 according to this exemplary embodiment and another substrate that faces the base substrate 110 . In this case, the transparent conductive film 130 according to this exemplary embodiment serves as the anode, i.e. the transparent electrode of the organic light-emitting diode 10 . According to this exemplary embodiment, the anode can be formed from ZnO to which a dopant is added. In addition, the cathode can be formed from a metal thin film of Al, Al:Li or Mg:Ag which has a smaller work function in order to facilitate the electron injection. The organic light-emitting layer can includes a hole injection layer, a hole transport layer, an emissive layer, an electron transport layer and an electron injection layer which are sequentially stacked on the anode. When the organic light-emitting diode 10 according to this exemplary embodiment is a white organic light-emitting diode that is applied for lighting, the light-emitting layer can have, for example, a multilayer structure that includes a high-molecular light-emitting layer which emits blue light and a low-molecular light-emitting layer which emits orange-red light. The light-emitting layer can also have a variety of other structures to emit white light. In addition, the organic light-emitting diode 10 can have a tandem structure. Specifically, the organic light-emitting diode 10 can include a plurality of organic light-emitting layers and interconnecting layers which alternate with the organic light-emitting layers.
[0049] With this structure, when a forward voltage is induced between the anode and the cathode, electrons from the cathode migrate to the emissive layer through the electron injection layer and the electron transport layer, and holes from the anode migrate to the emissive layer through the hole injection layer and the hole transport layer. The electrons and holes that have migrated into the emissive layer recombine with each other, thereby generating excitons. When these excitons transit from an excited state to a ground state, light is emitted. The brightness of the light emitted is proportional to the amount of current that flows between the anode and the cathode.
[0050] The base substrate 110 supports the light-scattering layer 120 and the transparent conductive film 130 which are disposed on one surface thereof. The base substrate 110 also serves as an encapsulation substrate which is disposed on one surface of the organic light-emitting device through which light from the organic light-emitting device is emitted, in order to allow the light from the organic light-emitting device to exit while protecting the organic light-emitting diode 10 from the external environment.
[0051] The base substrate 110 may be any transparent substrate that has superior light transmittance and mechanical properties. For example, the base substrate 110 can be formed from a polymeric material, such as a heat or ultraviolet (UV) curable organic film, or a chemically strengthened glass, such as a soda-lime glass (SiO 2 —CaO—Na 2 O) or an aluminosilicate glass (SiO 2 —Al 2 O 3 —Na 2 O)). When the organic light-emitting device including the organic light-emitting diode 10 and the light extraction substrate 100 according to this exemplary embodiment is applied for lighting, the base substrate 110 can be formed from the soda-lime glass. The base substrate 110 may be a substrate that is formed from a metal oxide or a metal nitride. The base substrate 110 can be formed from a piece of thin glass having a thickness of 1.5 mm or less. The thin glass can be made by a fusion process or a floating process.
[0052] The light-scattering layer 120 is disposed on the base substrate 110 . The light-scattering layer 120 is formed as a layer of a number of light-scattering particles 121 which is uniformly distributed. The light-scattering layer 120 serves to improve the light extraction efficiency of the organic light-emitting device by diversifying paths along which the light from the organic light-emitting device is emitted. According to this exemplary embodiment, the scattering layer 120 is closer to the organic light-emitting layer of the organic light-emitting diode 10 than in the related art since the transparent conductive film 130 serving as the anode of the organic light-emitting diode 10 is directly disposed on the light-scattering layer 120 . Accordingly, the ability of the light-scattering layer 120 to improve light extraction efficiency by scattering light can be further enhanced.
[0053] The light-scattering layer 120 according to this exemplary embodiment is the layer in which the number of light-scattering particles 121 are arranged. The bonding force between the light-scattering layer 120 and the base substrate 110 is maintained only by van der Waals force. Pores are formed between the light-scattering particles 121 . Some or all of the pores can be filled with ZnO, the metal oxide of the transparent conductive film 130 . The bonding between the ZnO and the base substrate 110 allows the light-scattering layer 120 to more reliably maintain its shape on the base substrate 110 . The phenomenon in which the pores of the light-scattering layer 120 are filled with the metal oxide of the transparent conductive film 130 occurs during the process of forming the transparent conductive film 130 on the light-scattering layer 120 by chemical vapor deposition (CVD). This will be described in more detail later in relation to the method of fabricating an substrate for an organic light-emitting device. The remaining pores that are not filled with the ZnO serve to scatter light like the light-scattering particles 121 .
[0054] According to this exemplary embodiment, the number of light-scattering particles 121 can be formed from at least one selected from among, but not limited to, ZnO, SiO 2 and TiO 2 . The diameters of the light-scattering particles 121 may range from 50 to 500 nm. It is preferred that the light-scattering particles 121 have a variety of diameters within this range in order to realize a better light-scattering effect.
[0055] The transparent conductive film 130 is disposed on the light-scattering layer 120 . The metal oxide of the transparent conductive film 130 occupies some of the pores defined between the light-scattering particles 121 of the light-scattering layer 120 , and during this process, comes into contact with the base substrate 110 . In the structural aspect, the light-scattering layer 120 is disposed inside the transparent conductive film 130 , more particularly, inside the lower layer portion of the transparent conductive film 130 which forms the boundary to the base substrate 110 . In addition, the upper layer of the transparent conductive film 130 is made only of the metal oxide. Accordingly, the transparent conductive film 130 has dual structural roles as a matrix layer which fixes the light-scattering particles 121 therein and as the anode of the organic light-emitting diode 10 . Since the substrate 100 for the organic light-emitting device according to this exemplary embodiment is provided with the transparent conductive film 130 which serves as the anode of the organic light-emitting diode 10 , the fabrication process for the organic light-emitting diode 10 can be simplified.
[0056] The transparent conductive film 130 according to this exemplary embodiment can be formed from ZnO to which a dopant is added. The dopant can be, for example, Ga or Al.
[0057] A description will be given below of the method of fabricating an substrate for organic light-emitting device with reference to FIG. 2 .
[0058] The method of fabricating the substrate for the organic light-emitting device includes a first dry deposition step and a second dry deposition step.
[0059] First, as shown in FIG. 2 , the first dry deposition step is carried out by forming a light-scattering layer 120 by depositing light-scattering particles 121 on a base substrate 110 by a dry deposition process. The dry deposition process can be chemical vapor deposition (CVD). In particular, according to this exemplary embodiment, the first dry deposition step can be carried out by atmospheric pressure chemical vapor deposition (APCVD). Accordingly, at the first dry deposition step, first, the base substrate 110 is loaded into a deposition chamber (not shown). The base substrate 110 can be heated in order to improve the deposition efficiency of the light-scattering particles 121 . Afterwards, one selected from among a ZnO precursor of diethyl zinc (DEZ), a SiO 2 precursor of tetraethyl orthosilicate (TEOS) and a TiO 2 precursor of titanium isoproxide (TTIP) and an oxidizer which are supposed to form the light-scattering particles 121 are supplied into a deposition chamber (not shown). The oxidizer can be at least one of vapor (H 2 O) and ozone (O 3 ). At the first dry deposition step, it is preferred that the deposition temperature be controlled to be in the range from 300 to 500° C. When the light-scattering particles 121 are deposited on the base substrate 110 by APCVD at the first dry deposition step, a number of the light-scattering particles 121 is uniformly distributed on the base substrate 110 and forms into a layer, whereby the light-scattering layer 120 is made. FIG. 3 is electron microscopy pictures showing light-scattering layers that are deposited by this process.
[0060] Afterwards, the second dry deposition step is carried out by forming a transparent conductive film 130 by depositing a conductive metal oxide on the light-scattering layer 120 by APCVD as at the first dry deposition step. At the second dry deposition step, the base substrate 110 which was initially loaded into the deposition chamber (not shown) for the first dry deposition step continues to be positioned on a conveyor belt 20 inside the deposition chamber (not shown). Accordingly, after the first dry deposition step, the base substrate 110 with the light-scattering layer 120 formed thereon is carried on the conveyor belt 20 for the second dry deposition step. According to this exemplary embodiment, the first dry deposition step and the second dry deposition step are continuously carried out in-line using the conveyor belt 20 . This can consequently improve productivity in the fabrication of a substrate 100 for an organic light-emitting device.
[0061] At the second dry deposition step, the base substrate 110 can be heated as at the first dry deposition step. Afterwards, according to this exemplary embodiment, an organic solvent of hydrocarbon such as oxtane is supplied, together with a ZnO precursor which are diluted in the organic solvent and an oxidizer, into the deposition chamber (not shown). The ZnO precursor may be diethyl zinc (DEZ) or dimethyl zinc (DMZ). The oxidizer can be at least one of vapor (H 2 O) and ethanol. In addition, at the second dry deposition step, it is preferred that the deposition temperature be controlled to be in the range from 250 to 550 ° C. Since this exemplary embodiment forms the transparent conductive film 130 serving as the anode of the organic light-emitting diode ( 10 in FIG. 1 ) on the light-scattering layer 120 , ZnO may be doped by injecting a dopant into the deposition chamber (not shown) while ZnO is being deposited or by ion implantation after the deposition of ZnO. The dopant can be Ga or Al. FIG. 4 is electron microscopy pictures showing transparent conductive layers that are formed by this process.
[0062] In the process of depositing the transparent conductive film 130 on the light-scattering layer 120 , the material that forms the transparent conductive film 130 , i.e. ZnO, can be disposed between the number of light-scattering particles 121 . This leads to a configuration in which the light-scattering layer 120 is disposed inside the transparent conductive film 130 . Thus, the light-scattering layer 120 which otherwise is fixed to the upper surface of the base substrate 110 only by van der Waals force can be more reliably fixed thereto, thereby achieving structural stability.
[0063] When the second dry deposition step is completed in this manner, the substrate 100 for the organic light-emitting device according to this exemplary embodiment is fabricated.
[0064] As set forth above, the method of fabricating the substrate for the organic light-emitting device can continuously deposit the light-scattering particles 121 and the transparent conductive film 130 on the base substrate 110 by the in-line process of the dry deposition process such as CVD, thereby improving productivity and efficiency in the fabrication of the substrate 100 . It is also possible to form the transparent conductive film 130 which serves as the anode of the organic light-emitting diode ( 10 in FIG. 1 ) and the matrix layer of the light-scattering particles 121 , thereby simplifying future diode fabrication processes.
[0065] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented with respect to the drawings. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible for a person having ordinary skill in the art in light of the above teachings.
[0066] It is intended therefore that the scope of the present invention not be limited to the foregoing embodiments, but be defined by the Claims appended hereto and their equivalents.
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The present invention relates to a substrate for an organic light-emitting diode, a method for manufacturing the same, and an organic light-emitting diode comprising the same, and more particularly, to a substrate for an organic light-emitting diode, the substrate having excellent productivity and manufacturing efficiency as well as an improved light extraction efficiency, a method for manufacturing the same, and an organic light-emitting diode comprising the same. To this end, the present invention provides a substrate for an organic-light emitting diode, the substrate being disposed on one side of the organic light-emitting diode from which light irradiated thereby is emitted outside, the substrate comprising: a base plate; a light-scattering layer comprising a plurality of light-scattering particles, the light-scattering layer being formed on the base plate; and a transparent conductive film formed on the light-scattering layer, wherein a part of, or all of the pores formed between the plurality of light-scattering particles are filled with metal oxides forming the transparent conductive film; a method for manufacturing the same; and an organic light-emitting diode comprising the same.
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BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The present invention relates to a cooler module and more particularly to a combination cooler module in which the base and the radiating fins are fastened together by a dovetail, hook or scarf joint.
[0003] (b) Description of the Prior Art
[0004] A conventional cooler module is known to comprise a plurality of aluminum or copper radiating fins, a plurality of heat tubes, and a base (copper base). The radiating fins are arranged in parallel. The heat tubes are inserted through the radiating fins to hold the radiating fins in parallel. Further, the heat tubes are soldered to the base by means of the application of a bonding medium, for example, solder paste. If the heat tubes and the base are made of different materials, a nickel-plating treatment is necessary before bonding the heat tubes to the base. This assembly process is complicated, resulting in a high manufacturing cost and low yield. Further, this assembly process will also lower the heat transfer efficiency between the base and the heat tubes.
[0005] When using the aforesaid cooler module, a frame holder may be affixed to the radiating fins to hold a cooling fan.
SUMMARY OF THE INVENTION
[0006] The present invention has been accomplished under the circumstances in view. According to the present invention, the combination cooler module comprises a plurality of radiating fins arranged in a stack, a plurality of heat tubes inserted through the radiating fins, and a heat conductive base fastened to the radiating fins and disposed in contact with the heat tubes, wherein male coupling means and corresponding female coupling means are provided at the radiating fins and the base for enabling the base to be affixed to the radiating fins by forcing the male coupling means into engagement with the female coupling means.
[0007] More precisely, male coupling means may be provided at either the radiating fins or the base, with corresponding female coupling means provided at the base or the radiating fins. Furthermore, both male coupling means and female coupling means may be provided at the radiating fins, with corresponding female coupling means and male coupling means provided at the base. The male coupling means and female coupling means may be arranged symmetrically or asymmetrically.
[0008] In one embodiment of the present invention, the male coupling means comprises a plurality of hooked portions downwardly extending from the radiating fins; the female coupling means comprises a plurality of locating grooves formed in the base and respectively forced into engagement with the hooked portions at the radiating fins.
[0009] In another embodiment of the present invention, the male coupling means comprises a plurality of protruded portions respectively protruded from the radiating fins and the base; the female coupling means comprises a plurality of locating grooves respectively formed in the radiating fins and the base; the protruded portions of the male coupling means at the radiating fins and the locating grooves of the female coupling means at the radiating fins are respectively forced into engagement with the locating grooves of the female coupling means at the base and the protruded portions of the male coupling means at the base.
[0010] In still another embodiment of the present invention, the male coupling means comprises at least one dovetail tongue provided at the radiating fins (or the base); the female coupling means comprises at least one dovetail groove provided at the base (or the radiating fins) and respectively forced into engagement with the at least one dovetail tongue.
[0011] In still another embodiment of the present invention, the radiating fins include a plurality of first radiating fins, a plurality of second radiating fins, and a plurality of third radiating fins, the first, second and third radiating fins each having a plurality of upper mounting through holes, the first and third radiating fins each further having a plurality of lower mounting through holes, the second radiating fins each further having a plurality of circularly arched bottom notches; the heat tubes are inserted through the upper mounting through holes and the lower mounting through holes of the radiating fins and attached to the circularly arched bottom notches of the radiating fins.
[0012] In still another embodiment of the present invention, the male coupling means comprises two engagement bars, the engagement bars each being formed of a plurality of protruding strips respectively downwardly protruded from the radiating fins at a bottom side; the female coupling means comprises two engagement grooves bilaterally formed in the base and respectively forced into engagement with the protruding strips of the engagement bars.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an exploded view of a combination cooler module according to a first embodiment of the present invention.
[0014] FIG. 2 is a schematic assembly view of the combination cooler module according to the first embodiment of the present invention before fixation.
[0015] FIG. 3 is a schematic assembly view of the combination cooler module according to the first embodiment of the present invention after fixation.
[0016] FIG. 4 is an perspective view of the combination cooler module according to the first embodiment of the present invention.
[0017] FIG. 5 is an exploded view of a combination cooler module according to a second embodiment of the present invention.
[0018] FIG. 6 is a schematic assembly view of the combination cooler module according to the second embodiment of the present invention.
[0019] FIG. 7 is a schematic assembly view of a combination cooler module according to a third embodiment of the present invention.
[0020] FIG. 8 is an exploded view of FIG. 7 .
[0021] FIG. 9 is a schematic assembly view of a part of a combination cooler module according to a fourth embodiment of the present invention.
[0022] FIG. 10 is a schematic assembly view of a part of a combination cooler module according to a fifth embodiment of the present invention.
[0023] FIG. 111 is a schematic assembly view of a part of a combination cooler module according to a sixth embodiment of the present invention.
[0024] FIG. 12 is a perspective view of a radiating fin for a combination cooler module according to a seventh embodiment of the present invention.
[0025] FIG. 13 is an exploded view of the combination cooler module according to the seventh embodiment of the present invention.
[0026] FIG. 14 is a schematic end view showing the combination cooler module of the seventh embodiment of the present invention assembled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring to FIGS. 1 ˜ 4 , a combination cooler module in accordance with a first embodiment of the present invention comprises a plurality of radiating fins 1 , a plurality of heat tubes 2 , and a base 3 .
[0028] The radiating fins 1 are flat metal sheet members arranged in a stack, each having a plurality of upper mounting through holes 11 . Some radiating fins 1 further have a plurality of lower mounting through holes 12 and two bottom hooked portions 14 . Further, some radiating fins 1 that have bottom hooked portions 14 have a series of circularly arched bottom notches 13 arranged between the respective bottom hooked portions 14 .
[0029] The heat tubes 2 are metal U-tubes, each having the two distal ends closed and a working fluid filled therein. The heat tubes 2 are respectively inserted through the upper mounting through holes 11 and lower mounting through holes 12 of the radiating fins 1 .
[0030] The base 3 is a plate member made out of copper, aluminum, or any of a variety of heat conductive materials, having two vertical sidewalls 32 , two locating grooves 321 respectively formed in the top side of the vertical sidewalls 32 and extending along the length of the vertical sidewalls 32 , and a plurality of positioning grooves 31 formed in the top surface and extending to the front and rear sides. The positioning grooves 31 have a circularly arched cross section. The two vertical sidewalls 32 have the front and rear sides respectively protruded over the front and rear sides of the positioning grooves 31 , therefore the base 3 shows an H-shaped cross section.
[0031] During assembly process, the heat tubes 2 are inserted with the respective two distal ends through the upper mounting through holes 11 and lower mounting through holes 12 and peripherally attached to the circularly arched bottom notches 13 to join the radiating fins 1 , and then the base 3 is attached to the heat tubes 2 and the radiating fins 1 to force the positioning grooves 31 toward the heat tubes 2 , and then a pressure is applied to the base 3 against the heat tubes 2 and the radiating fins 1 to force the positioning grooves 31 of the base 3 into engagement with the periphery of the heat tubes 2 and to simultaneously force the locating grooves 321 of the base 3 into engagement with the bottom hooked portions 14 of the radiating fins 1 (see FIG. 3 ).
[0032] FIGS. 5 and 6 show a combination cooler module in accordance with a second embodiment of the present invention. This embodiment is substantially similar to the aforesaid first embodiment with the exception of the location of the locating grooves 321 at the vertical sidewalls 32 of the base 3 . This embodiment is assembled in the same manner as the aforesaid first embodiment.
[0033] FIGS. 7 and 8 show a combination cooler module in accordance with a third embodiment of the present invention. According to this embodiment, the radiating fins 1 each have two bottom protrusions 15 that define with the bottom edge of the respective radiating fin a dovetail groove, and the base 3 has a corresponding dovetailed cross section that is forced into engagement with the dovetail groove between the two bottom protrusions 15 of each radiating fin 1 .
[0034] FIG. 9 is a schematic assembly view of a part of a combination cooler module according to a fourth embodiment of the present invention. According to this embodiment, the base 3 has an upper part forming a dovetail tongue 30 a that is forced into engagement with a corresponding dovetail groove 16 a at the bottom side of the radiating fins 1 .
[0035] FIG. 10 is a schematic assembly view of a part of a combination cooler module according to a fifth embodiment of the present invention. According to this embodiment, the radiating fins 1 each have two bottom dovetail tongues 17 a respectively forced into engagement with a corresponding dovetail groove 31 a at the base 3 .
[0036] FIG. 111 is a schematic assembly view of a part of a combination cooler module according to a sixth embodiment of the present invention. According to this embodiment, the radiating fins 1 and the base 3 are fastened together by means of a scarf joint 18 a / 32 a.
[0037] FIGS. 12 ˜ 14 show a combination cooler module in accordance with a seventh embodiment of the present invention assembled. According to this embodiment, the radiating fins 1 each have two bottom protruding strips 19 ; the base 3 has two engagement grooves 33 formed in the top surface and arranged in parallel at two sides of the positioning grooves 31 . When the radiating fins 1 are arranged in a stack, the bottom protruding strips 19 of the radiating fins 1 form two engagement bars that are forced into engagement with the engagement grooves 33 of the base 3 .
[0038] Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A combination cooler module is disclosed, which includes a plurality of radiating fins that are arranged in a stack, a plurality of heat tubes inserted through the radiating fins, and a heat conductive base affixed to the radiating fins by means of a dovetail joint, hook or scarf joint and disposed in contact with the heat tubes.
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BACKGROUND OF INVENTION
This invention relates to a light timing system that is portable and removable. Preprogramming light timing has been accomplished through the intervention of devices that control a light fixture at the wall receptacle through a lamp cord. One such design is disclosed for example in U.S. Pat. No. 4,575,659 issued to Pezzolo et al, on Mar. 11, 1986. Light timing has also been accomplished through the invention of devices that control a light fixture at the wall switch device, that either replaces the traditional conventional wall switch or a device that assists the wall switch to provide programming features. One such design is disclosed for example in U.S. Pat. No. 5,264,761 issued to Samuel Johnson, on Nov. 23, 1993.
One of the several disadvantages of the operation of the electrical control assemblies disclosed above is that in Pezzolo assembly designed to work only with fixtures that can be plugged into a wall receptacle. Eliminating the ability of circuit wired wall and ceiling fixtures from benefiting from a timed event sequence. A disadvantage of Johnson switch control device is that fixtures without a wall switch would not benefit from a timed event programming for light fixture control, examples would be considered traditional floor and table lamp fixtures with traditional power supply provided by plug cord wiring into a conventional wall receptacle, and inline circuit wired ceiling and wall fixtures that are operated by a simply pull chain that turn the power on and off at the fixture socket. Both Johnson and Pezzolo assemblies control their attached fixtures as a single unit, regardless of how many bulbs are contained and controlled in that said attached fixture. Whereas the general purpose and principal object of the present invention is to provide still further improvements in the art and technology of lighting fixture bulb control of the type described above. Another object of this invention is to provide a format, where all light fixtures that use screw type bulbs can have preprogrammed timed on/off lighting and can be preprogrammed for a special lighting effect by using the invention timer device attached to the bulb it controls, said device at the bulb attachment site would allow fixtures with multiple bulbs to have separate timed events for each bulb in a single fixture
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a light timing, event timing and light effects device that can control a single bulb (invention can accommodate a range of screw type bulb formats, e.g. Incandescent, fluorescent, halogen, etc. referred herein as “bulb”) at the fixture bulb position, (i.e. fixture bulb socket). That is, whereas the invention provides timed lighting control at the fixture bulb socket, control is provided after the power has passed through the fixture. That is, the invention positioned after the power is through the fixture provides for operation independent of the kind and type of power source, delivery line to the fixture, such as circuit wired fixtures, (i.e. hard wired ceiling and wall light fixtures) or temporary and movable fixtures such as, but not limited to table and floor lamps, said lamps are provided power through a conventional lamp cord plugged into an electrical wall receptacle as their power delivery line. Wherein, said power delivery lines can support a wide range of switch types, such as but not limited to a conventional wall toggle switch, wall push button switch, ceiling and wall pull chain switch, lamp turn switch, lamp pull chain switch and lamp post switch, to operate the lighting fixture, that is the invention with said at the bulb position will also operate independent of the above mentioned switch types. It is an additional object of the invention to provide a simple device for home or office that will provide an inline in-socket type timing device, said device provides a safe format for preprogrammed timed lighting in an electrical lighting fixtures. That is, said preprogrammed feature of the invention is controlled by an onboard time keeping assembly set like a conventional liquid crystal display watch, with two Timer modes that will turn a light on or off at a predetermined time. That is said time keeping assembly comprised of time circuits, time chip and rechargeable stored energy supply, said assembly is designed to maintain timing programs If power is interrupted to the light fixture, whereas the invention will continue to provide sequenced events when the power is restored without requiring a resetting of time and timer modes. Said time keeping assembly in a power-on electrical fixture extends the onboard stored energy supply by receiving a small continual recharge (i.e. trickle charge), while the fixture is receiving power through the fixture to the invention. Another feature of the invention, is the timed sequence and event programming is powered by its onboard rechargeable power source (i.e. rechargeable lithium battery), when power is interrupted or the timing assembly is not connected to an electrical lighting fixture. Whereas the time keeping assembly controls the power bridge to the bulb, that is the power bridge is opened when the timer preprogrammed ‘timeon’ is reached the power circuit is completed and the bulb attached to the timing assembly of the invention is lit, when the timer preprogrammed ‘timeoff’ is reached the power bridge is closed and the power circuit is interrupted to the bulb installed in the invention and the light goes out. The system of the invention was designed to support two timer modes that provide two timed lighting events in the same twenty-four hour period. That is, conventional electrical lighting fixtures supporting one or multiple screw type bulb sockets, will use the invention in one, all, or a select number of bulb sockets in said fixture, to provide independent light timing events at each bulb socket supporting the invention. At is said invention timing operation requires each invention unit to be screwed into a standard electrical light socket, then to have a light bulb it will control screwed into the invention, therefore the invention provides timing control at each bulb in the fixture socket that contains the invention. For a better understanding of the structure of the invention and its function, further explanation is given below with reference to the attached drawings. The invention is not limited, however, to the particular arrangement portrayed in the subject drawing figures. That is, where a cylindrical configuration is preferred, the interior circuit assemblies of the invention need not be limited to cylindrical shape of the timing assembly and may, instead, be configured in a variety of alternate shapes.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and other advantages of the present invention will be more fully understood from the following DESCRIPTION OF PREFERRED EMBODIMENTS with a detailed description and reference to the appended drawings, wherein:
FIG. 1 is a front elevation view of the inline in-socket screw type timing assembly (referred to herein as the “timing assembly”), highlighting socket contact for the hot lead connection of electrical service provided through the fixture ( 1 ), Socket screw designed metal fitting, to fit into electrical fixture's bulb socket ( 2 ), Right set button that displays time features ( 3 ), Liquid Crystal Display screen ( 4 ), Opening in unit bottom to receive socket end of light bulb ( 5 ), Lower half of timing assembly ( 6 ), Left set button to select mode settings ( 7 ), Upper half of timing assembly body ( 8 ).
FIG. 2 is a close-up front elevation of the timing assembly, illustrating the relative position of the liquid crystal display and the set button formats, shown in FIG. 1
FIG. 3 is a front elevation see-through view of the lower portion of the timing assembly shown in FIG. 1
FIG. 4 is a front elevation see-through view of the lower portion of the timing assembly shown in FIG. 3 with a bulb installed in the proper position in the timing assembly.
FIG. 5 is a top perspective view of the timing assembly in FIG. 1, with the top portion of the timing assembly open, illustrating relative position of time keeping assembly and power storage unit.
FIG. 6 is an exploded view of the timing assembly sections shown in FIG. 1, illustrating the orientation of the timing assembly main connection sections.
FIG. 7 is a cutaway views of the timing assembly shown in FIG. 1 illustrating the upper and lower sections, highlighting power transfer metal strip hot lead
FIG. 8 is a plan view of open timing assembly, lower portion, illustrating relative positions of power and time keeping assemblies.
FIG. 9 is a front elevation view of timing assembly shown in FIG. 1, with light bulb, ready to be screwed into any light socket.
FIG. 10 is a diagram view of timing assembly shown in FIG. 1 illustrating an electrical socket containing the timing assembly shown in FIG. 1 attached inline in-socket to a ceiling or wall permanent fixture controlled by a conventional wall switch.
FIG. 11 is a front elevation view of timing assembly shown in FIG. 1, with light bulb in the timing assembly, and said timing assembly installed in a table or floor lamp fixture controlled by a lamp socket post switch.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention is therefore directed to an inline in-socket time control assembly to provide time sequencing and time lighting effects for electrical fixtures, that said invention will provide timing control at the bulb socket position in an electrical fixture, and said assembly can control multiple bulbs in a single fixture independently controlled by a novel socket installed timing assembly comprised of a time keeping assembly, a power storage cell, and a programmable event and sequence assembly.
Turning now to a description of the components illustrated in the drawing figures, which is therefore followed by a discussion of how these various components work together in the invention.
FIG. 1 shows the timing assembly unit illustrating the central socket contact ( 1 ), for receiving the hot lead of the electrical service brought through the fixture, to said fixture bulb socket containing said timing assembly, shown is a socket screw designed metal fitting ( 2 ), said fitting illustrated, to show screw type portion of the timing assembly that provides a screw type fit into said electrical fixture's bulb socket, to conduct neutral electrical current through the fixture to the timing assembly to the bulb controlled by said timing assembly therefore lighting said bulb during the programmed timeon selected time for the duration of the selected timeon period, also illustrating the relative position of the right set button ( 3 ), that is, said right set button provides entry connection to program timing assembly features such as; time set, timer 1 set, timer 2 set, and effects set viewed through liquid crystal display ( 4 ), liquid crystal display screen for time and timer settings ( 4 ), shown is the entrance opening in the timing assembly ( 8 ), to receive socket end of light bulb to be controlled by said timing assembly, shown is the lower half of the timing assembly body ( 6 ), containing assembly components such as; power chip, time chip, LCD, programming buttons, lithium battery, socket to receive light bulb, shown is left set button ( 7 ), in position left of liquid crystal display ( 4 ), to select time and timer settings and select hour of day to provide program time control at the bulb socket position ( 5 ), shown is the upper half of timing assembly ( 8 ), containing socket connection that places the timing assembly in the electrical fixture bulb socket providing AC power that has moved through the fixture to said timing assembly, wherein said timing assembly control the bulb installed in receiving socket ( 5 ).
FIG. 2 provides a close-up view of the timing assembly liquid crystal display screen ( 4 ) and the relative position of the right set button ( 3 ), that is, said right set button provides entry connection to program timing assembly features such as; time set, timer 1 set, timer 2 set, and effects set viewed through liquid crystal display ( 4 ), and the left set button ( 7 ), in position left of liquid crystal display ( 4 ), to select time and timer settings and select hour of day to provide program time control at the bulb socket position ( 5 ), shown is the upper half of timing assembly ( 8 ), containing socket connection that places the timing assembly in the electrical fixture bulb socket, providing AC power that has moved through the fixture to said timing assembly, wherein said timing assembly control the bulb installed in receiving socket ( 5 ).
FIG. 3 is a see-through view of the timing assembly shown in FIG. 1, highlighting socket contact entrance opening in the timing assembly ( 5 ), to receive socket end of light bulb to be controlled by said timing assembly, shown is the screw type connection of upper and lower halves of timing assembly body ( 9 ), this screw connection allows entrance into the timing assembly to replace exhausted stored energy cell (i.e. lithium battery), also shown is the metal screw insert ( 10 ), that will receive socket end of light bulb the said timing assembly will control.
FIG. 4 is a see-through view of the timing assembly as shown in FIG. 3, illustrating the relative position of the light bulb ( 11 ), controlled by said timing assembly in the proper position, shown in the entrance opening in the timing assembly ( 5 ), to receive socket end of light bulb ( 11 ), to be controlled by said timing assembly, whereas, said receiving metal screw insert ( 10 ), that will receive socket end of light bulb the said timing assembly will control power delivery to said bulb ( 11 ).
FIG. 5 provides a perspective view of the timing assembly in FIG. 1, in an open position, illustrating the separation of the two main sections, said sections are opened and secured at the screw thread section ( 9 ), upper section shown is the upper half of timing assembly ( 8 ), containing socket connection that places the timing assembly in the electrical fixture bulb socket, providing AC power that has moved through the fixture to said timing assembly, wherein said timing assembly control the bulb installed in receiving socket ( 5 ), shown is the lower half of the timing assembly body ( 6 ), containing assembly components such as; power chip, time chip, LCD, programming buttons, lithium battery, socket to receive light bulb ( 11 ), shown is left set button ( 7 ), in position left of liquid crystal display ( 4 ), to select time and timer settings and select hour of day to provide program time control at the bulb socket position ( 5 ), also shown is power chip ( 12 ) and stored energy cell (i.e. lithium battery) ( 21 ).
FIG. 6 illustrates an exploded view of the timing assembly shown in FIG. 1, show are the sections that provide power to said timing assembly, socket contact for hot lead of electrical service ( 1 ), Socket screw designed metal fitting, to fit into electrical fixtures bulb socket, to conduct neutral electrical current ( 2 ), also shown is the section providing power to the bulb controlled by said timing assembly, shown in the entrance opening in the timing assembly ( 5 ), to receive socket end of light bulb FIG. 4 ( 11 ), to be controlled by said timing assembly, whereas, said receiving metal screw insert ( 10 ), that will receive socket end of light bulb the said timing assembly will control power delivery to said bulb FIG. 4 ( 11 ).
Also show is the position of the right button that displays, time set, timer 1 set, timer 2 set, effects set and minute display ( 3 ), liquid crystal display screen for time and timer settings ( 4 ), opening in unit bottom to receive socket end of light bulb ( 5 ), Lower half of said timing assembly body, containing, power chip, time chip, LCD, programming buttons, lithium battery, socket to receive light bulb ( 6 ), left set button used to select time and timer settings and select hour of day ( 7 ), Upper half of timing assembly body, containing socket connection that delivers AC power to said timing assembly ( 8 ), screw type connection of upper and lower halves of timer body ( 9 ), Metal screw insert to receive socket end of light bulb ( 10 ), rechargeable lithium battery ( 21 )
FIG. 7 shows cutaway views of the upper and lower sections of the timing assembly in FIG. 1, highlighting power transfer metal strip hot lead ( 15 ), power transfer metal strip neutral lead ( 14 ), timer chip components ( 13 ), Also shown is socket contact for hot lead of electrical service ( 1 ), Socket screw designed metal fitting, to fit into electrical fixtures bulb socket, to conduct neutral electrical current ( 2 ), Right button that displays, time set, timer 1 set, timer 2 set, effects set and minute display ( 3 ), Liquid Crystal Display screen for time and timer settings ( 4 ), Opening in unit bottom to receive socket end of light bulb ( 5 ), Lower half of said timing assembly body, containing, power chip, time chip, LCD, programming buttons, lithium battery, socket to receive light bulb ( 6 ), Left button to select time and timer settings and select hour of day ( 7 ), Upper half of timing assembly body , containing socket connection that delivers AC power to timing assembly ( 8 ), screw type connection of upper and lower halves of timer body ( 9 ), Metal screw insert to receive socket end of light bulb ( 10 ), rechargeable lithium battery ( 21 )
FIG. 8 plan view of timing assembly components such as; power chip ( 12 ) and timer chip sections ( 13 ), right set program button ( 3 ), liquid crystal display screen for time and timer settings ( 4 ), left set program button to select time and timer settings and select hour of day ( 7 ), time keeping components ( 19 ), power circuit boards and power component transfer ( 20 ), stored energy cell (i.e. lithium battery) ( 21 ), neutral power contact ( 16 ), hot power contact ( 17 ) neutral contract power transfer bridge ( 18 ).
FIG. 9 provides a front elevation view of timing assembly shown in FIG. 1, with light bulb in the proper control position, said timing assembly with bulb in control position are ready to be screwed into any socket in an electrical light fixture, providing light on-off control and lighting effects at the bulb position, after the service power moves through said electrical fixture.
FIG. 10 is a diagram view of timing assembly shown in FIG. 1 illustrating an electrical socket containing the timing assembly shown in FIG. 1 to illustrate a typical attachment to a in-line circuit to a permanently affixed ceiling or wall fixture controlled by a conventional wall switch ( 22 ), whereas control of attached bulb is through said timing assembly receiving power that has been brought through the fixture to the fixture socket contacts.
FIG. 11 is a front elevation view of timing assembly shown in FIG. 1, with light bulb in a table or floor lamp fixture, power is brought through the fixture to the fixture socket contacts and control for lighting the attached bulb in the timing assembly is program controlled by said timing assembly, also show is a lamp socket post type switch ( 22 ).
As shown in the accompanying drawing figures, the timing assembly in FIG. 1, of the present invention is everything needed to provide timed lighting to a working electrical light fixture at the said fixture's electrical bulb socket, e.g., as ( 22 ) in FIG. 10 and FIG. 11 . The timing assembly in FIG. 1, of the invention is thus designed to provide, each bulb controlled by said timing assembly or a single bulb controlled by said timing assembly in an electrical fixture with, programmed timed lighting and lighting effects at the selected socket position. A light bulb controlled by the timing assembly in FIG. 1 e.g., as ( 11 ) in FIG. 4, the light bulb would be inserted into the timing assembly bottom opening FIG. 1 ( 5 ). FIG. 1 and place the bulb contacts in contact with screw thread assembly in FIG. 4 ( 10 ). Power is moved from the fixture socket to the timing assembly FIG. 4 ( 1 ) and ( 2 ) through the timing assembly FIG. 4 ( 10 ) and FIG. 8 ( 17 ), then to the controlled bulb FIG. 4 ( 11 ). Lighting control through said timing assembly in FIG. 1, provides an initial time set through the following procedure; depress right set button FIG. 2 ( 3 ), whereas depressing said button displays program options in liquid crystal display FIG. 2 ( 4 ), program option SET in liquid display FIG. 2 ( 4 ), begins program option selection, depressing left set button FIG. 2 ( 7 ) refines program option selection, SET displayed in the liquid crystal display FIG. 2 ( 4 ), left set button FIG. 2 ( 7 ), will refine selection for time keeping unit set for AM and PM time ranges by depressing said button once for AM and twice for PM range identification. That is, depressing the left set button twice when selecting SET and the time set will be PM, press the left set button once when selecting SET and the time set will be AM, said SET mode selected the left set button FIG. 1 ( 7 ), directs the Hour set and the right set button FIG. 1 ( 3 ), directs the Minute set, time selection is accomplished by depressing the left set and right set button FIG. ( 3 )( 7 ),simultaneously. Whereas time keeping remains constant and accurate through power supplied from stored energy cell (i.e. lithium battery) and constant supplemental recharge through trickle charge feature, when timing assembly is positioned in electrical fixture bulb socket. That is said timing assembly stored energy cell (i.e. lithium battery) FIG. 5 ( 21 ), providing constant and accurate time keeping function for an extended period (i.e. up to one year), without any outside power to recharge stored energy cell (i.e. lithium battery), said stored energy cell feature provides for continuous program set support, wherein said stored energy cell FIG. 7 ( 21 ), receives continuous energy recharge (i.e. trickle charge) through the electrical fixture socket that is supporting said timing assembly (e.g. as in FIG. 10 and FIG. 11 ), that is, stored energy cell FIG. 6 ( 21 ) receive continual recharge (i.e. trickle charge), that could extend timing assembly FIG. 1, time keeping function accurate for extended periods (i.e. two or more years), stored energy cell is replaceable by disconnecting the timing assembly from the electrical socket, pressing the side wall of said timing assembly unit body lower half FIG. 5 ( 6 ), and turning the lower half counter clockwise, once a new stored energy cell (i.e. lithium battery) is installed FIG. 5 ( 21 ) and FIG. 7 ( 21 ), repeat time SET sequence described above. Whereas powered time chip FIG. 8 ( 13 ), provides timing assembly with time keeping function accurate through normal powered operation, described above, whereas said time chip provides accurate time keeping for a time when the timing assembly unit experiences power interruptions. Timing assembly FIG. 1, allows for two timed event sequences in a twenty-four hour period. To set a timer depress the right set button FIG. 1 ( 3 ) until TIMER 1 appears in the display FIG. 1 ( 4 ), press the left set button FIG. 1 ( 7 ) to refine time selection, depress right set button until timeon appears in the display, pressing left set button selects timeon repeating this procedure for timeoff selection will complete one timed event range. To select the second timed event in a twenty four hour period (whereas, second timed event is not required), press the right set button FIG. 2 ( 3 ), until TIMER 2 appears in the display FIG. 2 ( 4 ), and repeat the Timer set sequence described above for TIMER 1 .
Referencing FIG. 1 timing assembly supports an EFFECT feature, whereas said feature selection through the following procedure; depressing the right set button FIG. 1 ( 3 ), until EFFECT appears in the liquid crystal display FIG. 2 ( 4 ), depress the left set button FIG. 1 ( 7 ) to select EFFECT, depress right set button FIG. 1 ( 3 ), until NORMAL appears in the display, depress left set button FIG. 1 ( 7 ), to select NORMAL., whereas said NORMAL setting provides basic, on and off timed operation of the bulb FIG. 4 ( 11 ), controlled by timing assembly in FIG. 1, everyday that power is provided to the light fixture FIG. 11, FIG. 10 containing timing assembly in one or all fixture sockets the timed lighting feature TIMER 1 and TIMER 2 control select bulbs at designated time ranges in a twenty four hour period. Wherein, the timing assembly in FIG. 1, provides DAYS feature a selection of one through seven days to provide programmed timed events, that is on and off timed operation of the bulb controlled by the said timing assembly, on select days that power is provided to the light fixture containing said timing assembly, at the TIMER 1 and TIMER 2 designated time. Depress the right set button FIG. 1 ( 3 ), until EFFECT appears in the display, depress left set button FIG. 1 ( 7 ), to select EFFECT, press right set button FIG. 1 ( 3 ), until DAYS appears in the display, depress left set button FIG. 1 ( 7 ), to select DAYS, numbers one through seven (1234567) will appear in liquid crystal display FIG. 2 ( 4 ), depress left set button FIG. 1 ( 7 ), highlight each day the timed program is required, after each day is highlighted depress right set button FIG. 1 ( 3 ), to select the day, that is said feature will allow the programmed time event on select days, wherein to cancel said feature select NORMAL and the time event will occur everyday as described above. That is the days feature provides timed events on programmed select days, without this feature selected up to two timed events in a twenty four hour period will be repeated every twenty four hours. In addition to the NORMAL and DAYS effect feature of the timing assembly, said assembly provides a DOT and DASH lighting effect the allows the timed sequence event to blink in a fast DOT sequence or the blink in a slower DASH sequence providing a decorative mode at each bulb controlled by a timing assembly. That is said DOT and DASH effect can be programmed with similar procedure used to select NORMAL on off operation described above. That is a timed operation of the bulb controlled by said timing assembly in FIG. 1, everyday that power is provided to the light fixture FIG. 10, 11 , containing said timing assembly at the TIMER 1 and TIMER 2 designated times under the NORMAL setting or on select days under the DAYS setting.
Wherein said timing assembly FIG. 1, shall be installed in the following procedure; that is to install said timing assembly, after setting time and features as described above, screw an light bulb FIG. 4 ( 11 ) into the timing assembly opening FIG. 3 ( 5 ), FIG. 4 shows the timing assembly and controlled bulb complete for installation in an electrical ceiling or wall fixture, in all or a select fixture socket to control select bulb operation, said fixture operated by a wall switch FIG. 10, or in a table or floor lamp powered through a lamp cord controlled at the lamp socket FIG. 11 .
Another feature of the present invention is the normal use of the fixture supporting one or many timing assemblies without removing said assemblies, by passing timed events and lighting effects is accomplished by turning the power supply off to said fixture as described below; to shut the timed sequence off and use the light in its usual manner, simply turn the switch FIG. 10 ( 22 ), 11 ( 22 ), on and off three consecutive times and the timing assembly will allow the bulb to operate from the switch FIG. 10 ( 22 ), 11 ( 22 ), without any timed programming. To restore the programmed timed sequence turn the switch FIG. 10 ( 22 ), 11 ( 22 ), on and off two consecutive times and said timing assembly will resume programmed timed sequence events and programmed lighting effects. That is said timing assembly remains in place while the fixture is used without timed lighting, said timing assembly passes the power through to the bulb.
Wherein the timing assembly is in the powered electrical socket FIGS. 10, 11 , the hot lead FIG. 7 ( 1 ), goes directly to the end of the light bulb FIG. 4 ( 11 ), but the neutral lead FIG. 7 ( 14 ), is held at the time chip FIG. 8 ( 16 ), until the programmed time allows the opening of the neutral lead FIG. 8 ( 18 ), to the light bulb completing the circuit and turning on the light. When the timeoff designated time is reached said time chip FIG. 8 ( 16 ) closes the bridge to the neutral lead and the circuit is broken shutting off the bulb. Timing assembly provides an in-socket-timing device for electrical lighting fixtures. That is at the bulb control provides control at separate bulbs in a single fixture at provide independent control of each separate bulb, controlled by said timing assembly.
It is to be understood that the present invention is not limited in scope by the exemplified embodiments which are intended as illustrations of single aspects of the invention, and embodiments and methods which are functionally equivalent are within the scope of the invention. Indeed various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description.
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A system for an individual bulb timing assembly for providing direct bulb timed on-off sequencing. A timing assembly that is installed directly into an electrical fixture bulb socket, that provides electrical power to an individual timing assembly, allowing each bulb directly controlled by a timing assembly to be preprogrammed, enabling timed sequence events at the bulb for selected electrical lighting fixtures. The timing assembly receives electrical power that has moved through the select fixture, the invention positioned after the power is through the fixture provides for operation independent of the kind and type of power source, delivery line to the fixture, and the kind and type of switching device controlling the select fixture. The system is programmable at the attached controlled bulb for two timed events in a twenty four hour period. Programmed event timing is protected by the timing assembly's onboard energy storage cell. Events can be programmed for seven separate unique continuous twenty four hour periods and can provide a timed sequencing and time light control for all, or a select number of bulbs in a single fixture. The system relates to inline electrical light fixtures, as well as all portable and temporary light fixtures, such as, but not limited to electrical lamps and extension lighting without the need for hard wiring the system.
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FIELD OF THE INVENTION
The present invention is related in general to casting. More specifically, the present invention is related to the casting of metal matrix composites.
BACKGROUND OF THE INVENTION
Low volume fraction metal matrix composites are just beginning to gain market acceptance. Aluminum matrix composites with silicon carbide are now being used in a variety of applications. These materials provide higher stiffness and increased wear resistance and are being used to replace aluminum, steel, and cast iron components. Some of these components include extrusions, forgings, and castings for industrial and automotive applications. Components such as pump housings, brake rotors, engine blocks, cylinder liners, and bicycle frames are some of the current aluminum/silicon carbide composite applications.
Low volume fraction metal matrix composite materials are typically produced by one of three methods, all of which include producing an ingot of material which is solidified and later remelted and formed into a component. The three methods used to produce these ingots are stirring, powder metallurgy, and infiltration.
Aluminum low volume fraction composites are being produced by Duralcan and other companies by mixing silicon carbide particles in a crucible using a low-vortex stirrer as described in U.S. Pat. No. 4,865,806, incorporated by reference herein. As disclosed in this patent, the material is mixed in a crucible in an evacuated atmosphere between 15 minutes and 2 hours, and then the stirring head is replaced with a casting head. After the casting head has been put in place, the surface of the liquid metal is pressurized with a gas to force the liquid composite mixture into a water-cooled ingot mold. Later the ingot is remelted and restirred and cast in the shape of a component.
This is a batch-type operation which requires stopping and opening the mixing machine at various times during the mixing to scrape reinforcement off the side walls and to switch heads. All the material must be mixed first. Then the mixing is stopped and ingots are formed, the mixed material is used up, and a new batch is made. In this process, the size of the batch is controlled by the size of the crucible. Typically, 100 lbs. or less of material is produced per batch due to the difficulty in uniformly mixing large volumes of material.
An alternative method used to produce composite ingots is powder metallurgy. For example, powder aluminum can be mixed with silicon carbide particulate and then cold and/or hot pressed to form an ingot. This method is currently being used by Alcoa and DWA, Inc. to produce low volume fraction composite ingots. These ingots may then be extruded or remelted for casting.
In the infiltration method to produce composite ingots, different processes, including gas pressure infiltration and pressureless infiltration, may be used a number of different ways to create a composite ingot. Infiltration can be used to create a highly loaded composite ingot which can be diluted in a melt to the desired particle loading. An alternative method is to infiltrate the reinforcement located in the bottom of a crucible and then stir the melt to cause the infiltrated reinforcement to disperse.
All of the current methods of producing low volume fraction metal matrix composite components involve first creating solidified low volume fraction ingots in a batch process, remelting them, and then forming a component. Typically, after solidification and formation of a composite ingot, the composite ingots are then remelted in a crucible and stirred to keep the reinforcement dispersed. The material is then cast into a mold to produce one or more components. After the crucible of material is spent, the casting process is stopped, and a new batch is made by melting additional composite ingots.
This batch-type process requires a large amount of labor and equipment to produce low or medium volumes of components. This process is not ideally suited for high volume continuous component production. Also, the two heating cycles, one to produce the composite ingot, and the other to reheat and cast, requires a high energy consumption, especially in the case of aluminum, which has a high heat of fusion. Current processes are therefore expensive due to the high energy consumption and too slow for mass production due to the batching operations required. Also, only a few materials are available from suppliers which gives the component producer little flexibility in choice of material systems.
SUMMARY OF THE INVENTION
The present invention is a method and system for producing a continuous supply of low volume fraction castable composite material and for forming components directly without the interim step of forming an ingot. The process can be used on a wide variety of composite systems and allows in-process system modification. By mixing liquid metal and reinforcement in a continuous process instead of a batch process, a single continuous output supply can be attained. Further, the invention requires that the matrix material, such as a metal be melted only once. When the metal reaches the correct liquid temperature, reinforcement is distributed uniformly throughout the liquid metal in a mixing device and cast directly into the shape of a component. This process can be monitored and optimized by adjusting the inputs during casting as part of an on-line process. The process also provides the lowest cost and highest flexibility because users can tailor the material system on-line to optimize specific properties. Further, users can buy the lowest cost raw materials and combine them directly to produce components without going through secondary operations or suppliers. The system can be used to produce a wide variety of different composite systems with different materials, different metals, different additives, and different reinforcements. Users are not limited to the one or two materials such as aluminum/silicon carbide available from the current suppliers. With this process and system, it is just as easy to make magnesium, iron, or polymer composite components with a wide variety of reinforcements and loading levels.
The invention allows for the direct metered input of raw materials, the capability to mix those materials together, and then produce a continuous supply of castable material for direct high volume component production. In this invention, the material is only heated once above the matrix melting temperature resulting in the lowest cost composite system with minimum interaction between matrix and reinforcement, minimal loss of alloying additions to the atmosphere, and minimum segregation of the reinforcement in the matrix.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings the preferred embodiment of the invention and the preferred methods of practicing the invention are illustrated in which:
FIG. 1 is a schematic representation showing a continuous output composite material mixer feeding low volume fraction composite material into casting molds.
FIG. 2 is a schematic representation showing a pressure caster with a continuous mixing system.
FIG. 3 is a schematic representation showing a pressure caster with a continuous mixing system supplying material into a mold.
FIGS. 4a and 4b are schematic representations showing continuous horizontal and angled mixers, respectively.
FIGS. 5a and 5b are schematic representations showing continuous mixing devices with metal feeding through the stirring blades.
FIGS. 6a-6c are schematic representations showing various forms of input materials.
FIGS. 7a-7d are schematic representations showing different continuous mixing and supply systems and a reservoir for filling castings.
FIGS. 8a and 8b schematic representations showing continuous mixing and supply systems installed into pressure casting equipment.
FIG. 9 is a schematic representation showing an outer view of a pressure caster with continuous composite supply mixer contained within.
FIG. 10 is a schematic representation showing the filling of a pressure casting reservoir with a supply of low volume fraction mixed composite.
FIG. 11 is a schematic representation showing a pressure caster fitted with a composite mixer and automatic input supply feeder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings herein like reference numerals refer to similar or identical parts throughout several views, and more specifically to FIG. 1 thereof, there is shown a cross-section of a continuous mixer device 13. Liquid metal 1 is supplied from a matrix reservoir 2 into a mixing container 3. Reinforcement material 4 is supplied from a reinforcement reservoir 5 in metered amounts into the mixing container 3. A low-vortex zone stirring mechanism 6 is used to distribute the reinforcement 4 into the liquid metal 1. As material flows downward through the mixing container 3 the reinforcement 4 becomes uniformly distributed by the time it reaches the bottom. Uniformly mixed composite material 7 flows out of the mixing container 3 and directly into the mold 8 to form a net shape composite component 9. The net shape composite component 9 is a component whose shape is used as cast without remelting the matrix for an application. A net-shape component, as known in the art, differs from an ingot in that an ingot is a round or square chunk and is used as raw material whereas a net-shape component has a specific shape.
Flow of the composite material 7 may be disrupted or controlled by a valve or stopper 10. Single or multi-zone heating elements 11 may be used to control the temperature of the composite material 7 as it moves through the continuous mixing container 3. The stirrer 6 preferably has individual paddles or blades 15 which serve to mix the composite material 7 in that area, but do not force material up or down, or create any vortexes. Material is drawn down through the container 7 as it is used. The output and inputs are controlled so that the appropriate mixing time occurs to achieve uniform mixing. Raw materials are put in such as metal 1 and reinforcement 4 to match the output so that the proper amount of composite material 7 is maintained in the mixing container 3. Raw material inputs of metal 1 and reinforcement 4 may be batch or continuously supplied. Input of raw materials may also be based on the volume used in filling molds 8 with a given part 9 volume. Inputs may also be determined by the material level in the container 3, the weight of the container 3, and/or the amount of time flow occurs with the plug 10 open. Molds 8 may be located on a conveyor 12 to move the molds 8 in position under the outlet 14 of the mixing container 3. Alternatively, the mixing crucible 3 may be moved to position it over the molds 8. The output of the mixing crucible may also be fed into a holding reservoir, pressure caster, pouring crucible, extruder, die casting machine, or squeeze casting machine as will be described.
FIG. 2 shows a cross section of a pressure caster 20 with continuous composite mixing mechanism 13. Column 21 has a cover 22 and a seal 23 such that the internal area may be pressurized through a supply line 36. Gas may be controlled through control valve 37. The cover 22 has a mixing motor 26 attached to a mixing blade 27 such that inputs 28 of metal 1 and reinforcement 4 can be metered through a control valve 25 into the mixing column 21. The pressure caster 20 may also include a level sensor 29 to monitor the-level of material inside the column 21 such that additional inputs 28 may be added as required. A number of inputs 28 may be fed through individual input ports 24. These input ports 24 can supply metered amounts of inputs 28 such as metal 1, ceramic reinforcement 4, or additives such as silicon or magnesium to produce the desired alloy and composite composition. Inputs 28 may be solid material or liquid of one or more types. Inputs 28 may be computer controlled for feeding in the appropriate amount of each input 28 to get the desired uniformly mixed composite 7. By tying and monitoring the output of the pressure caster 20 to the inputs 28, the inputs 28 can be automatically adjusted to achieve a desired result, such as continuous supply of a specific alloy, loading level, etc. This continuous supply of composite casting material has many advantages over previous batch-type processes which necessitated stopping and reloading.
The pressure caster 20 includes heating elements 30 which control the temperature within the mixing column 21 such that the matrix 1 is maintained at the desired temperature. Single or multi-zone heating may be used. The heating may be done with induction coils or resistive elements. Preferably, the heating elements 30 are copper water-cooled induction coils and the mixing column 21 is a graphite susceptor. The outer portion of the pressure casting vessel 20 has a metal protective cover 32 which helps to hold insulation 31 around the coils 30 and mixing column 21. The pressure caster has a supply Channel 33 emanating from the bottom and feeding a reservoir 34. The reservoir 34 includes a plunger 35 which can be lifted to allow the composite mixture 7 to flow into a mold 8. A vacuum may be pulled inside the mixing column 21 by removing gases through supply line 36. Nitrogen or other gases may be bubbled through the composite material mixture 7 to remove trapped or dissolved gases. For instance, nitrogen may be blown through the stirring rod 27. A hollow stirring rod 27 may be used and holes 16 may be located in the rod 27 to feed gas bubbles into the mix at desired locations. In addition, a separate tube may be fed into the composite mixture to supply gas. Gas may also be supplied through a cover gas inlet 38 and pulled through the feeder channel 33 by use of a vacuum within the mixing column 21.
FIG. 3 shows the pressure caster 20 being used to cast a component 9 within a mold 8. Uniformly mixed composite material 7 is forced out of the mixing column 21 through the feeder channel 33 by gas pressure supplied through line 36. Gas 41 acts on the surface of the composite mixture 7 such that it is forced out the feeder channel 33 into the reservoir 34. A cover gas supplied through inlet 38 may be used to keep the composite material 7 in the reservoir 34 from oxidizing. Plunger 35 is lifted such that the composite mixture 7 can flow into the mold 8 to form a component 9. Once the mold 8 is filled, the plunger 35 is lowered to stop the flow, then the pressure is removed through supply line 36 which causes the composite material 7 in the reservoir 34 to flow back into the feeder channel 33.
The output of the pressure caster 20 may be fed directly into a mold 8 or into another forming apparatus, such as a continuous casting die, a vacuum or die caster, squeeze caster, pelletizer, or extrusion machine. The pressure within the mixing column 21 may be used to feed mixed composite material 7 directly into a mold 8, thus utilizing the pressure to help form and densify the component 9. Alternatively, the gas pressure may be used to feed a reservoir and then gravity is used to feed material into a mold 8. Pressure caster 20 may be enclosed inside of a vacuum or pressure vessel. By pulling a vacuum on the encapsulating vessel, an evacuated state may be created inside the composite material 7 and the mixing column 21. By placing a gas such as nitrogen inside the encapsulating vessel, this gas may be pulled through the composite mixture 7 by lowering the pressure in the mixing column 21 through inlet 36.
FIG. 4a shows a cross section of a horizontal mixing chamber 50 in which inputs 28 of matrix 1 and reinforcement 4 are loaded into the feed end 51. The stirring rod 52 is connected to a stirring motor 53 which goes through an insulating and sealing block 54. The opposite end of the stirring rod 52 is supported by a bearing block 55. Heating elements 56 are used to control the temperature inside the mixing chamber 57. The stirring rod 52 keeps the particles suspended, and by using different designs of stirring blades 58, the composite material 7 can be moved towards the output end 59. As the composite material 7 moves through the mixing chamber 57 the reinforcement 4 becomes uniformly dispersed. The composite material output 60 may be controlled by a control valve 61 which uses a piston to align a hole in a graphite or ceramic rod 62 such that composite material 7 can flow out of the mixing chamber 57. By metering the output 60, inputs 28 can be adjusted such that a desired volume is maintained inside the mixing chamber 57. Input feed system 63 can comprise a conveyer feed system which loads controlled volumes of inputs 28 into the mixing chamber 57. Many different input metering systems are available to feed a desired volume into the mixing chamber 57.
FIG. 4b shows an angled mixing system 70 in which the volume of material is kept below the fill port 71 such that the stirring motor 53 does not need to be sealed. Angled mixing chamber 70 has a plunger 72 for controlling the output 60. Liquid metal 1 is being fed into the angled mixing chamber 70 along with reinforcement 4. A controlled output vibratory feeder 73 can be used to supply the desired amount of reinforcement 4. Liquid or solid metal 1 or other matrix materials may be fed into the angled mixing chamber 70. A ceramic or ceramic coated stirring rod 74 may include different stirring blade 75 at increasing frequency towards the output end 59 such that the material 7 becomes more uniformly mixed as it progresses down through the angled mixing chamber 70. This type of design minimizes the entrapment of gas by minimizing the vortexes created near the surface where the inputs are placed. Mixing speeds between 50 and 2500 rpm are effective in distributing particulate reinforcement 4 throughout the matrix 1. Material output 60 is controlled such that material inside the mixing chamber 70 has the required amount of time to mix thoroughly before exiting the angled mixing chamber 70 between 5 minutes and 2 hours. The chamber length may be designed to provide a given output volume per hour. Mixing chambers of less than 12" in diameter are preferred to keep material uniformly mixed. Multiple mixing chambers may be used, if required, to fulfill a continuous supply requirement.
FIG. 5a shows a mixing apparatus 80 in which a hollow, stationary stirring rod 81 is used in conjunction with a rotating mixing column 82. The mixing column 82 is connected to a shaft 83 which is driven by a motor (not shown). The rotating mixing column 82 causes the material 7 to be mixed as it flows downward. By enclosing the system in a pressure vessel 86, the surface of the mixed composite material 7 may be forced downward such that the material 7 flows through the stationary stirrer 81 as composite output 60. This apparatus 80 can be used to provide a continuous supply of low volume fraction composite material since inputs 28 may be added while output 60 is removed.
FIG. 5b shows another embodiment in which the mixing column 82 is stationary, and the hollow stirrer 81 is rotated by a motor and drive 87 such that inputs are mixed into an uniform composite 7 as they flow through the mixing column 82. The mixing column 82 may be enclosed in a pressure vessel 86 such that when the vessel 86 is pressurized, the mixed composite 7 flows into a reservoir 88 with a plunger 89 for controlling low volume fraction composite output 60.
FIGS. 6a, 6b, and 6c are schematic representations of the different forms that input materials 28 may take. FIG. 6a shows particulates of reinforcement 4 being added with liquid matrix material 1. Particulate material 4 may be reinforcement or alloying additions to liquid matrix material 1.
FIG. 6b shows solid matrix material 90 being used as an input 28 along with agglomerates or clusters of reinforcement 91. Clusters 91 can be easier to mix into the melted matrix material 1. After the clusters 91 are mixed in, the clusters 91 may be broken up such that the individual particles in the clusters 91 are distributed uniformly in the matrix 1. This system of clustered particles 91 is valuable in applications where the particles tend to lay on the surface of the liquid matrix 1 and have difficulty going into the mixture 7. Clusters 91 may be formed by a variety of methods, including spray drying, pressing, and extrusion with pelletization or spheration. All of these processes are accomplished by mixing the reinforcement particulates 4 with a binder, such as wax, to hold the particles together. Other additives, such as silica, may be used to hold the particles together once the wax is removed. Clusters 91 may include additions other than reinforcement, such as fluxes or alloying additions which may aid in the dispersion of the reinforcement and creating the desired liquid matrix composition 1.
FIG. 6c shows input pellets 95 made up of a mixture of solid matrix material 90 and particulate reinforcement material 4. The pellets 95 are premixed to the desired concentration of each additive so that separate metering of the solid matrix material 90 and particulate reinforcement material into the mixing system is not required. Pellets 95 may be easily mixed and dispersed. Pellets 95 may be formed by co-spraying, pressing, and other operations, some of which involve using wax binders and/or heating to cause the pellets to hold together to be used as an input 28. The input pellets 95 may also be premade pieces of mixed composite material 7.
FIG. 7a shows a stand-alone mixing apparatus 100 incorporating a pressure vessel 101, insulation 102, heating elements 103, mixing column 104, a stirring rod with blades 105 connected to a mixing motor 106, an input feed 107 through which inputs 28 may be added, or vacuum or gas supplied. The vessel 101 also includes a pouring spout 108 and a pressure door 109. Composite material 7 is produced inside the mixing apparatus 100. The pressure door 109 may be closed during the mixing such that the mixing may occur in a vacuum, nitrogen, or inert atmosphere. After mixing, the vessel 101 may be tilted as shown in FIG. 7a and the pressure door 109 opened such that the composite material 7 is poured out as output 60. FIG. 7a shows composite material 7 being poured off the top of the mixing column 104. However, composite mixture 7 may be supplied from the bottom by connecting the pouring spout 108 with a channel 113 to the bottom of the mixing column 104 while blocking material from flowing from the top of the mixing column 104 as shown in FIG. 7c.
FIG. 7b shows another embodiment of a stand-alone continuous composite mixing unit 110 incorporating many of the same features as the unit in FIG. 7a, except that gas supplied through an inlet 36 is used to force composite mixture 7 through a supply tube 111 to provide output 60. Vacuum may also be drawn through inlet 36. Inputs 28 may be supplied through input feed lines 112 with the assistance of a gas to suspend the inputs 28 such that the inputs 28 provide the required volume to make-up composite material output 60 such that a continuous composite mixture 7 can be provided as required.
FIG. 7d shows the output 60 of the mixing device 13 feeding into a supply reservoir 120 which may incorporate stirring action to keep the particles suspended. If the input supply 60 is discontinuous, or the volume of each casting is more than the continuous supply input 60, the reservoir 120 may be used to accumulate composite mixture 7 such that the required output to fill molds 8 can be obtained. The flow from the reservoir 120 can be controlled through a valve or plunger 121.
FIGS. 8a and 8b show pressure casting equipment made for casting unreinforced materials modified for casting low volume fraction composites. FIG. 8a shows a pressure casting machine 130 which uses inert gas 131 to force material inside the vessel 130 through a feed tube 132 into a reservoir 133 through a control valve 121 to produce an output 60. The pressure casting apparatus 130 has been modified to produce a composite mixture 7 and cast this mixture into molds (not shown). The pressure vessel 130 has been modified to include a new top head 134 which includes a mixing device 13 set-up as described in FIG. 1 with inputs 28 reservoirs 135. Inputs 28 flow through their respective supply line 112, through a control valve 25 and are mixed in the mixing column 21 and are fed into the pressure caster reservoir 136. The composite mixture 7 may be kept suspended by an additional stirring motor (not shown) or by inductive coupling which may be used to cause currents within the liquid composite mixture 7.
FIG. 8b shows a similar setup to FIG. 8a except that the mixing column 21 intrudes into the reservoir area 136 such that the output feeds directly into the reservoir 136.
FIG. 9 shows the outside view of a continuous pressure caster 130 with a composite mixing device attached to the top of the pressure caster 130 such that inputs 28 are fed into the mixing system 150 to produce a composite mixture 7 which is fed out of the pressure caster to fill molds 8 as they are positioned under the pressure caster 130 by a conveyer system 151. A plunger 152 is used to control the flow of composite mixture 7 out of the pressure caster 130 so that no overfilling occurs.
FIG. 10 shows another embodiment in which the pressure caster 130 is filled by a separate composite mixer 160 as required such that the pressure caster 130 can continuously cast components.
FIG. 11 shows another embodiment in which a pressure casting machine 130 is connected to a continuous mixing machine 170 which is fed by an automatic feeder system 171 from a material reservoir 172. This setup provides a continuous supply of composite mixture 7 to cast large volumes of components, such as automotive rotors, calipers, engine blocks, etc.
In the preferred embodiment, with reference to FIG. 1, A356 aluminum pellets 1 and 600 grit silicon carbide particulates 4 are fed in metered amounts such that for every 100 grams of aluminum, 20 grams of silicon carbide is fed in a vacuum into a ceramic lined mixing column heated to 650° C. by elements 11. As the aluminum pellets melt, the silicon carbide particles 4 are mixed into the molten aluminum 1 with a ceramic coated steel stirrer 6. The stirrer 6 is not turned on until the first load of aluminum melts in the column. After this aluminum melts, the stirrer 6 is rotated at 250 rpm for 10 minutes which causes the composite material 7 to be uniformly mixed. The plug 10 at the bottom of the column 3 is then opened to pour out mixed composite material 7. More unmixed material inputs are fed into the mixer 13 to replace the mixed composite material 7 that was fed out of the mixing column when no additional output is required, the plug 10 is closed and no more material is fed into the mixing column 3. The output is controlled such that the materials have at least 5 minutes of stirring to uniformly distribute the silicon carbide particles 4 before the mixed composite material exits 7 the mixing column.
A291 magnesium composite components may also be cast in the same way except that the vacuum is not normally used, argon is used instead.
To produce copper composites, the mixing column 3 is heated to 50° to 100° C. above the melting point of the alloy such as 1180° C. for pure copper. Alumina reinforcement is preferred over silicon carbide since the silicon in silicon carbide dissolves in molted copper. Iron or nickel composite may be formed by inductively heating the mixing column 3. The mixing stirrer 6 should be replaced with a solid ceramic rod to prevent melting or alloying that occurs at the higher temperatures required. Alumina and aluminum nitride reinforcements are preferred since they do not dissolve in molten iron or nickel alloys.
The matrix material 1 can be comprised of metal, polymer, an alloy of aluminum, an alloy of magnesium, an alloy of copper or an alloy of iron, to name but a few examples. The reinforcement material 4 can be comprised of ceramic, metal, carbon, silicon carbide, to name but a few examples. The composite components 9 can be used for wear parts, automotive rotors or automotive calipers.
Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.
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A method and system for producing a continuous supply of low volume fraction composite material that can be fed continuously into one or more molds. Composite inputs are fed into a mixing device such that a continuous supply of mixed composite material is available from the output side of the mixing device. The operation removes the step of creating master ingots and removes the need for a two step process in which the material is melted twice. This invention reduces the cost of producing composite components, reduces batch-to-batch variations, and allows for a continuous production flow. In addition, the invention allows for a much greater flexibility in the selection and optimization of material systems.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is related to Application Ser. No. 09/159,271, filed the same day herewith, and incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
There are many conventional multiplication circuits that perform squaring. Typically, these circuits include an array of partial product bit generators, each bit generator providing a bit of a partial product by comparing the appropriate bits of the multiplicand and multiplier.
Each partial product bit of a common weight is provided to a column adder corresponding to the common weight. The complexity of the adder tree for a given column depends on the number of bits that are added in that column. Typically, the more complex an adder tree, the larger and slower the column adder. Therefore, a circuit and method for reducing the number of bits corresponding to a given column adder are desired.
This reduction is particularly important for the column with the most partial product bits. In many conventional circuits, each column is standardized with a common tree structure that is designed to meet the requirements of the column with the most bits. In these cases, a reduction in the maximum bits per column reduces the complexity of the adder tree structure for every column. Therefore, a circuit and method for reducing the maximum bits added per column is desired.
SUMMARY OF THE INVENTION
In accordance with the present invention, a circuit reduces the number of partial product bits in a column. The circuit includes a partial product bit generator, corresponding to the column, that generates a partial product bit of weight 2 2k (k is an integer). This partial product bit has a 1 value only if an input bit of weight 2 (k−i) has a 0 value while another input bit of weight 2 k has a 1 value. The circuit includes another partial product bit generator that receives the same two input bits. The second partial product bit generator provides a partial product bit of weight 2 2k+i , wherein the second partial product bit has a 1 value only if both of the input bits have a 1 value.
In accordance with the present invention, a method is provided in which a partial product bit of weight 2 2k is generated having a 1 value only if the input bit of weight 2 (k−1) has a 0 value while the input bit of weight 2 k has a 1 value. A partial product bit of weight 22 k+1 is generated having a 1 value only if both of the input bits have a 1 value. Another method includes providing the partial product bit generators described above.
The present invention and its advantages and features will be more fully understood in light of the following detailed description and the claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a squaring circuit according to the present invention.
FIG. 2 is a detailed gate level diagram of one embodiment of the partial product bit generator array of FIG. 1 .
FIG. 3A shows a portion of the partial product bit generator array of FIG. 2 .
FIG. 3B shows a portion that replaces the portion of FIG. 3 A.
FIG. 3C shows an alternative embodiment of the portion of FIG. 3 B.
DESCRIPTION OF THE INVENTION
Throughout the figures and description, like reference symbols indicate like elements unless otherwise noted.
Partial product bits in the conventional school book method of squaring are “mirrored”. For example, in the following multiplication, the italicized partial product bits are vertically mirrored about the bolded partial product bits.
001110011010
(922)
x001110011010
(922)
00000000000 0
0
0011100110 1 0
1
000000000 0 0 0
2
00111001 1 0 1 0
3
0011100 1 10 1 0
4
000000 0 000 0 0
5
00000 0 0000 0 0
6
0011 1 00110 1 0
7
001 1 100110 1 0
8
00 1 1100110 1 0
9
0 0 00000000 0 0
a
+ 0 00000000000
b
000011001111100010100100
(850, 084)
22221111111111
321098765432109876543210
(Column #)
The bolded partial product bits (hereinafter, “the mirror bits”) are generated by partial product bit generators that multiply a multiplicand bit of weight 2 k and a multiplier bit of the same weight, where k is the set of integers from 0 to n−1. The k'th bit from the right in the m'th partial product is referred to as “partial product bit mk” (or “bit mk”), where m is the set of integers from 0 to n−1. The partial product bits to the upper left and lower right of the mirrored bits are respectively referred to as “the upper bits” and “the lower bits”. For each upper (or lower) bit mk, there exists exactly one corresponding lower (or upper) bit km of equal weight and magnitude.
Squaring may also be performed by deleting all of the lower bits (“right bits”) and by shifting the upper bits 1 bit left as in the following example.
001110011010
(922)
x001110011010
(922)
00000000000 0
0
0011100110 1
1
000000000 0
2
00111001 1
3
0011100 1
4
000000 0
5
00000 0
6
0011 1
7
001 1
8
00 1
9
0 0
a
+ 0
b
000011001111100010100100
(850, 084)
22221111111111
321098765432109876543210
(Column #)
Each partial product bit generator that receives multiplicand bit k for the non-mirror bits receives a bit of weight 2 k and a bit of weight 2 m and generate a bit of weight 2 (k+m+1) . When deleting all of the lower bits, m is an integer greater than 0.
In the above method, the number of product bits is reduced from n 2 (e.g., 144) in the conventional method to n(n+1)/2 (e.g., 78), a reduction of almost 50%. Furthermore, the maximum number of partial product bits per column is [(n/2)+1] truncated (e.g., 7 if n equals 12). Therefore, the maximum number of carry save adders required for a column is reduced from n−2 (e.g., 10) to [(n/2)−1] truncated (e.g., 5).
FIG. 1 shows a block diagram of a circuit that accomplishes the above described squaring. In FIG. 1, two 12-bit registers 110 and 120 are each configured to store the same 12-bit value y[b 16 :0] to be squared. Each bit y[q] of the 12-bit value y[b 16 :0] has a weight 2 q , where for q is the set of integers from 0 to b 16 . Register 110 has lead lines corresponding to each bit y[b 16 :0] as does register 120 . In one embodiment, only one register 110 is used to provide bits y[b 16 :0]. In another embodiment, bits y[b 16 :0] are provided by a circuit (not shown) other than a register.
In response to a signal SQUARE on line 111 , signals representing each bit of value y[b 16 :0] are provided to a partial product bit generator array 130 (“array 130 ”). Array 130 generates partial product bits and provides the partial product bits to a respective one of column adders CA 0 to CA 23 that corresponds to the weight of the partial product bit. The column adders CA 0 to CA 23 may provide the resulting square in redundant form (i.e., a carry and sum bit for each bit place), in which case the result is provided to a carry propagate adder 140 .
FIG. 2 is a detailed gate level diagram of array 130 which may be, for example, an array of AND gates. Each AND gate mk (e.g., AND gate 1b 16 in FIG. 2) has two numbers m and k (e.g., 1 and b 16 ) associated with its input terminals. The left number m (e.g., 1 for AND gate 1b 16 ) indicates that one input terminal is configured to receive bit y[m] (e.g., bit y[1]) from registers 110 or 120 . The right number k (e.g., b 16 for AND gate 1b 16 ) indicates that the other input terminal is configured to receive bit y[k] (e.g., y[b 16 ]) from registers 110 or 120 . Each AND gate mk receives bits y[m] and y[k] on its input terminal and provides bit mk on its output terminal. For example, AND gate 1b 16 receives bits y[1] and y[b 16 ] and generates partial product bit 1b 16 . Likewise, AND gate 00 receives bit y[0] and provides partial product bit 00. The other AND gates and partial product bits are not labeled in FIG. 2 for clarity.
The column adders of FIG. 1 receive and add the partial product bits mk according to the following Table 1.
TABLE 1
# of
Column
partial
Adder
Partial product bits received
products
CA0
00
1
CA1
none
0
CA2
01, 11
2
CA3
02
1
CA4
03, 12, 22
3
CA5
04, 13
2
CA6
05, 14, 23, 33
4
CA7
06, 15, 24
3
CA8
07, 16, 25, 34, 44
5
CA9
08, 17, 26, 35
4
CA10
09, 18, 27, 36, 45, 55
6
CA11
0a 16 , 19, 28, 37, 46
5
CA12
0b 16 , 1a 16 , 29, 38, 47, 56, 66
7
CA13
1b 16 , 2a 16 , 39, 48, 57
5
CA14
2b 16 , 3a 16 , 49, 58, 67, 77
6
CA15
3b 16 , 4a 16 , 59, 68
4
CA16
4b 16 , 5a 16 , 69, 78, 88
5
CA17
5b 16 , 6a 16 , 79
3
CA18
6b 16 , 7a 16 , 89, 99
4
CA19
7b 16 , 8a 16
2
CA20
8b 16 , 9a 16 , a 16 a 16
3
CA21
9b 16
1
CA22
a 16 b 16 , b 16 b 16
2
CA23
none
0
Each column adder CA 0 to CA 23 receives the partial product bits as shown in Table 1 (plus carry in bits from the column to the right), and generates a sum and carry bit to be added by carry propagate adder 140 (FIG. 1) (and generates carry out bits to the column to the left).
As shown in Table 1, the maximum number of partial product bits received by any column adder is 7 received by column adder CA 12 . The maximum required number of 3:2 carry save adders needed to reduce the 7 partial product bits to a sum and carry value is only 5. Therefore, the above describes a circuit and method for squaring which reduces the number of required partial product bit generators by almost 50% compared to the prior art. This simplifies the adder tree and reduces the area of the adder tree needed to add the reduced number of partial product bits. Therefore, the above describes a squaring circuit that is faster and smaller than in conventional squaring.
In one embodiment, AND gates 00, 11, 22, 33, 44, 55, 66, 77, 88, 99, a 16 a 16 and b 16 b 16 are not used to generate respective partial product bits 00, 11, 22, 33, 44, 55, 66, 77, 88, 99, a 16 a 16 and b 16 b 16 . Instead, bits y[ 0 ], y[ 1 ], y[ 2 ], y[ 3 ], y[ 4 ], y[ 5 ], y[ 6 ], y[ 7 ], y[ 8 ], y[ 9 ], y[a 16 ] and y[b 16 ] are provided unaltered as respective partial product bits 00, 11, 22, 33, 44, 55, 66, 77, 88, 99, a 16 a 16 and b 16 b 16 . In this embodiment, the number of AND gates required to square is further reduced by n. For example, in squaring an n-bit value, the number of required AND gates is a mere n(n−1)/2 which equals 66 for a 12-bit value, a reduction by over ½ compared to the conventional circuit.
The maximum number of partial product bits per column may be reduced from [(n/2)+1] truncated (e.g., 7) to (n/2) truncated (e.g., 6) as is described hereafter. The reduction is accomplished by shifting one partial product bit from the column with the most partial product bits (e.g., column 12 ) to its more significant neighbor (e.g., column 13 ). The reduction is described with reference to FIG. 3 A and FIG. 3 B.
FIG. 3A shows a portion 300 of array 130 that includes only AND gates 56 and 66 . In portion 300 , column 12 generates two partial product bits 56 and 66 , while column 13 generates none. In FIG. 3B, portion 300 is replaced with a portion 310 in which column 12 generates only one partial product bit p′, while column 13 also generates a partial product bit p″. Although the total number of partial product bits does not change by replacing portion 300 with 310 , the number of partial product bits generated by column 12 of the partial product bit generator array 130 is reduced from 7 to 6. The number of partial product bits generated by column 13 is increased from 5 to only 6. The maximum number of partial product bits generated by any one column of array 130 is thus reduced by 1 to 6. Thus, the maximum number of 3:2 carry save adders required per column is reduced to 4 for squaring a 12-bit value.
The following truth table (Table 2) shows the relationship between portion 310 input bits y[ 5 ] and y[ 6 ] and output partial product bits p′ and p″.
TABLE 2
Input
Output
Bits
bit
Bits
y[5]
y[6]
56
p″
p′
X
0
0
0
0
0
1
0
0
1
1
1
1
1
0
“X” means that the output bits p′ and p″ are not dependent on bit y[ 5 ] if bit y[ 6 ] is 0. Bit p′ has a 1 value only if bit y[ 5 ] has a 0 value and bit y[ 6 ] has a 1 value. Bit p″ has a 1 value only if both of bits y[ 5 ] and y[ 6 ] have a 1 value.
FIG. 3B shows a circuit (portion 310 ) that implements truth Table 2. An AND gate 315 logically AND's bits y[ 5 ] and y[ 6 ] to generate bit 56 . Another AND gate 330 logically AND's bits 56 and y[ 6 ] to generate bit p″. An XOR gate 320 logically XOR's bits 56 and y[ 6 ] to generate partial product bit p′.
An alternative embodiment of portion 310 is shown in FIG. 3 C. AND gate 56 logically AND's bit y[ 5 ] and y[ 6 ] to generate partial product bit p″. An inverter 340 inverts bit y[ 5 ] to generate bit !y[ 5 ]. An AND gate 350 logically AND's bits !y[ 5 ] and y[ 6 ] to generate bit p′.
The above embodiments reduce the required number of partial product bit generators required to square. Furthermore, the required tree structure for adding the partial product bits is simplified. Therefore, what is provided is a faster squaring circuit and method that requires less space than conventionally known.
Although the principles of the present invention are described with reference to specific embodiments, these embodiments are illustrative only and not limiting. Many other applications and embodiments of the principles of the present invention will be apparent in light of this disclosure and the claims set forth below.
For example, although the lower bits are described above as being deleted while the upper bits are shifted left, the upper bits may be deleted while the lower bits are shifted left one bit as shown in the following example.
001110011010
(922)
x001110011010
(922)
000 0
0
0 1
1
0 0 0
2
1 1 10
3
0 1 010
4
0 0 0000
5
0 0 00000
6
1 1 011010
7
1 1 0011010
8
0 1 10011010
9
0 0 000000000
a
+ 0 0000000000
b
000011001111100010100100
(850, 084)
22221111111111
321098765432109876543210
(Column #)
For clarity, the most significant bit of the lower bits for each partial product is represented above a corresponding mirror bit of equal weight. Here, where only the upper bits are deleted, the partial product bit generators (corresponding to multiplicand bit k) for the non-mirror bits each receive a bit of weight 2 k and a bit of weight 2 m and generate a bit of weight 2 (k+m+1) , where m an integer is less than k.
Alternatively, a combination of upper and lower bits may be deleted so that there are no upper (or lower) bits that has a corresponding lower (or upper) bit. The remaining partial product bits are shifted left 1 bit.
001110011010
(922)
x001110011010
(922)
00 00 00 0
0
00 10 10 1
1
0 00 00 0
2
11 01 1 0
3
01 00 1 10
4
00 00 0 00
5
0 00 0 00
6
11 1 11 0
7
01 1 01 10
8
00 1 00 01
9
0 0 00 00
a
+ 0 00 00 0
b
000011001111100010100100
(850, 084)
22221111111111
321098765432109876543210
(Column #)
In this example, the following partial product bits mk are deleted: 03, 04, 07, 08, 0a 16 , 0b 16 , 10, 14, 15, 18, 19, 1b 16 , 20, 21, 25, 26, 29, 2a 16 , 31, 32, 36, 37, 3a 16 , 3b 16 , 42, 43, 47, 48, 4b 16 , 50, 53, 54, 58, 59, 60, 61, 64, 65, 69, 6a 16 , 71, 72, 75, 76, 7a 16 , 7b 16 , 82, 83, 86, 87, 8b 16 , 90, 93, 94, 97, 98, a 16 0, a 16 1, a 16 4, a 16 5, a 16 8, a 16 9, b 16 1, b 16 2, b 16 5, b 16 6, b 16 9 and b 16 a 16 . The other bits mk are shifted left 1 bit. Here, the partial product bit generators for the non-mirror bits each receive a bit of weight 2 k and a bit of weight 2 m and generate a bit of weight 2 k+m+1 , where m is an integer not equal to k.
The above describes a squaring circuit in which there are no bits mk that have a corresponding bit km. However, the advantages of the present invention may be obtained, although to a lesser extent, by only shifting left a single bit (e.g., bit 1b 16 ) and deleting the corresponding bit (e.g., bit b 16 1) as in the following example.
001110011010
(922)
x001110011010
(922)
00000000000 0
0
0 011100110 1 0
1
000000000 0 00
2
00111001 1 010
3
0011100 1 1010
4
000000 0 00000
5
00000 0 000000
6
0011 1 0011010
7
001 1 10011010
8
00 1 110011010
9
0 0 0000000000
a
+ 0 000000000 0
b
000011001111100010100100
(850, 084)
22221111111111
321098765432109876543210
(Column #)
The above described embodiments are illustrative only. Many other embodiments and variations will be apparent in light of this disclosure. The invention is defined by the following claims.
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A circuit for shifting the number of partial product bits per column in an adder tree is provided. A partial product bit is generated having a weight 2 2k that has a 1 value only if one input bit of weight 2 (k−1) has a 0 value while another input bit of weight 2 k has a 1 value. Another more significant partial product bit of weight 2 (2k+1) receives the same input bits and has a 1 value only if both of the input bits have a 1 value. In this manner, the number of partial product bits in the column of weight 2 2k is decreased by 1 while the number of bits is the column of weight 2 (2k+1) is increased by 1. Therefore, if the column of weight 2 2k had the greatest number of partial product bits of all columns, and if the column of weight 2 (2k+1) had at least two fewer bits than the column of weight 2 2k , the total maximum number of bits for all the columns is reduced by 1.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ink jet printing system and a method provided with an ink-jet print head for discharging ink by generating bubbles with the application of thermal energy.
According to the present invention, the term “printing” or “print” means that not only figurative or meaningful images such as characters and figures, but also nonfigurative images or images that do not communicate meaning such as patterns are formed on printed media.
Further, the term “printing apparatus” or “printer” used in the following description of the specification indicates an ink jet printer.
2. Description of the Related Art
Conventionally, there has been known as an ink jet printing method, a so-called bubble jet printing method, which applies thermal energy to ink in each of ink flow paths in a printing apparatus such as a printer to generate a bubble. As a result, the ink is discharged from each of discharge ports by an abrupt volumetric change associated with the formation of the bubble. A droplet of ink discharged is made to adhere to the surface of a printed medium so that an image will be formed thereon. One of the printing apparatuses using the above-mentioned bubble jet printing methods is disclosed in U.S. Pat. No. 4,723,129. This patent teaches a bubble jet printing apparatus, which is typically provided with discharge ports for discharging ink, liquid flow paths communicating with the respective discharge ports, and electrothermal converting elements arranged in the respective liquid flow paths as energy generating means for discharging the ink.
This type of printing method enables the printing apparatus to print out high-quality images at high speeds and low noise levels. In addition, a print head using this type of printing method arranges discharge ports in a compact apparatus more densely, which makes it easy to obtain a high-resolution printed image even though it is a color image. Thus, since the bubble jet printing method has lots of advantageous points, it has recently been employed for not only many office equipment, such as printers, copiers and facsimiles, but also industrial systems such as apparatuses used at printworks.
As the application of bubble jet technology expands to a wide range of products, various demands for the technology have been increasing through the years.
For example, to obtain a high-quality image, proper driving conditions have been proposed so that they can realize an ink discharging method capable of discharging ink properly at high speed under the influence of stable bubble generation. Further, from the high-speed print's point of view, improvements in the shape of a liquid flow path have been proposed to obtain an ink-jet print head capable of speeding up a refill of ink into the liquid flow path from which an amount of ink has been discharged.
It has conventionally been known that the front portion of a bubble generated by film boiling (of an edge shooting type) has a major impact on discharging of ink, but no attention is paid to a technique for efficiently using this portion to form discharged droplets. The inventors have carefully studied to solve technical problems on this matter.
Paying attention to the relationship between displacement or deformation of a movable member and generation of a bubble, the inventors acquired the following findings.
One of the findings is that a stopper can control the displacement of a free end of the movable member relative to the growth of a bubble. The stopper restricts the displacement of the movable member, which in turn restricts the growth of the bubble on the upstream side of the liquid flow path to transmit energy to the downstream side on which the discharge port is formed, thereby efficiently discharging ink.
The above-mentioned ink-jet print head discharges ink droplets nearly in the form of liquid columns with bulb-like tips at the instant of discharging the ink from the discharge ports due to generation of bubbles, respectively. The same phenomenon happens to a conventional head structure, but the ink-jet print head having such a movable member displaces or deforms the movable member in the process of growing a bubble. Then, when the movable member thus displaced comes in contact with the stopper, a substantially closed space is formed in the liquid flow path except the discharge port. Since the closed space is maintained until the bubble disappears and hence the movable member is separated from the stopper, energy generated by bubble disappearance serves as such a force as to move ink near the discharge port in the upstream direction. As a result, an ink interface or meniscus is rapidly pulled into the liquid flow path from the discharge port just after the bubble disappearance is started. Then, a tail portion connected with a discharged droplet outside of the discharge port to form part of a liquid column is cut off in a flash by a strong pulling force of the meniscus. This makes it possible to minimize generation of a satellite particle formed from the tail portion, and hence improve print quality.
Although the meniscus is rapidly pulled in, this phenomenon does not continue to pull the tail portion, which prevents reduction in the discharging speed. Further, since distance between the discharged droplet and the satellite particle becomes short, the satellite particle is attracted to the discharged droplet by means of so-called slipstream behind the discharged droplet. As a result, the discharged droplet and the satellite droplet could become united, which makes it possible to reduce image quality degradation.
To make image quality higher, the ink-jet print head having the above-mentioned movable member is further required to reduce image quality degradation caused by satellite droplets conspicuous at single-dot printing. In carefully studying this matter, the applicant acquired the following novel knowledge:
1. It is essential to manage or control physical properties of ink such as viscosity and surface tension, reduction in design flexibility such as a layout of the head nozzles or driving method, and a manufacturing tolerances.
2. Many satellite droplets tend to take place unevenly in only one direction, not in all scanning directions of a carriage.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above-mentioned facts, and an object thereof is to provide ink jet printing system and method capable of reduce the degradation of printed images due to satellite droplets.
In attaining the above-mentioned object and according to the present invention, there is provided an ink jet printing system constituted of an ink jet printing apparatus and a printer driver. The ink jet printing apparatus includes an ink jet head from which ink is so discharged that an image will be printed out on a recorded medium, conveying means for conveying the recorded medium, and a holding means for keeping the ink jet head reciprocating in the main or horizontal scanning direction intersecting the conveying direction of the recording medium. The printer driver creates image information in an information processing apparatus on the basis of density information. The ink jet printing system according to the present invention comprises image information detecting means and image information changing means. The image information detecting means receives first image information to detect whether the first image information represents an image prone to significant degradation due to detrimental effects of satellite dots. The image information changing means changes information to be used, if it is detected that the first image information represents an image prone to significant degradation due to detrimental effects of satellite dots, from the first image information to second image information representing an image less influenced by the satellite dots than the first image information.
In the above-mentioned configuration of the ink jet printing system, when printing is to be made on the basis of the first print information on a single-dot print tending to generate satellite dots, only main droplets are discharged with adding the second print information continuously to the discharge of the main droplet based on the first print information. The second print information is information for generating not satellite dots. In this case, the changing means changes the print information composed of the first print information alone into the print information composed of the first print information and the second print information. In other words, main droplets discharged on the basis of the second print information are hit on respective satellite dots alighted adjacent to but slightly spaced with the main droplets discharged on the basis of the first print information, which makes the satellite dots inconspicuous.
The ink-jet print head may have a heating element for generating thermal energy to generate a bubble in an ink flow path. Alternatively, the ink-jet print head may have a movable member with a free end provided in a bubble generating region in the ink flow path communicating the discharge port, and displaced or deformed with the growth of the bubble.
According to the present invention, there is also provided an ink jet printing method for creating image information from density information, driving an ink jet head on the basis of the image information, and discharging ink to a recorded medium so that an image will be printed on the recorded medium. The ink jet printing method comprises the following two steps: one receiving first image information to detect whether the first image information represents an image prone to significant degradation due to detrimental effects of satellite dots, and the other changing image information to be used, if detected that the first image information represents an image prone to significant degradation due to detrimental effects of satellite dots, from the first image information to second image information less influenced by satellite dots than represented by the first image information.
In the above-mentioned ink jet printing method, two or more ink dots are continuously discharged in a continuous discharging process, which can reduce image quality degradation resulting from generation of satellite dots, especially noticeable in single-dot printing. The continuous discharging process may be carried out on a printer driver side in a host computer, or on the ink jet printing apparatus in which the inkjet print head is mounted.
The ink jet printing method may further comprising the step of creating print data indicative of an arrangement of continuous pixel data in the main or horizontal scanning direction, where each pixel corresponds to each dot hit on the printed medium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of the main part of an exemplary ink-jet print head in which a stopper is formed.
FIGS. 2A, 2 B, 2 C, 2 D and 2 E are side sectional views for explaining a first discharge of ink from the ink-jet print head shown in FIG. 1 and generation of a satellite dot.
FIGS. 3A, 3 B, 3 C, 3 D and 3 E are side sectional views for explaining a second discharge of ink following the first shot.
FIG. 4 is a perspective view of part of the head shown in FIG. 1 .
FIG. 5 is a schematic perspective view illustrating an example of an ink jet printing apparatus.
FIG. 6 is a block diagram of the general structure of the ink jet printing apparatus shown in FIG. 5 .
FIG. 7 illustrates matrix patterns created by a matrix printing method practiced as a first embodiment of the present invention.
FIG. 8 illustrates other matrix patterns created by the matrix printing method practiced as the first embodiment of the present invention.
FIGS. 9A and 9B illustrate dither patterns created by a quantization technique according to a second embodiment of the present invention.
FIG. 10 illustrates related pixels in the process of error diffusion according to a third embodiment of the present invention.
FIGS. 11A, 11 B and 11 C illustrate a continuous two-dot printing method using error diffusion according to the third embodiment of the present invention.
FIG. 12 is a flowchart for explaining the continuous two-dot printing using error diffusion according to the third embodiment of the present invention.
FIG. 13 illustrates examples of continuous two-dot data according to the third embodiment of the present invention.
FIGS. 14A and 14B illustrate examples of setting of a thinning-out mask according to a fourth embodiment of the present invention.
FIG. 15 is a flowchart illustrating timing of executing pattern matching according to a fifth embodiment of the present invention.
FIG. 16 illustrates an example of a dot added by pattern matching according to the fifth embodiment of the present invention.
FIGS. 17A, 17 B, 17 C, and 17 D illustrate other examples of dots added by pattern matching according to the fifth embodiment of the present invention.
FIGS. 18A and 18B illustrate examples of dots added by pattern matching according to a fix embodiment of the present invention.
FIGS. 19A, 19 B, 19 C, 19 D, 19 E, 19 F, 19 G and 19 H illustrate other examples of dots added by pattern matching according to the sixth embodiment of the present invention.
FIGS. 20A and 20B illustrate quantization levels when single-dot printing and continuous dot printing are used properly according to an eighth embodiment of the present invention.
FIGS. 21A and 21B illustrate hitting positions of main and satellite droplets in both cases where printing is made by moving a carriage at low and high speeds.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(First Embodiment)
FIG. 1 is a side sectional view of the main part of an exemplary ink-jet print head properly mounted in an ink jet printing apparatus according to the embodiment.
Description will be made first about the structure of the ink-jet print head with reference to FIG. 1 .
The ink-jet print head includes a substantially flat device substrate 1 having a heating element 10 as bubble generating means and a movable member 11 , a top plate 2 with its groove portion forming a stopper 12 , and an orifice plate 5 in which a discharge port 4 is formed.
A liquid flow path 3 through which ink flows is formed by fixing the device substrate 1 and the top plate 2 in the form of a laminate. A plurality of liquid flow paths 3 are formed in parallel with an inkjet print head so as to communicate with respective discharge ports 4 formed downstream (left side in FIG. 1) for discharging ink therefrom. A bubble generating region exists in the neighborhood of the surface on which the heading element 10 comes in contact with ink. Further, a large-capacity common liquid chamber 6 is formed upstream of the liquid flow paths 3 so that the liquid flow paths 3 communicate with the common liquid chamber 6 at the same time. In other words, each liquid flow path 3 is branched from the single common liquid chamber 6 . The height of the common liquid chamber 6 is set higher than that of the liquid flow path 3 .
The movable member 11 is a cantilever member supported at one end and fixed to the device substrate 1 upstream of the ink flow so that the downstream side from a fulcrum point 11 a can be moved up and down with respect to the device substrate 1 . In an initial state, the movable member 11 is located substantially in parallel with the device substrate 1 with a space between the movable member 11 and the device substrate 1 .
The movable member 11 thus provided to the device substrate 1 is so arranged that a free end 11 b is positioned substantially in a central region of the heating element 10 . Further, the stopper 12 provided in the top plate 2 restricts an upward displacement or deformation of the free end 11 b of the movable member 11 when it comes in contact with the stopper 12 . When the stopper 12 comes in contact with the movable member 11 to restrict the displacement or deformation of the movable member 11 (at the time of contacting the movable member), the movable member 11 and the stopper 12 cooperate to close the liquid flow path 3 . This phenomenon substantially divides the liquid flow path 3 into the upstream and downstream sides of the movable member 11 and the stopper 12 .
It is preferable to even up an edge Y of the free end 11 b and one end X of the stopper 12 on a plane perpendicular to the device substrate 1 . It is further preferable to even up the edges X, Y, and a center Z of the healing element 10 on the plane perpendicular to the substrate.
The liquid flow path 3 is so formed that the downstream side from the stopper 12 rises sharply. Such a sharp rise in height can keep room in the liquid flow path enough to grow a bubble downstream of the bubble generating region even when the movement of the movable member 11 is restricted by the stopper 12 . Therefore, a flow of ink can be smoothly moved toward the discharge port 4 without retarding the growth of the bubble. Further, unevenness of pressure balance in height from the lower end to the upper end of the discharge port 4 can be reduced, which ensures proper discharging of ink. If this configuration of the liquid flow path is adopted in a conventional ink-jet print head having no movable member 11 , a stagnation will take place in such a portion of the liquid flow path that the height rises on the downstream side of the stopper 12 . In this case, a bubble tends to stand in the stagnation, and this tendency is unfavorable for proper discharging of ink. In contrast, the embodiment makes the flow of ink reach up to the stagnation, which extremely reduces the effect of standing or dead bubbles.
If no movable member 11 is provided in the above-mentioned configuration, fluid resistance on the downstream side of the bubble generating region becomes lower than that on the upstream side, which makes it difficult to direct discharging pressure toward the discharge port 4 . On the other hand, in the embodiment, the movable member 11 substantially blocks the movement of the bubble to the upstream side from the bubble generating region during bubble formation, which urges discharging pressure toward the discharge port 4 . Further, the fluid resistance on the upstream side of the bubble generating region becomes low at the time of supplying ink, which results in a quick supply of ink to the bubble generating region.
The provision of the movable member 11 makes a downstream growing component and an upstream growing component of the bubble nonuniform so as to reduce the upstream growing component, and thereby restrict the movement o fink to the upstream side. Since the flow of ink to the upstream side is restricted, the amount of retrogression of the meniscus after discharging ink is reduced to reduce the amount of projection of the meniscus from the orifice surface 5 a during refilling ink. Thus meniscus vibration is prevented so that stable discharge can be carried out at any driving frequency ranging from low frequency to high frequency.
In the embodiment, part of the liquid flow path between the downstream side of the bubble and the discharge port 4 is in a “linear communication state” in which the flow of liquid is kept moving straight ahead through the liquid flow path. It is further preferable that the propagation direction of a pressure wave produced by generation of the bubble, and directions of flowing and discharging ink associated with the propagation of the pressure wave linearly match with one another. This makes it possible to form such an ideal state that discharging conditions such as the direction and speed of a discharged droplet 66 to be described later are highly stabilized. To achieve or make an approximation to the ideal state, the embodiment defines such a simple configuration that the discharge port 4 and the heating element 10 , especially the discharge port 4 side (downstream side) of the heating element 10 wielding influence over the bubble on the discharge port 4 side, are directly connected with each other in a straight line. In this configuration, the heating element 10 , especially the downstream side of the heating element 10 , can be observed as viewed from the outside of the discharge port 4 in such condition that the ink-jet print head has run out of ink.
Next, description will be made about a first discharge of ink from the ink-jet print head according to the embodiment, generation of a satellite droplet, and dot placements (hitting positions) of the first shot of ink droplet and the satellite droplet on a sheet with reference to FIGS. 2A to 2 E. Then, hitting positions of a second shot of ink droplets on the sheet will be described with reference to FIGS. 3A to 3 E. In these drawings, M denotes a moving direction of a carriage.
FIG. 2A indicates a state of the print head before energy such as electric energy is applied to the heating element 10 , that is, it indicates the state of the print head before the heating element 10 generates heat. In this state, the movable member 11 is placed in a position in which the movable member 11 will face half the upstream side of a bubble generated by heat from the heating element as described later. The carriage with the ink-jet print head mounted thereon is moving upward in FIGS. 2A to 2 E.
FIG. 2B indicates a state just after a bubble 40 starts bubbling due to film boiling by the application of heat from the heating element 10 to part of ink. In other words, a pressure wave produced by generating the bubble 40 due to film boiling is propagated through the liquid flow path. With propagation of the pressure wave, the flow of ink is branched to downstream and upstream sides across a demarcation line around the center of the bubble generating region. The flow of ink on the upstream side causes the movable member 11 to be deformed with the growth of the bubble 40 . Further, the upstream movement of the ink is directed to the common liquid chamber 6 through a gap or clearance between the inner wall of the liquid flow path 3 and the movable member 11 . As the movable member 11 is deformed, the clearance between the stopper 12 and the movable member 11 becomes narrower. Under this condition, a discharge of the discharged droplet 66 is started from the discharge port 4 .
FIG. 2C indicates a state at the time the free end 11 b of the movable member 11 displaced or deformed with further growth of the bubble 40 comes in contact with the stopper 12 .
The movable member 11 comes in closer proximity to and in contact with the stopper 12 . In this case, the height of the stopper 12 and the clearance between the upper surface of the movable member 11 and the end portion of the stopper 12 are set to desired dimensions, which makes sure of the timing of contacting the movable member 11 with the stopper 12 . Once the movable member 11 has come in contact with the stopper 12 , the free end 11 b is inhibited from further deforming upward to largely restrict the upstream movement of the ink. The growth of the bubble 40 to the upstream side is also restricted by the movable member 11 . At this time, since the moving force of the ink in the upstream direction becomes large, such a stress as to pull the movable member 11 in the upstream direction is exerted on the movable member 11 to cause the middle portion of the movable member 11 to be deformed in a convex shape. Although the bubble 40 remains growing, the stopper 12 and the movable member 11 restrict the growth of the bubble 40 to the upstream side, resulting in further growth of the bubble 40 to the downstream side. In other words, the height of the bubble 40 on the downstream side from the heating element 10 becomes higher than that in a case where no movable member 11 is provided.
On the other hand, since the displacement or deformation of the movable member 11 is restricted by the stopper 12 , the upstream side of the bubble 40 does not grow so much. The dimensions of the upstream side of the bubble 40 are kept so small that an inertia force of the flow of ink to the upstream side only puts stress on the movable member 11 to bend the same to the upstream side in the convex shape. The upstream portion of the bubble 40 is restricted by the stopper 12 , the nozzle walls, the movable member 11 and the fulcrum point 11 a , so that the amount of ink flowing into the upstream region is reduced to almost zero.
Thus the liquid flow to the upstream side is considerably restricted to prevent a reverse flow of the liquid to the liquid supply path or pressure vibration so as to prevent an interruption of a high-speed refill of the liquid.
FIG. 2D indicates a state of the print head when inner negative pressure of the bubble 40 , generated as described above after film boiling, exceeds the downstream movement of the ink in the liquid flow path 3 to start contracting.
As the bubble 40 contracts, the movable member 11 is displaced downward. The downward displacement of the movable member 11 is accelerated by cantilever stress of the movable member 11 itself and the above-mentioned stress that causes the movable member 11 to be displaced upward in the convex shape. At this time, the downstream flow of the ink has low flow resistance on the upstream side of the movable member 11 , that is, in a low-resistance flow-path region formed between the common liquid chamber 6 and the liquid flow path 3 . As a result, a large flow of ink rushes into the liquid flow path 3 through the stopper 12 to lead the ink from the common liquid chamber 6 into the liquid flow path 3 . The ink led into the liquid flow path 3 passes through the clearance between the stopper 12 and the downward displaced movable member 11 as it is to flow into the downstream side of the heating element 10 while accelerating complete disappearance or extinction of the bubble 40 . This flow of the ink helps the extinction of the bubble to make a further flow of ink toward the discharge port 4 , which helps the meniscus recovery to improve refilling speed.
At this stage, the liquid column together with the discharged droplet 66 going out of the discharge port 4 forms a main droplet 67 discharged to the outside. Discharge of the main droplet 67 , however, runs the danger of tearing off the tail end of the main droplet 67 during discharge to cause a satellite droplet of droplets to separately hit the printed medium.
Further, the above-mentioned flow of ink into the liquid flow path 3 through the clearance between the movable member 11 and the stopper 12 accelerates the velocity of flow along the wall surface of the top plate 2 . As a result, residual fine bubbles generated in this portion are extremely reduced, contributing to stable discharging.
Further, cavitation resulting from extinction of the bubble occurs at a point deviated from the bubble generating region in a downstream direction, so that damage to the heating element 10 can be reduced. This phenomenon can also reduce adherence of burnt deposits to the heating element 10 to improve stability in the discharging process.
FIG. 2E indicates a state where the movable member 11 is overshot and displaced downward from its initial state after the bubble 40 has completely disappeared.
The overshoot of the movable member 11 will become weak and be settled in a short time to return to the initial state, depending on the stiffness of the movable member 11 and the viscosity of the ink.
On the other hand, the main droplet 67 and the satellite droplet 68 hit the sheet surface to form a main dot 67 a and a satellite dot 68 a . The generation of the satellite droplet 68 in single-dot printing makes the hitting position of the satellite dot 68 a separated from the hitting position of the main dot 67 a , and hence the satellite dot 68 a conspicuous.
Following the first shot of ink through the sequence of discharging operations from FIGS. 2A to 2 E, a second shot of ink is discharged in the same manner through a sequence of discharging operations from FIGS. 3A to 3 E. In the process of discharging the second shot of ink following the first shot, however, the satellite droplet can catch up with the main droplet 67 during discharge as shown in FIG. 3 D. As a result, only the main droplet is hit on the printed medium without generation of any satellite dot on the image. Further, as shown in FIG. 3E, the second shot of the droplet forms a second dot 70 adjacent to the first dot 69 on the sheet surface to form a united dot.
FIG. 4 is a perspective view of part of the head shown in FIG. 1 . Referring next to FIG. 4, projecting bubble portions 41 of the bubble 40 rising from both sides of the movable member 11 and the meniscus of ink in the discharge port 4 will be described in detail. Although the shape of the stopper 12 and the shape of the low-resistance flow-path region 3 a shown in FIG. 4 are different from those shown in FIG. 1, basic characteristics are the same as those described above.
In the embodiment, there are slight clearances between surfaces of both side walls constituting the liquid flaw path 3 and both sides of the movable member 11 , and these slight clearances allow a smooth displacement or deformation of the movable member 11 . Further, in the process of growing the bubble by means of the heating element 10 , the bubble 40 displaces or deforms the movable member 11 while rising from the upper surface of the movable member 11 through the clearances and slightly breaking into the low-resistance flow-path region 3 a . The projecting bubble portions 41 of the bubble rising from the upper surface of the movable member 11 and breaking into the low-resistance flow-path region 3 a passes around behind the back surface (the surface opposite to the bubble generating region) of the movable member 11 . This makes it possible to prevent the movable member 11 from shaking, and hence stabilize the discharging characteristics.
Further, in the process of making the bubble 40 extinct, the projecting bubble portions 41 of the bubble 40 promote the flow of the liquid from the low-resistance flow-path region 3 a to the bubble generating region. As a result, bubble disappearance is promptly completed along with high-speed pulling of the meniscus from the discharge port 4 . Particularly, the liquid flow caused by the projecting bubble portions 41 makes it difficult to leave part of the bubble around the movable member 11 or in the corners of the liquid flow path 3 .
In the above-mentioned configuration of the ink-jet print head, the discharged droplet 66 is discharged nearly in the form of a liquid column with a bulb-like tip at the instant of discharging the ink from the discharge port 4 due to generation of the bubble 40 . This phenomenon also occurs in the conventional head, but the present invention differs from the conventional in that the movable member 11 is displaced or deformed with the growth of the bubble. Then the movable member 11 displaced comes in contact with the stopper 12 to form a substantially closed space in the liquid flow path 3 having the bubble generating region except the discharge port. Since the closed space is maintained until the bubble disappears and hence the movable member 11 is separated from the stopper 12 , energy generated by the bubble disappearance mostly serves as such a force as to move the ink near the discharge port in the upstream direction. As a result, the meniscus is rapidly pulled into the liquid flow path 3 from the discharge port 4 just after the bubble disappearance is started. Subsequently, a tail portion connected with the discharged droplet 66 outside the discharge port 4 to form part of the liquid column is cut off in a flash by a strong pulling force of the meniscus. This makes it possible to reduce the size of the satellite droplet 68 formed from the tail portion. In this case, however, there is a danger of forming a dot on the printed medium from the satellite droplet 68 unevenly in only one direction, not in all scanning directions of a carriage HC, as will be described later, depending on the design of the print head.
It should be noted that in the embodiment the movable member 11 is provided in the above-mentioned ink-jet print head for restricting only part of the bubble 40 that grows upstream against the flow of ink toward the discharge port 4 . However, it is further preferable to position the free end 11 b of the movable member 11 substantially in the central portion of the bubble generating region. In this configuration, a back wave to the upstream side and an inertia force generated with the growth of the bubble bat not directly related to an discharge of ink can be prevented while directing the downstream component of the bubble 40 to the discharge port 4 as it is.
Further, since the low-resistance flow-path region 3 a opposite to the discharge port 4 across the stopper 12 as the boundary has a low flow resistance, the low-resistance flow-path region 3 a causes a large flow of ink in the upstream direction with the growth of the bubble 40 . Therefore, when the displaced movable member 11 comes in contact with the stopper 12 , a stress sufficient to pull the movable member 11 in the upstream direction is exerted on the movable member 11 . As a result, a force able to move the ink upstream with the growth of the bubble 40 remains influential until repulsion of the movable member 11 exceeds the force t move the ink, thereby maintaining the above-mentioned closed space for a fixed period of time. In other words, when repulsion of the movable member 11 exceeds the force needed to move the ink upstream with the growth of the bubble in the process of making the bubble 40 extinct, the movable member 11 is displaced or deformed downward to return to its initial state. As the movable member 11 is displaced or deformed downward, a downstream flow occurs even in the low-resistance flow-path region 3 a . Since the downstream flow in the low-resistance flow-path region 3 a has a low flow resistance, a large flow rushes into the liquid flow path 3 through the stopper 12 . As a result, the downstream movement of the ink toward the discharge port 4 applies a sudden brake to the pulling of the meniscus into the liquid flow path 3 , which makes it possible to settle the meniscus vibration at high speed.
FIG. 5 is a schematic perspective view of an exemplary ink jet printing apparatus in which the above-mentioned ink-jet print head is incorporated. In FIG. 5, the carriage IIC is equipped with an ink tank 90 for storing ink and a head cartridge from which the ink-jet print head 200 is removable. The carriage HC reciprocates in the main or horizontal scanning direction (the direction of arrow Y in FIG. 5) corresponding to the wide direction of a printed medium 150 such as printing paper conveyed by the printed-medium conveying means.
When a driving signal is supplied from driving-signal supplying means, not shown, to ink discharging means on the carriage HC, ink is discharged from the discharge ports 4 of the ink-jet print head 200 to the printed medium 150 .
In the embodiment, the ink-jet printing apparatus includes a motor 111 as a driving source for driving the carriage HC as the printed-medium conveying means, gears 112 , 113 for transmitting power from the driving source to the carriage HC, a carriage shaft 115 , and the like.
FIG. 6 is a block diagram of the general structure of the ink jet printing apparatus for printing images using the above-mentioned ink-jet print head and any one of the ink jet printing methods to be described later.
The ink jet printing apparatus receives print information as a control signal from a printer driver 400 installed in a host computer. The print information is temporarily stored in an input interface 401 inside the ink jet printing apparatus and converted into data capable of being processed in the ink jet printing apparatus. The converted print information is input to a CPU (Central Processing Unit) 402 functioning as head driving-signal supplying means concurrently. Upon receipt of the data, the CPU 402 processes the input data using peripheral units such as a RAM (Random Access Memory) 404 and the like on the basis of a control program stored in a ROM (Read Only Memory) 403 so that the input data will be converted into data to be printed (image data).
The CPU 402 also creates driving data for driving a driving motor 406 which moves the carriage HC with the print head and a printed sheet mounted thereon in synchronization with the image data so that the image data will be printed out in position on the printing sheet. The image data and the motor driving data are transmitted through a head driver 407 and a motor driver 405 to the print head 200 and the driving motor 406 , respectively, so that each element will be driven at controlled timing to form an image properly.
The printed medium 150 used in the above-mentioned ink-jet printing apparatus and applied with a liquid such as ink may be any material such as various types of paper or OHP sheet, a compact disk, plastic material for use as a decorative plate or the like, a cloth, metallic material made of aluminum or steel, a cowhide, a pigskin, an artificial leather, wood like timber or plywood, bamboo material, ceramic like a tile, a three-dimensional structure like a sponge, etc.
Further, the ink jet printing apparatus may be a printer for printing images on various types of paper or an OHP sheet, a printer for printing images on plastic material such as a compact disk, a printer for printing images on a metal plate, a printer for printing images on leather, a printer for printing images on wood or lumber, a printer for printing images on ceramic, a printer for printing images on a three-dimensional structure such as a sponge, and a printer for dyeing a cloth or fabric.
Furthermore, the discharged liquid for use with the ink-jet print head may be any type of liquid as long as it suits the printed medium and satisfies the printing conditions.
The above-mentioned ink-jet head and ink jet printing apparatus are also applicable to other embodiments to be described below, and description of the following embodiments uses the same reference numerals or symbols as those used in the above-mentioned embodiment.
It should also be noted that the present invention is not limited to the above-mentioned embodiment as long as it is applied to ink-jet print heads on which image degradation due to satellite dots occurs. For example, the present invention includes a print head having no movable member and a print head having a discharging energy generating element other than the heating element.
Description will be made next of an ink jet printing method according to the embodiment for preventing printed quality degradation due to adherence of satellite dots on the printed medium.
FIG. 7 illustrates matrix patterns created by a matrix printing method practiced as this embodiment of the present invention.
As disclosed in Japanese Patent Laid-Open Application No. 2000-127459, the matrix printing method transfers relatively low-resolution, high-value quantized, processed image data to a printer main body by means of a printer driver in a host computer. Upon receipt of the image data, the printer main body develops the received image data to print data conforming to a predetermined dot matrix and prints out the print data. This method can reduce the amount of data transmission between the host and the printer while preventing image quality degradation.
FIG. 7 shows a 300 ppi grid with matrix patterns divided according to the printer-side print resolution into four 600-by-600-dpi (horizontal scanning direction X vertical scanning direction) grids to be used by the printer driver for processing on the host computer. The 300 ppi grid is quantized at three levels, that is, the quantization levels include a case where the number of created dotted grids within the 300 ppi grid is zero (level 0), a case where it is two (level 1), and a case where it is four (level 2). Their developed dot patterns are set not to form a single-dot printed grid in the horizontal scanning direction X. Using symbols a through d written in the 300 ppi grid at level 0 to explain this, creation of a single-dotted grid a, b, c and d, and creation of dotted grids a and c, or b and d are prohibited. On the other hand, creation of dotted grids a and b or all of a, b, c and d is allowed. When print information for use in printing onto a printed medium is first print information of a single-dot print, the CPU 402 as the changing means adds second print information for generating no satellite dots continuously after the first print information. In other words, the CPU 402 changes the print information composed of the first print information alone into the print information composed of the first print information and the second print information.
This change in the print information allows a main droplet discharged according to the second print information to be hit on a satellite dot alighted adjacent to but slightly spaced with a main droplet discharged according to the first print information, thereby making the satellite dot inconspicuous.
FIG. 8 shows a 300 ppi grid with matrix patterns divided according to the printer-side print resolution into eight 1200-by-600-dpi (horizontal scanning direction X vertical scanning direction) grids to be used by the printer driver for processing on the host computer. The 300 ppi grid is quantized at eight levels, from level 0 to level 7. In this case, their developed dot patterns are also set not to form a single-dot printed grid in the horizontal scanning direction X.
In other words, the ink jet printing method according to the embodiment creates print data or dot patterns indicative of such an arrangement that two or more pixels data corresponding to dots hit on the printed medium are always aligned in the horizontal scanning direction at actual printing. Thus the ink jet printing method creates a dot pattern to perform printing on the basis of the dot pattern, so that the satellite dots can be made inconspicuous in single-dot printing, thereby achieving stable, high-quality printing.
It should be noted that although the embodiment described the relationship between processing resolution and actual printing resolution and associated dot patterns, the present invention is not limited to the embodiment.
The following describes a possible modification of the embodiment. In this case, the 300 ppi grid is quantized at more levels, namely four levels. The quantization levels include a case where the number of created dotted grids within the 300 ppi grid is zero (level 0), a case where it is one (level 1), a case where it is two (level 2), and a case where it is four (level 3). Description will be made below using symbols a through d written in the 300 ppi grid at level 0 in FIG. 7, where level 1 contains a dotted grid a, level 2 contains dotted grids a and b, and level 3 contains dotted grids a, b, c and d.
In this case, since the isolated level-one matrix forms an isolated dotted grid, the quantization should be so set that use of the level-one matrix is kept to a minimum. If no level-one matrix is used, this modification will be exactly lie same as the above-mentioned embodiment. Even if the level-one matrix is used, the probability of generation of the level-one matrix can be set extremely low so that use of the level-zero, or level-two or higher matrixes will become dominant, which can also achieve an improvement equivalent to that in the above-mentioned embodiment.
This modification is effective in a case where a common matrix pattern is used for all colors but satellite characteristics are different between colors.
(Second Embodiment)
FIGS. 9A and 9B illustrate dither patterns created by another quantization technique different from that of the first embodiment. Two exemplary patterns shown in FIG. 9 are created to imitate characteristics of a fatting (centralized type) pattern (FIG. 9A) and a Bayer (distributed type) pattern (FIG. 9 B), both of which are known as dither patterns, but this embodiment is not limited thereto. Further, FIGS. 9A and 9B each show a four- by four-pixel pattern in the interests of simplicity, in which the numerical values indicate criteria of binary judgment when there are 0 to 16 inputs.
Even in this case, the dither patterns are set so that two or more dots are always aligned in the horizontal scanning direction during actual printing to reduce the influence of satellite dots on image quality degradation. In other words, the patterns are so set that two or more pixels with the same numerical value (for example, pixels with “6” as enclosed with a thick-line box ion FIGS. 9A and 9B) are aligned in the horizontal scanning direction.
In this embodiment, single-dot printing can also be avoided on the print data in the same manner as in the first embodiment. Therefore, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
(Third Embodiment)
Description will be made next about the process to create print data for forming continuous dots using error diffusion as still another quantization method different from those of the first and second embodiments.
FIG. 10 shows related pixels in the process of error diffusion according to this embodiment. It should be noted that this embodiment illustrates a three- by three-pixel pattern as an example to simplify the explanation.
In FIG. 10, the pixels are given symbols a′ to i′ as distinguished from one another. Further, a pixel observed last time, a pixel observed this time and a pixel added this time are distinguished from one another by varying hatching types. It should be noted that the pixel observed this time indicates a pixel to be quantized this time. In FIG. 10, the pixels in each row are quantized from left to right (for example, the quantized order is d′-e′-f′ in the middle row).
Referring next to FIGS. 11A to 11 C and the flowchart of FIG. 12, detailed description will be made about continuous two-dot printing method using error diffusion according to the embodiment. It should be noted that the symbols a′ to i′ are omitted in FIG. 11 in the interests of simplicity.
At first, a pixel e′ observed this time is recognized and quantized by a normal error diffusion technique to leave the printer driver to determine whether the dot should be printed (step 51 ). As shown in FIG. 11A, if no dot should be printed at the pixel observed, an error is spread to peripheral pixels (step 58 ). Then the observed pixel is forwarded to the right to a pixel f′ (step 59 ) to process the next pixel.
On the other hand, if the pixel e′ observed this time should be printed, a dot is printed at the pixel (step 52 ) and an error of the pixel observed this time is spread to peripheral pixels (step 53 ).
It is then determined whether a dot has been printed at the pixel d′ observed last time (step 54 ). As shown in FIG. 11B, if the dot has been printed at the pixel d′ observed last time, the observed pixel is forwarded to the pixel f′ next to the pixel e′ (step 59 ). As shown in FIG. 11C, if no dot has been printed as the pixel d′ observed last time, a dot is printed at the dot addition object pixel f′ (step 55 ). At this time, the dot is forcedly printed regardless of the level of the dot addition object pixel. Further, the dot addition object pixel is processed as if the dot was added to the dot addition object pixel regardless of the level of the dot addition object pixel to spread an error of the dot addition object pixel to peripheral pixels (step 56 ). Even if the level of the dot addition object pixel is too low to print a dot at the pixel, since the error is stored as a whole, it will have little effect on the printed image. Then the observed pixel is forwarded to a pixel next to the dot addition object pixel (step 57 ).
As a result of the above-mentioned processing, continuous dots are always printed as shown in FIG. 13 . Thus the third embodiment can avoid single-dot printing on the print data in the same manner as in the first and second embodiments.
As discussed above and according to the first to third embodiments, two or more continuous dots are generated on the print data, that is, at the stage of quantization for deciding printing positions of the dots, so that a single-dot printing can be avoided. As a result, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
(Fourth Embodiment)
Description will be made next about setting of a thinning-out mask for realizing a continuous-dot print in multi-path printing.
The multi-path printing is to prevent image quality degradation due to differences in the amount of discharge between scans on the head or between nozzles in the head, or irregularities in the motion of each nozzle. In other words, the multi-path printing is a known technique for preventing image quality degradation, in which an image is formed through plural nozzles in the head by scanning an image area plural times at the image printing while thinning out the print in each scanning process.
In executing the above-mentioned multi-path printing, continuous two dots are separately printed at adjacent pixels at the multi-path printing even if print data of a continuous two-dot printing type are created, for example, using any one of techniques described in the first to third embodiments. The multi-path printing results in single-dot printing after all, which makes it difficult to use a mechanism for continuously discharging ink from the ink-jet print head having the movable member 11 according to the present invention so that satellite dots will be reduced. Consequently, the effects of the present invention can not be obtained in the multi-path printing process.
To solve this drawback, a thinning-out mask is used to avoid single-dot printing of the print data of a continuous two-dot printing type at multi-path printing, especially at two-path printing, as shown in FIGS. 14A and 14B.
The pattern shown in FIG. 14A is adaptable to the matrix printing method shown in FIG. 8, or the dither pattern having Bayer characteristics as shown in FIG. 9 B. On the other hand, the pattern shown in FIG. 14B is adaptable to the dither pattern having fatting characteristics as shown in FIG. 9 A. Both of the patterns shown in FIGS. 14A and 14B are to print two or more continuous dots by continuously discharging ink in each scan period on the basis of a relationship between the dot arrangement of each quantization method and the thinning-out pattern in each multi-path printing process. If the dither pattern having Bayer characteristics shown in FIG. 9B is combined with the thinning-out mask shown in FIG. 14A, continuous two dots are printed at pixels indicated in FIG. 9B with values of judgment 2 , 14 , 8 and 12 at first-path printing. Then continuous two dots with values of judgment 6 , 10 , 4 and 16 are printed at second-path printing.
Thus the single-dot printing can be avoided using a combination of print data and a thinning-out mask to print two or more continuous dots less influenced by satellite dots even at multi-path printing, allowing the ink-jet print head to perform stable, high-quality printing with less satellite dots.
The fourth embodiment illustrates the above-mentioned quantization and thinning-out mask combination as an example, but the fourth embodiment is not limited thereto. The fourth embodiment is aimed at correlating setting of the thinning-out mask with any one of the quantization methods described in the first to third embodiments so that generation of a single dot will be prevented. As a result, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
(Fifth Embodiment)
Description will be next about a replacement of dots using pattern matching.
The above-mentioned embodiments taught the printing methods for creating and revising necessary data on the printer driver side prior to printing. Unlike the above-mentioned embodiments, this embodiment performs pattern matching of previously created print data to change a dot arrangement so as to realize continuous dots.
At first a description will be made of execution timing of pattern matching when data created by halftoning to contain a single dot are processed by pattern matching.
FIG. 15 is a flowchart illustrating execution timing of pattern matching when print data created by halftoning are processed by pattern matching according to this embodiment.
At first, the printer driver in the host computer executes color correction (step 101 ) and halftoning (step 102 ) to create data containing a single dot. Then the printer driver encodes a print command (step 103 ). The above-mentioned sequence of operations is carried out by the printer driver 400 in the host computer.
After the data is passed through the I/F interface 401 (step 104 ), the print command is decoded on the printing apparatus side (step 105 ) to prepare the printing apparatus for the next scan data (step 106 ) before printing (step 107 ).
When the data created to contain a single dot according to normal halftoning procedures as shown in FIG. 15 are processed by pattern matching, the pattern matching could be executed at one of three timings.
Timing A: Execution of Pattern Matching A
Pattern matching A is executed (step 108 ) after the printer driver 400 in the host computer creates data by halftoning (step 102 ) and before the printer driver 400 encodes the print command (step 103 ). In this case, since the printer driver 400 in the host computer executes the pattern matching A, the hardware limitations and load arc kept to a minimum, but the processing speed is relatively low.
Timing B: Execution of Pattern Matching B
Pattern matching B is executed (step 109 ) after the print command is decoded in the ink jet printing apparatus (step 105 ) and before the ink jet printing apparatus is prepared for the next scan data (step 106 ). In this case, if the pattern matching is carried out in an ASIC (Application-Specific Integrated Circuit), the processing speed becomes high enough to increase efficiency. On the other hand, if the pattern matching is carried out by the CPU 402 on the ink jet printer side, the processing speed will depend on the processing speed of the CPU 402 . In either case, the processed data need to be stored in a buffer provided inside the ink jet printing apparatus, which causes a high frequency of memory access to increase the processing load.
Timing C: Execution of Pattern Matching C
Pattern matching C is executed (step 110 ) before the printing is performed (step 107 ). In this case, since the data are converted at the time they are extracted from the buffer and transferred to the head 200 , the processing speed becomes the highest. On the other hand, since this pattern matching is the most hardware-dependent mode, the processing has the least flexibility.
The pattern matching can be executed at any one of the above-mentioned timings depending on characteristics required for the print, such as to decide which assures a higher priority, the processing speed or reduction in the hardware limitations or load.
As discussed above and according to the fifth embodiment, the printing method can not only use conventional printer driver and halftoning techniques as they are, but also retains independence of functions by designing the pattern matching portion as an additional function.
Using a one- by three-pixel matrix shown in FIG. 16, the following describes a salient feature of the pattern matching according to the embodiment. The salient feature of the pattern matching according to the embodiment is to replace single-dot data isolated in the horizontal scanning direction with continuous dot data, which is executed at any one of the above-mentioned three timings.
In FIG. 16, the left matrix represents data containing a single dot (black dot) created by halftoning.
If such data as to contain a single dot isolated in the horizontal scanning direction are detected, an additional dot (indicated by a hatched dot) is added in a position next to the single dot as shown in the right matrix in FIG. 16, thus realizing continuous dots. In other words, if a dot arrangement “0-1-0” appears in the horizontal scanning direction, where “0” represents no dot and “1” represents the presence of a dot, the dot arrangement is replaced with a dot arrangement “0-1-1”.
FIGS. 17A to 17 D illustrate several gray-scale dot patterns of 4- by 4-pixel matrix data, showing how each gray-scale dot pattern is replaced when additional dots are added according to the embodiment. In FIGS. 17A to 17 D, the left matrixes represent such data before replacement as to contain at least one single dot, while the right matrixes represent data to which additional dots have been added to replace the single dot with continuous dots.
FIGS. 17A and 17B show cases where 12.5%- and 25%-dense data composed of single dots isolated in the horizontal scanning direction are replaced with 25%- and 50%-dense data composed of continuous dots aligned in the horizontal scanning direction, respectively.
FIG. 17C shows how a single dot (indicated by arrow a 1 ) at the bottom most right end (in the fourth row and the fourth column) of the matrix data before replacement is replaced with continuous dots. In this case, an additional dot may be put in a position indicated by arrow a 2 (in the first row and the fourth column) of data to be processed next as indicated by a broken grid, or in a position indicated by arrow a 3 (in the third row and the fourth column) of the currently processed matrix data.
FIG. 17D shows a case where 50%-dense data are patterned by halftoning in a zigzag manner. Since the data are replaced with a 100% solid pattern, the actual image may be cut in gray scale by about 50 percent. In this case, although necessary processing such as creation of print image data and adjustment of density should be performed on the printer driver side, the embodiment does not refer to these techniques.
As discussed above and according to the fifth embodiment, data created by halftoning to contain at least one single dot are replaced with continuous dot data created not to contain any single dot by means of the pattern matching according to the embodiment. Since single-dot printing is avoided on the print data, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
Although in the embodiment the pattern matching is executed on a bit basis, the present invention is not limited thereto.
As a modification, the embodiment can be applied to a matrix pattern on a quantized-grid basis. A description will be made here of a case where a 300 ppi grid is divided into four quantization levels. In other words, the quantization levels include the case where the number of created dotted grid to the 300 ppi grid is zero (level 0), the case where it is one (level 1), the case where it is two (level 2), and the case where it is four (level 3). Using symbols a through d written in the 300 ppi grid at level 0 in FIG. 7 to describe their developed patterns, level 1 contains a dotted grid a, level 2 contains dotted grids a and b and level 3 contains dotted grids a, b, c and d.
In this modification, it such data that the matrix levels are aligned as “0-1-0” in the horizontal scanning direction are detected, the isolated level-one matrix will be replaced with the level-two matrix. In this case, the arrangement of the matrix levels becomes “0-2-0” and continuous dotted grids are obtained.
Even when the pattern matching is executed for each matrix level according to this modification, the pattern matching can be carried out at any one of three timings similar to those in the embodiment. Like in the embodiment, the pattern matching can be executed at any one of the above-mentioned three timings depending on characteristics required for the print, such as to decide which assumes a higher priority, the processing speed or reduction in the hardware limitations or load.
Further, the method of detecting single-dot data for each matrix level described in this modification can be combined with the dot adding method described in the embodiment to realize continuous-dot data in the same manner.
(Sixth Embodiment)
Description will be made next about another pattern matching technique in which continuous dots are realized by moving single dots as well as addition of additional dots.
For example, as shown in FIG. 18A, if data are created by halftoning to contain a single dot, an additional dot can be put in a position next to the signal dot to create continuous dot data in the same manner described in the fifth embodiment. On the other hand, if data contains single dots aligned as shown in FIG. 18B, the single dot data located at the right end will be eliminated (as crossed out in FIG. 18 B). Then additional dot data are added to the left of the other single dot data (that is, the newly crated dot a 5 is put to the left of the previously created dot a 4 ) to create continuous dot data. In other words, this embodiment is such that if dots are aligned as “0-1-0-1” in the horizontal scanning direction, the dots will be realigned as “0-1-1-0.” In this case, since one of the dots is moved without adding any additional dot, the number of dots does not increase. As a result, the density of the replaced data does not vary from that of the data before replacement.
FIGS. 19A to 19 H illustrate several gray-scale dot patterns of 4- by 4-pixel matrix data, showing how each gray-scale dot pattern is replaced by the pattern matching according to the embodiment. In FIGS. 19A to 19 H, the left matrixes represent such data before replacement as to contain at least one single dot, while the right matrixes represent data after additional dots have been added by the pattern matching so that the single dot would be replaced with continuous dots.
As shown in FIG. 19A, if a single dot is contained in a line (in the horizontal scanning direction), an additional dot is so added that both dots are made continuous in the same manner as described in the fifth embodiment. In this case, since single dots at highlight pixels are replaced with continuous dots, although the density of these pixels become high, the printer driver can adjust the gray scale for the density variations to reduce variations in the number of levels of gray.
As shown in FIG. 19B, if two single dots are placed at every other pixel in a line (in the horizontal scanning direction), the right single dot data will be eliminated while adding additional dot data to the left of the eliminated dot data. Thus the continuous dot data are obtained.
As shown in FIG. 19C, if a single dot is placed at the bottommost right end (in the fourth row and the fourth column) of the data before replacement, an additional dot will be added in the same manner described in the fifth embodiment. In other words, the additional dot may be put in a position indicated by arrow a 6 (in the first row and the fourth column) of data to be processed next, or in a position indicated by arrow a 7 (in the third row and the fourth column) of the currently processed matrix data.
FIG. 19D shows a case where 50%-dense data arc patterned in a zigzag manner. In this case, the single dot located at the right end in each line is moved to the left adjacent pixel, which makes it possible to maintain the density of 50 percent.
In other cases as shown in FIGS. 19E and 19F, the same processing as described in FIG. 19D is performed to maintain the density before replacement.
If no single dot exists as shown in FIGS. 19G and 19H, no replacement will be required because there is no need to consider the effect of the satellite dots.
The above-mentioned pattern matching may also be carried out at any one of the three timings described in the fifth embodiment in connection with FIG. 15 .
As discussed above and according to the sixth embodiment, data crated by halftoning to contain at least one single dot in the same manner as in the fifth embodiment are replaced with continuous dot data created not to contain any single dot using the pattern matching according to the embodiment. Since single-dot printing is avoided on the print data, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
Further, if the pattern matching according to the embodiment is executed by merely moving dots without adding any additional dots, the number of dots does not increase, and therefore printing can be made without varying the density of data.
(Seventh Embodiment)
Each of the above-mentioned embodiments described the printing method for creating and revising necessary data on the printer driver side prior to printing, or the printing method for executing pattern matching to data created to contain a single dot or dots to change the dot arrangement so as to realize continuous dots. Unlike the above-mentioned embodiments, this embodiment illustrates a control method for the print head to achieve appropriate printing without changing print image data.
The control method in the embodiment is implemented in a combination of the following features, that is, by giving the following functions to the CPU 402 of the ink jet printing apparatus shown in FIG. 5 :
(1) A function for counting the number of continuous discharged dots for each nozzle;
(2) A function for judging whether the count value for the pixel concerned is one; and
(3) A function for controlling the nozzle concerned to discharge ink at a pixel next to the pixel concerned without fail when the judgment result is affirmative.
In this configuration, a control signal is sent to the head driver 407 to drive the print head 200 . Thus the head is controlled in a manner which corresponds to the pattern matching described in the fifth embodiment. In other words, even if printing is performed on the basis of data created to contain a single dot or dots isolated in the horizontal direction, the head is controlled so that it discharges ink to a pixel or pixels next to the single dot or dots. This makes it possible to form continuous dots on the printed medium.
Further, to control the head in a manner which corresponds to the pattern matching described in the sixth embodiment, that is, in a manner which corresponds to data replacement shown in FIG. 18B, the CPU 402 further includes the following function in addition to the above-mentioned functions:
(4) A function for controlling the nozzle concerned not to discharge ink at a pixel next to the pixel concerned after completion of the above-mentioned processing step 3.
Of all the above-mentioned functions of the CPU 402 , the function (3) may be replaced with:
(3′) A function for generating a further one-dot discharging pulse to the nozzle concerned in addition to the normal discharging pulse when the judgment result is affirmative.
In other words, the same nozzle from which the single dot has been formed is controlled to form a dot at a pixel next to the single dot so that continuous dots will be formed. In this case, the continuous dots are formed earlier than in the normal discharging period. The earlier discharge makes the additional dot hit at a position closer to the first dot, which makes it possible to reduce image quality degradation accompanied with noticeable granularity.
As discussed above and according to the seventh embodiment, the head can be controlled to form continuous dots without any single dot without the need to change the print image data. Consequently, image quality degradation due to satellite dots tending to be generated in single-dot printing on the ink-jet print head can be reduced, allowing stable, high-quality printing.
(Eighth Embodiment)
Description will be made next about a printing method capable of reducing granularity by using single dots and continuous dots properly according to this embodiment.
In a practical printing system, for example, at such multi-path printing that a raster is scanned two or more times, satellite dots may be conspicuous when scanning forward and inconspicuous when scanning backward. Such irregularities of generation of satellite dots can occur because of the relationship between the discharging angle from the ink-jet print head to the paper surface and the scanning speed of the carriage. To reduce granularity in highlight portions, this embodiment positively uses single dots in one scanning direction in which the satellite dots are inconspicuous.
FIGS. 20A and 20B illustrate a first technique according to the embodiment. As shown in FIGS. 20A and 20B, the first technique sets the following quantization levels:
Satellite-inconspicuous scanning direction: Ternary quantization levels (FIG. 20A)
Satellite-conspicuous scanning direction: Binary quantization levels (FIG. 20B)
When scanning is on the way, since satellite dots are inconspicuous, quantization is carried out at three levels, that is, in ternary, so that single dots are formed in highlight portions, thereby reducing granularity. On the other hand, when scanning is on the way back, since satellite dots become conspicuous, all dots are formed in binary, that is, either “0 dots” or “2 dots”, to solve the satellite problems.
Using the processing for changing “single dots” to “consecutive dots” described in the above-mentioned embodiments, a second technique according to the embodiment is to perform selective processing as follows:
Satellite-inconspicuous scanning direction: “Single dots” to “consecutive dots” processing not applied.
Satellite-conspicuous scanning direction: “Single dots” to “consecutive dots” processing applied.
Such selective processing allows satellite dots to be cancelled while reducing granularity in highlight portions.
A third technique according to the embodiment sets the following pseudo shades:
Satellite-inconspicuous scanning direction: light dots
Satellite-conspicuous scanning direction: dark dots
Such an arrangement that only the pseudo “light dots” are put in the highlight portions would also be effective in reducing granularity. In this case, lights and shades can be processed by any known technique.
(Ninth Embodiment)
The eighth embodiment illustrated the printing method for positive use of single dots to reduce granularity. On the other hand, this embodiment illustrates a printing method for positive use of satellite dots to reduce granularity.
In other words, the embodiment is to reduce granularity using a tendency of satellite dots to be hit far away from main droplets at such high-speed printing that the carriage HC is moved at high speed.
FIG. 21A shows hitting positions of main droplets and satellite dots at such low-speed printing that the carriage HC is moved at low speed. FIG. 21B shows hitting positions of main droplets and satellite dots at such high-speed printing that the carriage HC is moved at high speed.
Distance l 1 between a main droplet 267 and a satellite dot 268 at low-speed printing shown in FIG. 21A is much shorter than distance l 3 between the main droplet 267 and the satellite dot 268 at high-speed printing shown in FIG. 21 B. The distance l 1 at low-speed printing is short enough, that is, the main droplet 267 and the satellite dot 268 are hit closer to each other enough to be regarded as one droplet. When the main droplet 267 and the satellite dot 268 are regarded as one droplet, distance l 2 between main-satellite droplets 270 becomes longer than the distance l 3 between the main droplet 267 and the satellite dot 268 at high-speed printing.
To be more specific, if the main droplet 267 and the satellite dot 268 are hit closer to each other at low-speed printing enough to be regarded as one droplet, such united large droplets will be arranged relatively far away from each other. On the other hand, if the main droplet 267 and the satellite dot 268 are hit far away from each other at high-speed printing, they will form an image as respective small dots as if to imitate the operations of a head having a small amount of discharge.
It is assumed that the size of the main droplet relative to the satellite dot is 2:1 in FIGS. 21A and 21B. If granularity is approximated by (discharge amount of each dot X mean distance between dots), the proportion of granularity at low-speed printing to granularity at high-speed printing is determined as:
Granularity at low-speed printing: Granularity at high-speed printing=(3×1.41421356): 1.5×1=3:1
In other words, high-speed printing wherein the carriage HC is moved at high speed can reduce granularity by about one-third of granularity obtained at low-speed printing where the carriage HC is moved at low speed.
In the case that satellite dots are always hit far away from droplets, the quality of an image such as a text or a fine lines must be considerably degraded to degrade the total image quality. Even in this case, as described in the above-mentioned embodiments, processing for discharging at least two continuous dots can used to eliminate satellite dots.
If the processing for discharging at least two continuous dots is performed to the following areas while using satellite dots on the other areas to reduce granularity, the total image quality can be improved:
1. Black/color text areas
2. Fine-line/vector-image areas
3. Right-and-left end areas of a photographic image or the like in the horizontal scanning direction
4. Vicinities of extremely dense pixels in a photographic image or the like
5. Other high contrast areas in the horizontal scanning direction
This technique also features improvement of image quality together with the improvement of printing speed resulting from speed-up of the movement of the carriage.
(Tenth Embodiment)
Description will be made next about a printing method for positive use of satellite dots to improve image quality in gray-scale printing.
In gray-scale printing, light ink tends to be used in highlight portions of a landscape or the like. In this case, satellite dots are simply used in the entire area to reduce granularity.
On the other hand, dark ink is mostly dotted in areas already formed with the light-color ink in the landscape. If only the dark-color ink is used to form an image, the image can mostly be color characters. In this case, the processing for discharging at least two continuous dots can be always performed to eliminate satellite dots.
The relation between light and shade can be replaced with the relation between black and color on the basis of the same theory. In other words, if an image is dotted with color ink, satellite dots are simply used in the entire area to reduce granularity. On the other hand, if an image is dotted with black ink, the processing for discharging at least two continuous dots can be always performed to eliminate satellite dots.
This can eliminate the need for image judgment or the like to turn the processing On and Off, which makes it possible to obtain the optimum image quality almost all the areas from highlight portions to the densest portions in simple On/Off operations of the processing for each color.
Although the above-mentioned first through seventh embodiments described the data processing for making satellite dots incognizable, the positive use of satellite dots described in the eight through tenth embodiments can be obtained on the basis of the processing for making satellite dots incognizable described in the first through seventh embodiments. In other words, the On/Off operations of the processing described in the first through seventh embodiments can make satellite dots incognizable or leave satellite dots as they are. If satellite dots run the danger of reducing the printed quality, the processing described in the first through seventh embodiments can be turned on to make the satellite dots incognizable. On the other hand, if satellite dots are positively used to reduce granularity, the processing described in the first through seventh embodiments will be turned off.
(Eleventh Embodiment)
Description will be made next about a technique for improving granularity expected to be degraded by printing highlight portions using the processing for at least two continuous dots, especially for improving granularity of an image dotted with black ink.
If an image is dotted with black ink, though depend on the system design, the following characteristics are generally expected.
1. Black ink is designed to be discharged by larger amount than color ink is.
2. Even if the amount of discharge is the same, the densest ink forms the roughest granular image.
These characteristics may run the danger of reducing granularity during the processing for at least two continuous dots described in the first through seventh embodiments.
To avoid this, process black (composite black) formed of color inks such as cyan, magenta, yellow and the like, is used in highlight to light portions instead of black ink. The process black is created from color inks smaller in the amount of discharge and lower in the density than the black ink, so that it can reduce granularity compared to the black ink. It is preferable to start printing with black ink after the process black is made dense enough for use as black ink.
The idea of “use of process black to reduce granularity of black ink” is not new, but a combination of the process black with the processing for at least two continuous dots described in the above-mentioned embodiments will especially work wonders.
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A ink jet printing system includes an ink jet head from which is discharged to form an image on a recording medium, an ink jet apparatus provided with a conveyer means for conveying the recorded medium, and a casing for scanning the ink jet head in the main or horizontal scanning direction intersecting the conveying direction of the recording medium, and a printer driver for creating image information to be output to the ink jet apparatus on the basis of density information. According to the present invention, the ink jet system comprises: an image information detecting section for receiving first image information to detect whether the first image information is seriously damaged due to detrimental effects of satellite dots; and an image information changing section for changing information to be used, if it is detected that the first image information is seriously damaged due to detrimental effects of satellite dots, from the first image information to second image information less influenced by the satellite dots than the first image information.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to modified ethylene/n-butyl acrylate (EnBA) copolymers having improved adhesion to non-polar substrates. Significantly improved metal adhesion is obtained by grafting a half-ester of maleic acid, e.g., monopropyl maleate, to EnBA copolymers.
2. Description of the Prior Art
The ability of ethylene to be polymerized with a variety of monomers, such as vinyl esters, is well known. For example, vinyl acetate (VA) is polymerized with ethylene to produce ethylene/vinyl acetate (EVA) resins which are widely used in hot-melt and other adhesive systems. It is also known that ethylene can be copolymerized with n-butyl acrylate (nBA) to produce EnBA copolymers. While EnBA and EVA resins containing comparable molar amounts of the comonomer exhibit minor differences in polarity, density, tensile, elongation, softening point, heat stability, low temperature flexibility, etc., the resins are sufficiently similar so that they can be used in many of the same Comparisons of EVA and EnBA resins of the type used in hot melt adhesive systems are discussed in an article by D. C. Wielinski, Adhesives Age, November 1989, pp. 30-33.
Even though EVA and EnBA resins are useful for the formulation of hot melt adhesive and sealant systems, adhesion to metals, such as aluminum, is generally considered to be quite low. We have now found that significant improvement of metal adhesion can be achieved by crafting a half-ester of maleic acid, such as monopropyl maleate, to EnBA copolymers. While it is generally known that adhesion to metals and other non-polar substrates can be enhanced by incorporating adhesion promoting carboxylic monomers, the improvement obtained with the present invention is unexpected compared to the results obtained with comparable grafted EVA copolymers.
Numerous adhesion promoting monomers, primarily acrylic acid and maleic acid (or derivatives thereof), have been incorporated into ethylene copolymers either by direct polymerization or grafting. Ethylene/vinyl acetate/methacrylic acid terpolymers, for example, are known and commercially available from E. I. duPont le Nemours and Company under the trademark Elvax. Ethylene/monomethyl maleate/alkyl acrylate polymers are disclosed in U.S. Pat. Nos. 2,599,119 and 2,599,123. Ethylene and monomethyl maleate are copolymerized in British Pat. 963,380 and copolymers of ethylene and monobutyl maleate are disclosed in Canadian Pat. 1,118,141. Polymers of monoalkyl esters of maleic acid and vinyl acetate, with and without other comonomers, are disclosed in U.S. Pat. Nos. 4,013,805, 4,116,913, 4,347,341, and 4,599,378.
Numerous references are also known which disclose grafting of unsaturated polycarboxylic compounds and their partial or complete esters to a variety of polymer substrates. Generally, grafting is accomplished using peroxide but some processes use other radical-generating means. For example, polypropylene and propylene/α-olefin copolymers are thermally degraded and grafted in U.S. Pat. Nos. 3,480,580 and 3,481,910. Mono- and diesters of maleic acid are disclosed as suitable grafting monomers in both references. Maleic semiesters and semiamides are disclosed for grafting a variety of polymer substrates, including polyethylene and EVA, in U.S. Pat. No. 4,347,341.
SUMMARY OF INVENTION
The present invention relates to modified EnBA copolymers which exhibit improved adhesion to non-polar substrates. The modified copolymers are carboxylic functionalized polymers having a melt flow rate greater than 0.5 comprised of a randomly copolymerized ethylene/n-butyl acrylate backbone having grafted thereto an amount of a lower alkyl monoester of maleic acid such that the functionalized polymer has an acid number greater than 3. Typically, the copolymer will containing from 15 to 45 weight percent in nBA and be grafted with a mono-C 1-4 alkyl maleate to an acid number of 4 to 15. There is also provided a method for improving the metal adhesion of ethylene/n-butyl acrylate copolymers which comprises grafting an amount of a lower alkyl monoester of maleic acid onto an ethylene/n-butyl acrylate copolymer having a melt index greater than 2 and containing from 15 to 45 percent n-butyl acrylate to increase the acid number to a value greater than 0.5.
DETAILED DESCRIPTION
Modified EnBA copolymers exhibiting improved adhesion to non-polar substrates, particularly metal surfaces, are obtained by the present invention. The improvement is obtained by grafting a half-ester of maleic acid onto an EnBA copolymer backbone to produce what is referred to herein as the modified EnBA copolymer.
EnBA copolymers which can be utilized to obtain the improved modified products of the invention are any of those products conventionally prepared by copolymerizing ethylene and n-butyl acrylate. Such copolymerizations are well known in the prior art and generally are carried out at pressures up to about 15,000 psi and temperatures from 150° C. to 250° C. in the presence of a suitable catalyst. The copolymerization of ethylene and lower alkyl acrylates is, for example, described in U.S. Pat. No. 2,200,429.
The EnBA copolymer resins will typically contain 15 to 45 weight percent nBA. In a particularly useful embodiment the EnBA copolymers will have from about 20 to 40 weight percent nBA copolymerized. The melt index of these copolymers can range from fractional values up to about 400 or above. Most usually, the melt index of the EnBA will be from about 0.5 up to about 125, and more preferably, from 0.5 up to about 50 for the intended applications. All melt indexes referred to herein are determined at 190° C. in accordance with ASTM D1238, condition E, and are expressed in grams per 10 minutes. Typically, the EnBA copolymer prior to modification with the maleic half-ester will not have an acid number or the acid number will be negligible. Useful EnBA copolymers of the above types are commercially available from Quantum Chemical Corporation USI Division and sold under the trademark ENATHENE. Specifications of four ENATHENE products which can be used are as follows:
______________________________________ EA EA EA EAENATHENE 80807 80808 89821 89822______________________________________Wt. % nBA 28 35 35 35Melt Index 40 40 110 400% Elongation 700 620 440 220Tensile Strength (psi) 500 310 240 200Density (g/cm.sup.3) 0.9241 0.9255 0.9248 0.923Shore A Hardness 80 70 62 59R&B Softening point (°F.) 225 230 187 178______________________________________
The maleic half-esters used to modify the EnBA copolymer have the general formula ##STR1## where R is an alkyl radical having from 1 up to about 12 carbon atoms. Most preferably, the alkyl substituent R will have from 1 to 8 carbon atoms. Highly desirable results are obtained when the alkyl moiety has from 1 to 4 carbon atoms and monopropyl maleate has been found to be particularly advantageous. The half-esters are obtained using conventional esterification procedures by reacting one equivalent of maleic anhydride or maleic acid with one equivalent of an aliphatic alcohol. As will be understood by those skilled in the art, while products of such reactions are referred to as half-esters they may, in addition, contain minor amounts of fully esterified species and species which have no ester groups.
The maleic half-ester is grafted to the EnBA polymer backbone using established procedures known to the art. The grafting can be accomplished in solution but most commonly is carried out in the polymer melt. While free radical initiating sources are typically utilized to facilitate the grafting, the half-ester may be grafted using thermal or photochemical initiation. In a particularly preferred embodiment, a small amount of organic peroxide having a suitable decomposition temperature is added to the resin melt in a mixer, such as a Brabender or extruder, and maintained for a period of time sufficient to decompose the peroxide and effect grafting If the organic peroxide is a solid it may be dissolved in a small amount of solvent to facilitate introduction into the polymer melt.
The amount of maleic half-ester grafted onto the EnBA copolymer backbone will be sufficient to achieve the desired acid number for the modified, i.e. grafted copolymer. The acid number of the modified EnBA copolymer should be greater than 3 in order to achieve acceptable adhesion values. Acid numbers in the range of 4 to 15 and, more preferably, 5 to 12 have been found to provide particularly useful results The amount of maleic half-ester used in the grafting operation can vary widely depending on the particular procedure used. However, since the presence of maleic half-ester, unreacted graft monomer has a detrimental affect on adhesion, it is preferred to use the lowest level of graft monomer possible and to employ the most effective grafting method. This minimizes the amount of residual monomer present with the modified EnBA copolymer and the problems associated therewith. In some instances, it may be advantageous or even necessary to remove unreacted residual maleic half-ester monomer from the product prior to use.
EXAMPLES
The following examples demonstrate the improved adhesion realized with the modified EnBA copolymers of this invention obtained by grafting maleic half-esters onto an EnBA copolymer. In these examples all percentages are on a weight basis. Melt indexes are determined at 190° C. in accordance with ASTM D1238, condition E, and acid numbers are determined using the titration procedure described in U.S. Pat. No. 4,376,855. Reported adhesion values were determined using laminated aluminum panels in the T-peel test in accordance with ASTM D1876-72. This test provides a measure of the peel resistance of adhesives to various flexible substrates, i.e., substrates which can be put through any angle up to 90° C. without breaking or cracking.
Modified copolymer products used in the examples were prepared by grafting monopropyl maleate onto the EnBA copolymer. Grafting was carried out by mixing all of the ingredients in a Brabender mixer at 165° C. for 15-20 minutes. 3.2 Percent monopropyl maleate and 0.5 percent dicumyl peroxide were used for all of the reactions. After the grafting operation, unreacted monopropyl maleate was removed by dissolving the modified product in xylene and precipitating in acetone. The modified product was dried prior to adhesion testing and acid number determination.
EXAMPLE 1
To demonstrate the improved results obtained by the present invention a commercially available EnBA copolymer (ENATHENE 80807) containing 27.6 percent n-butyl acrylate and having a melt flow rate of 4.2 was grafted with monopropyl maleate in accordance with the above-described procedure. The unmodified EnBA copolymer had no measurable acid number. After grafting, the modified EnBA copolymer had an acid number of 9.3 and melt flow rate of 0.60. Whereas the commercial EnBA copolymer had an adhesion value of only 0.13 psi in the T-peel test, the modified EnBA copolymer grafted with the monopropyl maleate had an aluminum adhesion value of 8.5 psi.
EXAMPLE 2
To further demonstrate the superior adhesion obtained when EnBA copolymers are modified with maleic half-esters, a higher nBA content copolymer (ENATHENE 80809) was grafted with monopropyl maleate. The copolymer contained 38.8 percent nBA and had a melt index of 7.6 and no measurable acid number. After grafting with 3.2 percent monopropyl maleate, the modified EnBA copolymer had an acid number of 8.4 and melt flow rate of 1.35. The modified EnBA copolymer had a T-peel adhesion value of 21.6 psi compared to a value of only 0.99 psi for the unmodified EnBA copolymer control.
The superior adhesion observed with aluminum using the modified EnBA copolymers of Examples 1 and 2 is even more apparent when it is considered that a commercially available product, ELVAX 4355 (ethylene/vinyl acetate/acrylic acid terpolymer; acid number 6.5; melt index 5.2), widely promoted as an adhesive resin only had a T-peel adhesion value of 3.76 psi. Even though the commercial terpolymer adhesive resin has an acid number which is comparable to that of the modified EnBA copolymers and contains a comparable level of copolymerized comonomer, the aluminum adhesion value obtained with this product is significantly lower than achieved with the modified EnBA copolymers, particularly the higher nBA content copolymer of Example 2.
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Modified ethylene/n-butyl acrylate copolymers obtained by grafting a half-ester of maleic acid onto a randomly copolymerized ethylene/n-butyl acrylate backbone are provided. The carboxylic functionalized polymers of the invention exhibit superior adhesion to non-polar substrates. They are particularly effective for adhering metals.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to improving the leak-proof or spill-resistant quality of gussets in reclosable packages, particularly those made with multi-wall paper or woven polypropylene.
[0003] 2. Description of the Prior Art
[0004] In the prior art of reclosable packages or bags, it is well known to use gussets between the front and rear walls to increase the capacity of the package or bag with only a small increase in the packaging material, such as multi-wall paper or polypropylene.
[0005] However, the use of gussets can increase the tendency for the contents of the reclosable package or bag to leak from the gusset area proximate to the intersection of the package or bag walls and the zipper. More specifically, the contents can travel up the center of the package or bag, between the zipper profiles and out the gusset.
OBJECTS AND SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to eliminate or reduce the leakage of contents of a gusseted reclosable package or bag through the gussets proximate to the intersection of the zipper profiles and the package or bag walls.
[0007] This and other objects are attained by applying glue or adhesive to the walls of the package or bag within the gusset proximate to the zipper assembly, typically within the gusseted area which is between the zipper flanges.
DESCRIPTION OF THE DRAWINGS
[0008] Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein:
[0009] FIG. 1 is a plan view, partially in phantom, of a prior art gusseted package or bag, showing the route through which contents may inadvertently escape.
[0010] FIG. 2 is a cross-sectional view along plane 2 - 2 of FIG. 1 .
[0011] FIG. 3 is a plan view of the gusseted walls of a reclosable package or bag, prior to application of a zipper assembly, illustrating where the glue or adhesive is applied in an embodiment of the present invention.
[0012] FIG. 4 is a cross-sectional view along plane 4 - 4 of FIG. 2 .
[0013] FIG. 5 is a plan view, partially in phantom, of the gusseted package or bag of the present invention.
[0014] FIG. 6 is a plan view, partially in phantom, of a first alternative embodiment of the present invention.
[0015] FIG. 7 is a cross-sectional, partially exploded, view along plane 7 - 7 of FIG. 6 .
[0016] FIG. 8 is a cross-sectional view, partially exploded, along plane 8 - 8 of FIG. 6 (not including the zipper).
[0017] FIG. 9 is an alternative cross-sectional, partially exploded view, along plane 4 - 4 of FIG. 3 , thereby illustrating a second alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1 is a plan view, partially in phantom, of a prior art reclosable package or bag 100 and that FIG. 2 is a cross-sectional view thereof. The package or bag 100 is formed from co-extensive front wall 102 and rear wall 104 which are typically formed from polymeric materials (such as, but not limited to, polyethylene or polypropylene, including woven polypropylene), multi-wall paper or laminates. Gussets 106 , 108 (illustrated in phantom in FIG. 1 and in cross section in FIG. 2 ) are formed as inwardly pointing folds between the side edges of front and rear walls 102 , 104 , typically integral with, or at least of the same material as, front and rear walls 102 , 104 . Gusset 106 is formed from gusset walls 106 a , 106 b in an inwardly pointing V-shaped configuration while gusset 108 is formed from gusset walls 108 a , 108 b in an inwardly pointing V-shaped configuration. The bottom edges of front and rear walls 102 , 104 are sealed or otherwise closed or joined to form bottom 110 . Mouth 112 is formed between the top edges of front and rear walls 102 , 104 . Zipper assembly 200 is sealed, glued or otherwise secured to the upper exterior of front and rear walls 102 , 104 . As shown best in FIG. 7 , zipper assembly 200 includes first profile 202 and second profile 204 which are, referring back to FIG. 1 , sealed together at ends 205 , 207 . First profile 202 includes first interlocking element 206 and first flange 210 . Second profile 204 includes second interlocking element 208 and second flange 212 . First and second flanges 210 , 212 are sealed, glue or otherwise secured to the upper exterior of front and rear walls 102 , 104 , respectively. Typically, zipper assembly 200 includes slider 214 mounted on first and second profiles 202 , 204 . Slider 214 operates in a conventional manner of interlocking first and second interlocking elements 206 , 208 with each other when moved in a first direction and separating first and second interlocking elements 206 , 208 when moved in a second direction. However, alternatively, first and second interlocking elements 206 , 208 may have a “press-to-close” configuration in which no slider is required.
[0019] As shown by the circuitous path indicated by the arrow in FIG. 1 , this design is susceptible to contents within package or bag 100 traveling up the center of the package or bag 100 , between the first and second flanges 210 , 212 and out the gussets 106 , 108 . This leakage or spillage is illustrated for the first gusset 106 but is equally applicable to the second gusset 108 .
[0020] As shown in FIGS. 3 , 4 and 5 , this leakage or spillage can be prevented or minimized by placing a smear of glue or adhesive 400 , 402 in the gussets 106 , 108 in the corner areas 300 , 302 . These smears can be on both the internal and external sides of gusset walls 106 a , 106 b , 108 a and 108 b so that gusset wall 106 a is glued to the interior of front wall 102 and to gusset wall 106 b ; gusset wall 106 b is further glued to the interior of rear wall 104 ; gusset wall 108 a is glued to the interior of front wall 102 and to gusset wall 108 b ; and gusset wall 108 b is further glued to the interior of rear wall 104 .
[0021] FIG. 5 shows, in phantom, glued areas 220 , 222 which are formed between first and second profiles 202 , 204 . Glued areas 220 , 222 are formed to block off or gasket-close the space above the front and rear walls 102 , 104 and below the first and second interlocking elements 206 , 208 . This further provides the leak-proof characteristics of the package or bag 100 . An alternative configuration to create the desired gasket effect is to apply glue along the top of the gussets 106 , 108 or on the gussets 106 , 108 and pressing the package or bag 100 so that the glue is urged into the space above the front and rear walls 102 , 104 and below the first and second interlocking elements 206 , 208 .
[0022] In a first alternative embodiment of the present invention, shown in FIGS. 6 , 7 and 8 , a series of glue or adhesive dots 500 (shown in an exaggerated or elongated in the exploded views of FIGS. 7 and 8 ) is placed between gusset walls 106 a , 106 b in corner area 300 and between gusset walls 108 a , 108 b in corner area 302 .
[0023] In a second alternative embodiment of the present invention, shown in FIG. 9 , glue smear 400 ′ is placed between the external sides of gusset walls 106 a , 106 b and glue smear 402 ′ is placed between the external sides of gusset walls 108 a , 108 b . In other words, in this second alternative embodiment, glue smears 400 ′, 402 ′ are intended to glue the respective gusset walls together with minimal, if any, contact with the interior of front and rear walls 102 , 104 .
[0024] The resulting package or bag 100 has reduced leakage and can be filled, transported and used in the same way as similar packages or bags.
[0025] Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.
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Reclosable gusseted packages or bags have improved resistance to leaking or spilling through the gussets by way of glue or adhesive applied in the gussets in the areas proximate to the reclosable zipper of the bag. This can be done by applying a glue smear to the interior and exterior of the gusset walls; applying glue dots between the exterior facing walls of the gussets; or by applying the glue smear between the exterior facing walls of the gussets.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to a one-piece aluminum heat exchanger tank and a method for fabricating such a tank.
2. Description of the Related Art
Various heat exchanger tanks exist in the art that are formed from a single sheet of metallic material. These one-piece tanks are typically fabricated by rolling an aluminum-clad sheet into a structure having integrally formed sidewalls and then joining two opposed side edges of the walls together along a common joint. The resulting tank is then connected to a core subassembly using conventional nuts and gasket seals in combination with discrete mounting brackets that must be positioned on the tank before the tank is connected to the core.
An example of a one-piece aluminum tank which utilizes separate mounting brackets for mounting the tank to a radiator core is disclosed in U.S. Pat. No. 6,167,953 (“Kobayashi et al.”). The Kobayashi et al., tank features a cylindrical body formed by brazing opposed end edges of an aluminum sheet together to form a joint that extends along the length of the tank. Specifically, one of the end edges of the joint overlaps the other on the exterior surface of the tank.
Although forming a single, overlapping joint on the exterior of the Kobayashi et al., tank arguably reduces the number of steps required to fabricate the tank, it does nothing to minimize the space occupied by the tank once it has been connected to a core subassembly. It also creates a rough, marred exterior surface which is so uneven that it renders the tank unuseable. Furthermore, the process of connecting the tank to the core is complicated by the use of the discrete mounting brackets. Each bracket must be separately brazed to the exterior of the tank before the tank can be attached to the core. Given the recent attention focused on creating an aluminum radiator that eliminates the header crimp area between the core and tanks, the marred surface created by overlapping the mounting brackets and exterior joint of the Kobayashi et al., invention fails to provide a suitable solution for minimizing the space occupied by a one-piece header tank.
Although Kobayashi et al., and other references specifically disclose aluminum tanks having brazed joints and which are mounted onto cores using separate brackets, the references fail to provide any type of connecting joints that are strong, yet result in a tank having a space-saving and smooth exterior surface. The references also do not disclose a tank featuring such a joint in combination with an integrally-formed bracket or rail for use in connecting the tank to a core.
BRIEF SUMMARY OF THE INVENTION AND ADVANTAGES
The invention provides a heat exchanger tank formed from a single sheet of clad material. The sheet extends through a rectangular cross-section and defines a tube wall with tube holes extending therethrough. A parallel joint wall is spaced from the tube wall. Spaced parallel sidewalls interconnect the joint and tube walls to define a chamber and opposed open ends. The joint wall has an integrally formed tab that extends therefrom into the chamber. A first of the sidewalls is disposed in sealing engagement with the outside of the tab to enclose the tab within the chamber.
The subject invention also provides a method of fabricating a heat exchanger tank. The method includes the step of forming a single sheet of material with a cladding on at least one surface thereof to define a tank extending through a rectangular cross-section and having a tube wall, a parallel joint wall spaced from the tube wall, and spaced parallel sidewalls interconnecting the joint and tube walls to define a chamber having opposed open ends. An additional step is forming an integral tab extending from the joint wall into the chamber. A first of the sidewalls is disposed into engagement with the exterior of the tab to enclose the tab within the chamber, and brazing the first sidewall to the tab.
Accordingly, the subject invention overcomes the limitations of the related art by providing a one-piece heat exchanger tank specifically designed to minimize the exterior surface area occupied by the tank after it has been installed on a radiator core. This is achieved by providing a smooth exterior surface created by joining the opposed side edges of the tank in a manner that positions the overlapped edges inside the chamber of the tank, and by incorporating an integrally-formed mounting bracket on the tank without jeopardizing the leak integrity of the tank.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a perspective view of a heat exchanger tank according to one embodiment of the present invention and showing end caps;
FIG. 2 is an end view of the tank of FIG. 1 ;
FIG. 3 is an enlarged view of the tank shown in FIG. 2 illustrating the interior braze joint;
FIG. 4 is a perspective view of a tank according to FIG. 1 prior to forming holes, slots or recessed areas on the flange thereof,
FIG. 5 is an exploded end view of the tank of FIG. 1 illustrating a method of forming the tank;
FIG. 6 is a perspective view of a heat exchanger tank according to an alternative embodiment of the present invention;
FIG. 7 is a perspective view of yet another embodiment of a tank but prior to forming holes, slots or recessed areas on the flange thereof;
FIG. 8 is an end view of the tank shown in FIG. 7 ; and
FIG. 9 is an enlarged view of the tank shown in FIGS. 6 , 7 and 8 illustrating the exterior braze joint.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a heat exchanger tank for a cooling system is shown generally at 10 in FIG. 1 , and at 110 in FIG. 6 . The tank is formed from a single sheet of material having a cladding 12 on at least one surface thereof. The sheet material shown in the Figures is aluminum sheet material with 4000 series braze on the exterior surface thereof. The sheet extends through a rectangular cross-section to define a tube wall 14 and a parallel joint wall 16 spaced therefrom. Spaced parallel sidewalls 18 interconnect the joint wall 16 and tube wall 14 to define a chamber 20 and opposed open ends 22 , 24 for permitting fluid flow through the tank 10 . The tube wall 14 includes tube holes 25 through which elongate tubes 26 are received. Each of the tubes 26 defines a passage 28 which extends through the tube 26 to permit fluid flow into the chamber 20 . End caps 30 , 32 , are positioned for being sealingly engaged with the open ends 22 , 24 of the tank.
Each tank also includes a tab 34 integrally formed with the joint wall 16 . The tab 34 extends into the chamber 20 . A first sidewall 36 of the sidewalls 18 is disposed in sealing engagement with the outside of the tab 34 and encloses the tab 34 within the chamber 20 . In particular, the first sidewall 36 includes an interior joint surface 38 positioned within the chamber 20 . The tab 34 includes an exterior surface 40 with the cladding 12 thereon. The cladding 12 seals the exterior surface 40 into engagement with the joint surface 38 to define an internal braze joint 42 within the chamber 20 .
The first sidewall 36 extends above the joint wall 16 and the tab 34 to define a mounting flange 44 . The flange 44 includes a plurality of holes 46 for receiving complementary fasteners therethrough for mounting the tank 10 on the cooling system. The flange 44 has a peripheral edge 48 from which spaced slots 50 extend toward the tab 34 . Like the holes 46 , the slots 50 are used to mount the tank 10 to structure of the cooling system. Recessed areas 52 , 54 extend from the peripheral edge 48 toward each of the ends 22 , 24 of the tank for positioning the flange 44 in closely-conforming relation to the cooling system.
A heat exchanger tank according to another embodiment of the invention is shown generally at 110 in FIG. 6 . With the exception of the flange, the tank 110 includes the same components and is formed from the same materials as the tank 10 .
The flange 44 of the tank 110 is formed from a double thickness of the sheet material to define primary and reinforcing walls 114 and 116 . The reinforcing wall 116 overlaps the primary wall 114 on the interior thereof and extends transversely over the joint wall 16 on the exterior thereof The cladding 12 on the joint wall 16 seals the reinforcing wall 116 into engagement the joint wall 16 to define an exterior braze joint 118 . A U-shaped fold 120 integrally joins the reinforcing wall 116 with the primary wall 114 .
Other than extending through a double thickness of sheet material rather than a single thickness, the holes 122 , slots 124 and recessed areas 126 , 128 on the tank 110 are identical to the respective holes 46 , slots 50 and recessed areas 52 , 54 of the tank 10 . Furthermore, other than extending across the double thickness of the sheet material, the peripheral edge 130 from which the slots 124 extend is identical to the peripheral edge 48 of the tank 10 .
The subject invention also includes a method of fabricating a heat exchanger tank. The method includes the steps of forming a single sheet of material having a cladding 12 on at least one surface thereof to define a tank 10 extending through a rectangular cross-section and having a tube wall 14 with a parallel joint wall 16 spaced from the tube wall 14 . Spaced parallel sidewalls 18 interconnect the joint and tube walls 16 and 14 to define a chamber 20 having opposed open ends 22 , 24 . The joint wall 16 and tube wall 14 are interconnected by forming an integral tab 34 that extends from the joint wall 14 into the chamber 20 , and a first sidewall 36 of the sidewalls 18 is disposed into engagement with the exterior of the tab 34 to enclose the tab 34 within the chamber 20 . The first sidewall 36 is then brazed to the tab 34 .
The method is further defined as extending the first sidewall 36 upwardly above the joint wall 14 and the tab 34 to project outwardly from the joint wall 14 to define a flange 44 . Still another step is extending holes 46 through the flange 44 for receiving fasteners therethrough to mount the tank 10 on the cooling system. Spaced slots 50 are also formed on the flange 44 and extend from a peripheral edge 48 thereof toward the tab 34 for connecting the tank 10 to the cooling system. In addition, the method includes the step of forming a recessed area 52 , 54 on each end of the flange 44 that extends from the peripheral edge 44 thereof toward an adjacent end 22 , 24 of the tank 10 .
The method continues in an alternative way by doubling the sheet defining the flange 44 to further define a primary wall 114 and a reinforcing wall 116 . The method is further defined by forming a U-shaped fold 120 which integrally joins the primary wall 114 and reinforcing wall 116 . The method also includes the step of overlapping the primary wall 114 and the joint wall 16 with the reinforcing wall 116 . The reinforcing wall 116 is then brazed to the primary wall 114 and the joint wall 16 .
A final step is sealing end caps 30 , 32 with the open ends 22 , 24 on each of the tanks 10 , and 110 .
Obviously, many modifications and variations of the present invention are possible in light of the teachings set forth above. The invention may be practiced other than as specifically described within the scope of the claims. Furthermore, the foregoing description of the preferred embodiment 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 one-piece header tank includes side edges that are overlapped and brazed together to form a joint positioned within the interior of the tank. The tank also includes an integrally formed mounting flange that may be fabricated without jeopardizing the leak integrity of the tank.
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RELATED U.S. APLICATIONS
This is a continuation-in-part application of U.S. application Ser. No. 09/018,514 which was filed Feb. 4, 1998, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the production of synthetic polymeric material in filament form for use in fiber manufacture and, more particularly, to apparatus and methods for heatsetting such filamentary material, particularly polyethylene terephthalate (PET) materials commonly referred to as polyester.
In the conventional manufacture of synthetic yarns, a molten polymeric material is extruded in the form of multiple continuous filaments which, after quenching to cool the filaments, are gathered and transported longitudinally in a lengthwise co-extensive bundle commonly referred to as a tow. Particularly with polymeric materials such as PET, the tows are subjected to a subsequent drawing and heating operation to orient and heatset the molecular structure of each constituent filament in each tow.
A typical drawing and heatsetting operation involves transporting multiple tows in side-by-side relation sequentially through two or more drawstands operating at progressively greater driven speeds to exert a lengthwise stretching force on the tows and their individual filaments while traveling between the drawstands thereby performing a drawing to molecularly orient the individual filaments, followed by a calender structure having a series of heated rolls about which the tow travels peripherally in a sinuous path to be sufficiently heated to set the molecular orientation of the filaments. Normally, the tow is transported through a quench stand to be cooled immediately following the calender structure and is finally transported through a crimper, such as a so-called stuffer box, to impart texture and bulk to the individual filaments.
Tow drawing and heatsetting lines of the type above-described have proven to be reasonably effective and reliable for the intended purpose. However, as the fiber industry continually strives to improve efficiency and reduce manufacturing costs, much effort has been devoted to attempts to increase the number of filaments bundled in each tow and to increase the lineal traveling speed at which the filaments are processed through the drawing and heatsetting line, which presents particular difficulties and problems in construction of the apparatus within the line and in effectively accomplishing heatsetting of all of the constituent filaments in a tow.
In particular, it is not uncommon for a tow being processed through a conventional drawing and heatsetting line to have a cumulative denier of all of the constituent filaments in the tow on the order of five million denier. Polymeric materials generally, and PET in particular, exhibit a low thermal conductivity and, in a tow comprising collectively numerous individual fine denier filaments, the interstitial spaces between the individual filaments exacerbate the difficulty of transferring heat throughout the thickness of a tow. With calender rolls having the capability of only heating the tow surface in contact with the rolls, the applied heat penetrates relatively slowly through the thickness of the tow which, in turn, necessitates the provision of a sufficient number of successive calender rolls together with a sufficiently slow traveling speed to ensure that the entire thickness of the tow is uniformly heated.
To better promote more rapid heat transfer through a tow, it has become commonplace to construct calenders with cantilevered rolls to permit the spreading of the individual filaments of the tow in the form of a ribbon or band along the length of the roll.
These various factors not only increase significantly the capital investment necessary for a conventional drawing and heatsetting line, the processing lines of this type in current use nevertheless must operate at lower than desirable processing speeds in order to uniformly heatset all filaments within a tow.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved apparatus and method for calendering a traveling multi-filament tow to heat its individual filaments which will substantially improve the rate of heat transfer through the tow thickness and enable processing to be carried out at correspondingly increased traveling speeds of the tow. A more specific object of the present invention is to provide such improvements in calendering apparatus and methods which can be retrofitted to existing drawing and heating lines. A further object of the invention is to enable the construction and fabrication of a new generation of calendering equipment which, reduces the need for many or all of the calender rolls. Further objects, effects and advantages of the present invention will be apparent from the specification hereinafter provided.
Briefly summarized, the present invention achieves these objectives by providing a calendering apparatus and method for heating a traveling multi-filament tow which, in its most fundamental aspect, basically comprises electromagnetic radiation simultaneously applied in the direction of the traveling tow, such as by means of an electromagnetic radiation source arranged in opposed spaced facing relation to the tow.
Optionaly, the calendering apparatus and method utilizes a plurality of such heated rolls arranged relative to one another for travel of the tow in a sinuous path successively about the respective rolls, with an electromagnetic radiation source directed at the portion of each roll which is in peripheral engagement with the tow. The radiation source may produce electromagnetic waves in either of the infrared, radio or microwave spectrums, or possibly a combination thereof, although it is presently believed to be preferable to utilize infrared lamps associated with each roll in an arcuate arrangement generally conforming to the cylindrical periphery of each respective roll.
An embodiment of the present apparatus and method particularly adapted to be retrofitted to conventional calenders of the type described above would simply equip such calenders with suitable arcuate arrangements of infrared lamps adjacent one or more of the heated calender rolls of the apparatus. As an alternate embodiment, it is contemplated to provide a new form of calender apparatus and method utilizing no calendar rolls or a substantially reduced number of heated calender rolls (in comparison to conventional calenders), each of which may have associated therewith an arcuate arrangement of infrared lamps or other appropriate electromagnetic radiation source directed at the periphery of the respective roll, followed by one or more tunnels through which the tow is transported between opposing electromagnetic radiation sources, such as infrared lamps, to be further radiantly heated downstream of the calender rolls, if calender rolls are employed.
Fundamentally, this combination of calender rolls for surface heating of one side of a tow in conjunction with simultaneous electromagnetic radiant heating of the opposite side of the tow or using opposing electromagnetic radiant heating sources, enables the heating of the filaments in a tow at a rate on the order of twice that utilizing conventional surface heating of a tow by calender rolls alone and, in turn, correspondingly enables a given drawing and heating line to be operated at a lineal tow throughput speed on the order of twice that which is possible utilizing a conventional calender.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating a conventional prior art system for drawing and heatsetting continuous filaments in the form of a tow;
FIG. 2 is a similar schematic diagram illustrating one embodiment of a system for drawing and heatsetting a tow utilizing a calendering apparatus and method according to one embodiment of the present invention; and
FIG. 3 is another similar schematic diagram illustrating an alternative embodiment of calendering apparatus and method according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings and initially to FIG. 1, a conventional PET processing line for drawing and heatsetting filamentary tow of the type over which the present invention seeks to improve is depicted schematically and indicated in its totality at 10 . The line basically comprises a series of machine units arranged in alignment with one another for transport of a tow sequentially from one machine unit to the next. Preferably each machine unit comprises a central upstanding frame from one side of which tow engagement rolls extend outwardly in cantilevered fashion.
Basically, tow from storage cans or another suitable source of supply is initially delivered to a pretensioning stand 12 having a series of driven cylindrical rolls 14 arranged alternatingly along upper and lower horizontal lines along the lengthwise extent of a central frame 16 for travel of the tow t in a serpentine path in engagement with the periphery of each upper and lower roll in sequence, whereby the multiple rolls 14 collectively establish an initial tensioning point in the processing line 10 preliminary to downstream drawing of the tow t.
Two drawstands 18 , 20 are disposed at a downstream spacing from the pretensioning stand 12 and from one another, each drawstand 18 , 20 similarly comprising a central upstanding frame 22 from which multiple cylindrical cantilevered rolls outwardly extend alternatingly along upper and lower horizontal lines for travel of the tow t in like manner along a sinuous path peripherally about each roll 24 in sequence, whereby the two drawstands 18 , 20 establish additional tensioning points along the processing line 10 . A vat 26 containing a predrawing bath, preferably a water-based emulsion, is disposed between the pretensioning stand 12 and the drawstand 18 , for application to the tow t before entering the first drawstand 18 . A series of rolls 28 are mounted at the entrance and exit ends of the vat 26 and also within the vat 26 below the bath level to direct the travel of the tow t for immersion in the bath. A first draw chest 30 , basically constructed as an enclosed tunnel containing an atmosphere of warm water sprays, is situated between the two drawstands 18 , 20 to apply warm water to the tow t while traveling between the drawstands 18 , 20 . Another draw chest 32 is disposed at the downstream side of the second drawstand 20 , but operates at a higher temperature than the first draw chest 30 , applying steam to the tow t while traveling through the tunnel of the chest.
A calender frame 34 is located immediately downstream of the second draw chest 32 and basically comprises a relatively massive structure having a large central frame 36 from which a plurality of large-diameter calender rolls 38 are cantilevered outwardly alternatingly along upper and lower horizontal lines for serpentine travel of the tow t peripherally about the rolls 38 in sequence, in like manner to that previously described with respect to the pretensioning stand 12 and the drawstands 18 , 20 . The cylindrical periphery of each calender roll 38 is heated from the interior of the roll 38 by any suitable conventional means to a sufficient temperature (selected according to the physical characteristics of the tow, its traveling speed, and other known variables) to heatset the individual filaments in the tow t, the serpentine travel of the tow t accomplishing heat application to both sides of the tow t as it travels from one roll 38 to the next.
Immediately downstream of the calender frame 34 , a quench stand 40 , similarly comprising a frame 42 having sequential cantilevered rolls 44 extending outwardly therefrom, is provided for cooling the tow t sufficiently below the heatsetting temperature established by the calender frame 34 to control shrinkage of the tow t. The tow t next travels from the quench stand 40 through a spray stand 46 in which a spray of a suitable finishing composition adapted to enhance subsequent crimping of the filaments in the tow t is applied to the traveling tow t.
As aforedescribed, the tow t in a conventional full speed commercial operation of the processing line 10 will typically comprise filaments totaling up to approximately five million denier and, hence, in order to optimize the uniform application of drawing forces and, in particular, heating to all constituent filaments within the tow t, the filaments are spread from the normal rope-like bundled configuration of the tow t into a thin substantially flattened ribbon-like or band-like configuration while traveling about the various rolls of the upstream machine units. However, conventional apparatus for imparting crimp to the tow t is unsuitable for handling such a flattened thin ribbon-like tow band. Hence, preparatory to a final step of crimping the tow t, the filaments must be condensed into a thicker band, which is accomplished by a so-called stacker frame 48 situated immediately downstream of the spray stand 46 . The stacker frame 48 comprises a plurality of rolls 50 arranged as shown in FIG. 1 to define separate travel paths by which divided portions of the tow t can be directed to travel along independent paths, the rolls 50 which define the different tow travel paths being oriented in known manner out of parallel relation with the other rolls 50 to direct the divided portions of the tow t to a common point along the exit roll of the stacker frame 48 at which the divided portions of the tow t are reassembled atop one another to form a thicker tow band.
The tow t is delivered from the stacker frame 48 into a so-called dancer frame 52 of a known construction basically having stationary entrance and exit rolls 54 , 56 between which a third roll 58 is movable to take up tension fluctuations in the tow t, thereby to ensure that the tow t is delivered downstream at a substantially constant tension.
The tow t is transported from the dancer frame 52 through a steam atmosphere in a tunnel-like steam chest 60 and therefrom is delivered into a crimper 62 , which may be of any known construction to impart crimp or texture to the tow t, e.g., a so-called stuffer box, a gear crimping unit, or other suitable alternative device. Downstream of the crimper 62 , the thusly crimped or otherwise textured tow t is dried, then cut to staple lengths and the staple filaments collected in bale form for delivery to a conventional spinning operation for manufacture of spun yarn.
As described above, while the PET processing line 10 represents the most effective structure and methodology under the current state of the art for drawing (molecular orientation), heatsetting and texturing of continuous synthetic filaments, the overall structure is quite massive and very expensive, due in large part to the size required of the calender frame 34 , particularly the diametric dimension of the calender rolls 38 and the structural requirements of the frame 36 and the bearing structures therein to support the rolls 38 against deflection, in order to satisfactorily apply heat uniformly throughout the entire tow t to all constituent filaments thereof. Even utilizing the technique of spreading the tow t into the form of a relatively thin ribbon-like tow band, the calender frame 34 must still be quite massive, as the proportions in FIG. 1 depict, and the difficulty in uniformly imparting a sufficient heatsetting temperature throughout the tow band imposes limitations on the traveling speed at which a tow t of a given collective denier can be processed.
Fundamentally, the present invention substantially overcomes these difficulties and disadvantages of conventional heatsetting by providing an improved calendering apparatus and methodology by which substantially increased tow processing speeds can be attained and capital outlay for heatsetting equipment may be considerably reduced. With reference to FIGS. 2 and 3 of the accompanying drawings, two differing embodiments of the present invention are depicted.
Referring initially to FIG. 2, a drawing and heatsetting line is shown with a calender frame 134 basically comprising a conventional calender frame 34 of the type shown and described above in FIG. 1 retrofitted with the present invention. Essentially the only change in the calender frame 134 over the conventional calender frame 34 is the addition of an arrangement for applying electromagnetic radiation, preferably in the form of infrared radiation, for radiant heating of the traveling tow t simultaneously with the conductive heating applied by the heated calender rolls 38 . More specifically, the frame 136 is equipped with a series of subframes 136 disposed adjacently above or below each calender roll 38 along the full length thereof, with each subframe 136 supporting a plurality of infrared lamps 137 arranged side-by-side one another at a close radially outward spacing from the respective calender roll 138 along an arc following and conforming to the portion of the calender roll in peripheral heating engagement with the traveling tow t. In this manner, while conductive heat is being applied from the heated calender rolls 138 to one side of the traveling tow t, the infrared lamps 137 are applying radiant heat simultaneously to the opposite outward side of the tow t.
Advantageously, infrared radiation from the lamps 137 penetrates through the thickness of the traveling tow, rather than only applying heat to the tow surface, thereby inherently promoting heating throughout the thickness of the tow t. Moreover, as is known, the absorption of infrared radiation is relatively independent of the temperature of the material to which the radiation is applied so that, in contrast to the conductive heating by the calender rolls 138 the efficiency of which reduces as the temperature of the tow increases, this supplemental infrared heating promotes more rapid heating of the tow t to the desired heatsetting temperature. In addition, the disposition of the infrared heating lamps 137 directly opposite the portion of each respective calender roll 138 contacting the tow t provides the supplementary advantage of reducing radiant and convective heat loss from the outward surface of the tow to the ambient atmosphere.
Those persons skilled in the art will recognize that the precise rate at which the combined effect of the calender rolls 138 and the infrared lamps 137 will impart heat to the tow t will depend upon the interplay of a variety of specific factors, including, for example, but without limitation, the traveling speed of the tow, the denier of the tow, the density of the tow (particularly the interstitial air spaces within the tow), the thickness of the tow, the wavelength of the infrared radiation, and the physical (molecular) characteristics of the tow material (e.g., thermal conductivity and heat capacity), etc.
The provision in the present invention of the supplementary infrared heating lamps 137 is expected in the greater majority of embodiments to essentially double the productivity of a conventional calender frame 34 , either by enabling the tow to be transported at essentially twice the lineal traveling speed at which the calender would be operated without the infrared lamps or by enabling the calender to handle a tow of twice the collective denier which would be processed in the absence of the infrared lamps, or a combination of such increases.
Of course, persons skilled in the art will also recognize that the application and advantages of the present invention's combined use of calender roll heating and infrared or other electromagnetic radiant heating is not restricted to retrofitting applications in conventional calender frames. Indeed, it is contemplated that optimal use and application of the present invention and the greatest achievement of the attendant advantages obtained therefrom can be realized by adapting the present invention to the construction of an essentially distinct generation of calender equipment, one possible embodiment of which is depicted in FIG. 3 . Specifically, with the increased rates of heating achieved by the present invention and the enhanced ability to apply heat into the interior thickness of a tow as opposed to only surface heating, the prior need to utilize calender rolls, as well as the number thereof, can be significantly reduced or eliminated while still achieving effective heatsetting of a given tow at conventional throughput rates.
An exemplary form of such a calender frame is shown at 234 in FIG. 3 . The calender frame 234 is basically constructed similarly to that of the calender frame 34 , having a central upstanding frame 236 from one side of which heated calender rolls extend outwardly in cantilevered fashion, but a substantially reduced number of such calender rolls 238 is necessary, with only four such rolls being provided in the illustrated embodiment. Of course, the calender rolls may be eliminated altogether. As with the retrofitted calender frame 134 of FIG. 2, infrared lamps 237 in FIG. 3 are provided in an arcuate arrangement about the respective portions of the cylindrical peripheries of the rolls 238 which contact the traveling tow t to provide supplementary infrared heating. The primary calender structure of FIG. 3 is a calender tunnel unit 235 basically comprising two longitudinally spaced roll stands 239 each supporting a vertical series of deflection rolls 241 at vertically offset axes for travel of the tow t horizontally back-and-forth between the two roll stands 239 in an elongated serpentine manner. Between the two rollstands, the tunnel unit 235 defines a series of tunnel-like pathways enclosing each horizontal segment of the serpentine travel path of the tow with horizontal arrangements of infrared lamps 243 along each opposite upper and lower side of each travel path segment to provide continued application of infrared radiant heating to the traveling tow t through the tunnel unit 235 .
The combination of the calender frame 234 with the tunnel unit 235 may better enable the balance between conductive surface heating of the tow t and electromagnetic radiant heating of the tow t to be more precisely engineered and controlled toward the ultimate goal of reducing the size and capital expense while achieving the most efficient application of heatsetting energy to the tow t at the highest feasible throughput speed and/or rate. As previously indicated and as will be recognized, infrared heating provides the potential for more rapid and efficient heat application throughout the thickness of a given tow.
In sum, as the foregoing specification demonstrates, the present invention advantageously serves the ultimate goal of optimizing the speed and/or rate of a tow heatsetting operation and, in turn, reducing the attendant costs thereof (either or both processing costs and capital costs) by the fundamental concept of replacing all or some of the calender roll heating of the tow with infrared radiant heating of the tow. Importantly, however, those persons skilled in the art will recognize that this basic inventive concept is not restricted to the two embodiments which have been provided for illustrative purposes only. Many other variations and possibilities within the fundamental invention as disclosed will occur to persons skilled in the art. For example, while infrared radiant heating is considered preferable within the confines of equipment and technology currently known and available, it is also contemplated that infrared heat generation and application other than by the described arrangements of infrared lamps could be utilized and, moreover, other forms of electromagnetic radiant heating, e.g., by radio frequency or microwave radiation, could be effectively implemented with many or all of the same advantages described above.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A calendering apparatus and method for heatsetting a traveling multi-filament tow basically utilizes plural heated rolls about which the tow travels in a sinuous path to be conductively heated by the rolls and, at each roll, a plurality of infrared lamps in an arcuate arrangement facing the portion of the respective roll in contact with the tow simultaneously applies infrared radiation to the opposite side of the tow. In one embodiment, this arrangement of infrared lamps is retrofitted to a conventional calendering apparatus. An alternative embodiment provides for reducing or eliminating the number of calender rolls followed by a series of infrared heating tunnels collectively effective to accomplish heatsetting of the tow. The speed and/or throughput rate of each calendering apparatus and method is effectively twice that of conventional equipment of similar size.
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BACKGROUND OF THE INVENTION
Substitute natural gas may be prepared by a coal gasification process. A general discussion of coal gasification is set forth in Environmental Science and Technology, December 1971, Vol. 5, No. 12 in an article entitled "Gas from Coal, Fuel of the Future" by G. Alex Mills. Generally in the methanation portion of a coal gasification process, nickel is used as a catalyst to convert the synthesis gas, CO and H 2 , produced in the gasification step into methane as the final product.
The prior art teaches the placement of the nickel catalyst on an aluminum oxide substrate. When nickel is used on an aluminum oxide substrate, it is necessary to remove substantially all of the sulfur contained in the feed gas to the methanator. In particular, it is necessary to reduce the sulfur content of the feed gas to a level of less than about 0.1 ppm because the sulfur poisons the catalyst if present in any higher concentration. In order to achieve such a low sulfur content in the feed gas, it is necessary to clean initially the feed gas in a hot carbonate scrubbing operation or any other of a number of cleaning operations which reduces the sulfur to a level in the range of from 10 to 100 ppm. A second cleaning is necessary to reduce the sulfur concentration of the gas below 0.1 ppm. This second step is generally accomplished by an absorption process, whereby the sulfur is absorbed in zinc oxide, iron oxide or a number of other materials.
Sulfur is found in the feed gas to the methanator because sulfur is found in most coal supplies. On the average, the synthesis gas produced in a coal gasification process will contain at least 3,000 ppm sulfur prior to any sulfur removal treatment. The treatment of this gas to remove sulfur is a costly operation and when the treatment entails a two step removal process, the cost is increased. The process step of removing the sulfur from 10 to 100 ppm down to less than 0.1 ppm is very costly because of the large volume of gas which is processed to remove small amounts of sulfur and the expense of replacement or recovery of the absorbent.
It is an object of this invention to provide a methanation catalyst which is not easily poisoned by sulfur. It is a further object of this invention to provide a methanation process in which the gas fed to the process can contain in the range from 10 to 100 ppm of sulfur and can contain substantially higher sulfur levels for short periods of time.
SUMMARY OF THE INVENTION
This invention relates to a catalyst for a methanation operation, and, also to a process of methanating a suitable feed gas stream.
In accordance with one aspect of the teaching of this invention, a catalyst for a methanation operation includes a substrate formed of zirconium oxide and a catalyst material thereon of nickel. The nickel is present on the zirconium oxide in a range from 0.5% to 60% by weight, and, preferably, in a range from 20 to 50 percent by weight.
In accordance with another aspect of this invention, a synthesis gas stream prepared by gasifying coal is processed to remove sulfur therefrom by a single sulfur removal operation. The resulting synthesis gas stream contains in a range from 10 to 100 ppm of sulfur. This synthesis gas is passed over a methanation catalyst in which the substrate is zirconium oxide and the catalyst material is nickel. Even at the relatively high sulfur concentrations of 10 to 100 ppm, the methanation process is effective to produce substantial quantities of methane gas from the feed gas.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Catalyst Preparation
A specific method for preparing a catalyst in accordance with the teachings of this invention is as follows. A high surface area zirconia (ZrO 2 ) powder, having a surface of about 80 square meters per gram is contacted with an aqueous solution of nickel nitrate Ni(NO 3 ) 2 . Only enough nickel nitrate solution is used to just wet the zirconia. The zirconia powder, with the solution thereon, is dried in air at about 100° C to remove the moisture therefrom. The material is reduced in hydrogen gas at about 450° C in order to reduce the nickel to nickel metal on the zirconia base. The catalyst is stabilized by cooling it slowly in hydrogen gas to room temperature, removing the hydrogen gas by introduction of nitrogen gas and then by slowly adding oxygen. The slow addition of oxygen results in oxidation of the nickel on the surface without unnecessarily overheating the catalyst. After this preparation, the catalyst may be handled and it is ready for use in a methanation operation. However, prior to the actual methanation operation, it is necessary to re-reduce the surface nickel oxide by heating the same in hydrogen gas from 300° to 450° C.
The amount of nickel placed on the zirconia substrate can be varied from very low concentrations of metal, from about 0.5% by weight, to very high concentrations of up to 60% nickel by weight. The preferred range of nickel concentration is in the range from 20 to 50 percent by weight. If desired, as an optional step, the catalyst material may be calcined after the nickel nitride solution has been dried thereon. This step is carried out before the reduction step. The important part of preparing the catalyst is that zirconium oxide is used as the substrate.
The substrate zirconium oxide and resulting catalyst may exist in any number of forms. The original zirconium oxide may be in the form of pellets of any size and shape which are then impregnated with a solution containing nickel and then dried and/or calcined and reduced. A second form may be to coat a monolithic honeycomb support structure with a zirconium oxide slurry to form a zirconium oxide layer on the support surface. The support structure may consist of a metal, metal oxide such as cordierite, alumina, silica, silicon nitride, silicon carbide or any other number of materials. After coating the support structure with the zirconium oxide layer, it is dried and/or calcined. Nickel is then added to the coated structure by impregnation with a nickel containing solution.
The catalyst product of this invention can be used in a methanation operation carried out on gaseous products produced as the result of coal gasification. The catalyst is effective even though the feed gas to the methanator contains 10 to 100 ppm of sulfur. Such a level of sulfur generally remains from coal gasification feed stock after that feed stock has been subjected to a hot carbonate scrubbing operation to remove therefrom the originally substantially higher quantities of sulfur in the range from 3000 ppm to 5000 ppm.
Operating Conditions
Tests were carried out on a 5% nickel zirconia catalyst and a 2% nickel aluminate (Al 2 O 3 ) catalyst. The results of the test are shown in Table 1.
Table 1______________________________________Effect of H.sub.2 S on Rate of CO Methanation(400° C, H.sub.2 /CO = 3.8, PH.sub.2 + P.sub.CO = 0.75______________________________________atm) Rate × 10.sup.2 (Turnover number, S.sup..sup.-1)H.sub.2 S level 5% Ni/ZrO.sub.2 2% Ni/Al.sub.2 O.sub.3______________________________________Steady-state 2.21 7.981 ppm H.sub.2 S 0.349 0.3135 ppm H.sub.2 S 0.671 0.17610 ppm H.sub.2 S 0.826 0.168193 ppm H.sub.2 S 1.001000 ppm H.sub.2 S 0.561______________________________________
The important points to be noted from Table 1 are as follows. The rate of CO hydrogenation in Ni/Al 2 O 3 decrease by a factor of 20 in the presence of 1 ppm H 2 S while the activity of the Ni/ZrO 2 catalyst first decreases then increases as H 2 S level is increased. The activity in the range of 10 to 200 ppm is approximately half that in the absence of H 2 S. Although the Ni/Al 2 O 3 catalyst starts at a higher activity, at 10 ppm H 2 S the Ni/ZrO 2 catalyst is five times more active than the Ni/Al 2 O 3 catalyst. Exposure of the Ni/ZrO 2 catalyst to very high levels of H 2 S, e.g., 1000 ppm, lowers the activity but as H 2 S is decreased the activity increases to its former level. This reversibility implies the catalyst would not be affected by accidental sulfur breakthrough due to failure of pretreatment equipment upstream of the methanator reactor.
In actual operating conditions for a commercial methanator reactor, the temperature of operation could be in the range from 250° to 700° C. The pressure for operation could be in the range from 20 to 100 atmospheres. In general, the feed gas for the methanator reactor could have the following formulation: hydrogen 45% by volume, carbon monoxide 15% by volume, carbon dioxide 20% by volume, methane 20% by volume and water at a vol/vol ratio of 0.5. Hydrogen sulfide or carbonyl sulfide can make up to 100 ppm of the feed gases. These feed gases can be achieved by an ordinary coal gasification process with the treatment of the so produced gases by any number of commercial cleaning apparatus such as a hot carbonate scrubbing operation to remove the heavy sulfur concentrations. Prior known catalyst, namely Ni on Al 2 O 3 , require the sulfur be reduced to a level of less than 0.1 parts per million which requires the treatment of the gas after the hot carbonate scrubbing operation by an additional step namely absorption on a metal oxide.
Other elements may also be added to the nickel zirconia catalyst to improve the same. Such additions are known in the art for the purpose of improving the catalyst life, or for making the catalyst resistant to various trace materials which can poison the catalyst over long periods of exposure.
There has been disclosed herein a nickel zirconia catalyst useful for methanation of a feed gas stream having relatively a high sulfur content. There has also been disclosed herein a process for methanating a feed gas stream containing a relatively high concentration of sulfur. In view of the teachings of the specification, those skilled in the art will make many modifications of this invention which do not depart from the true spirit thereof. It is intended that all such modifications be included within the scope of the appended claims.
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This application teaches a methanation catalyst in which nickel is employed on a zirconium oxide substrate. This catalyst may be used in a methanation process in which the feed gases to the process contain between about 10 to 100 ppm (parts per million) of sulfur.
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BACKGROUND OF THE INVENTION
[0001] The invention concerns use of an active biological algaecide, algaestat, bacteriostat or sanitizer in the embodiment of a filter, for example, a filter designed primarily for use in pool and spa applications, however, it's application extends to any body of water in which active control of sanitizers or bacteria/algae control is desired.
[0002] The construction of the filter utilizes materials and or natural elements that are either designed to or naturally contain chemicals, materials or natural properties that are employed or actively engage in either sanitizing, oxidizing, aid in sanitizing and oxidizing, inhibit the growth or formation of algae or bacteria or prevent the growth or formation of algae or bacteria.
[0003] The invention uses said materials either within its main construction, or as part of the screening material of the embodiment itself.
[0004] Currently, pool and spa filters are manufactured out of a media of some sort and a structure designed solely to support the filter media, afford attachment to the unit, and to allow water to flow freely through the filter.
[0005] Algaecides and algaestats are used in the pool and spa industry to aid sanitizers in the growth inhibition, killing and curtailing of future growth of algae. These chemicals, compounds and elements are manufactured and constructed into shapes allowing maximum surface area. These pieces are then placed into vessels to provide treatment packages that are inserted into a filter or filter housing, allowing the water to flow through the vessels and contact the materials while flowing through the filter.
[0000] Definitions of Treatment Materials:
[0006] Algae: A single-celled plant. Of the thousand of varieties, the most common in spas and pools are: blue-green, yellow mustard or black. Algae commonly known as “Pink” algae is actually a bacteria and is usually present as a slime. Algae can transpose itself over very broad areas or in individual spots or areas. A condition with a low sanitizer level is conducive for algae growth.
[0007] Algaecide: A chemical that kills algae. They are commonly available in a variety of chemical types: quaternary ammonium compounds, copper, silver or polymer (poly quat). Chlorine and bromine function as algaecides. Different types show varying effects against different strains of algae (i.e. some are better than others at killing certain strains of algae).
[0008] Algaestat: A chemical or element that inhibits or retards algae growth, however, it does not necessarily kill the algae. Zinc is a common example of an algaestat.
[0009] Such treatment packages are not part of the filter or system itself. In such situations the material status and usefulness cannot easily be monitored or replaced. Additionally, replacement of the material or unit requires extensive and cumbersome procedures.
SUMMARY OF THE INVENTION
[0010] The present invention allows the treatment materials to be manufactured into the filter or sanitizing media embodiment itself, allowing both monitoring when the filter or equipment is serviced, and/or replacement when the filter or other such equipment is replaced, as scheduled and required. As will be seen, when the water flows around or through the material, the properties of the material are either added to the composition of the water, or the act of contacting the water allows the material being utilized to chemically affect the water as it comes into contact with the material itself. In this regard, extensive distribution and effect of the treating material is made possible by its extensive use on filter surfaces, as opposed to a single spot use of treatment material, in a local added package. There are situations where water flow through or by the material is beneficial, as well as situations where just the presence of said materials in the body of water will afford the desired chemical or sanitizing results. In either case, including the material in the embodiment of the filter or filter housing itself satisfies both circumstances.
[0011] Accordingly, invention utilizes the materials, mainly algaecides and algaestats, as materials of construction for the filter itself. No longer will the filter and algaecide/algaestat be used as separate pieces. The chemicals and compounds that are the algaecide and algaestat are the materials used to construct the filter structure itself. This will afford the support of the filter media, afford attachment to the unit as well as allowing water to flow freely through the filter, all the while accomplishing the desired contact of the flowing water with the algaecide or algaestat.
[0012] An additional benefit of utilizing the algaestat zinc is the fact that zinc will act as a sacrificial anode in the water, thus helping to prevent the corrosion of any metal parts in the pool or spa. This is similar to the concept of using a zinc bar in a hot water heater—the corrosion occurs to the zinc bar, not the hot water heater.
[0013] The central support of the filter, referred to as the center core is the component most likely to be manufactured out of an algaecide or algaestat. Other configurations include, but are not limited to utilizing strands or threads of algaecide or algaestat in the construction of the media itself, or building an inner or outer screen out of the algaecide or algaestat.
[0014] Accordingly, it is a major object of the invention to provide, for use in a pool or spa, or other body of water, a combination that includes:
[0015] a) filter structure in the path of pool or spa water flow,
[0016] b) substance on a surface or surfaces of said filter structure, to contact said flow,
[0017] c) said substance characterized as being one of the following:
i) bacteria inhibiting ii) an algaecide iii) an algaestat iv) a sanitizer v) bacteriostat
[0023] As will be seen, the substance typically has the form of a coating on said filter structure surface or surfaces or as the material of manufacture of the filter internals. The filter unit or structure typically includes a pleated filter element or wall facing element, on which said substance is coated; or the filter structure typically includes a perforate tube in the filter structure interior to receive and pass filtered water, and on which said substance is coated, or the substance may be widely spaced on many filter surfaces exposed to water flow, or processed into the filter structure, as produced.
[0024] Another object includes provision of the water treating substance plated or adhered to one or more of such elements, or the element itself may be at least partly formed by that substance, which is typically metallic, consisting of one or more of the following:
[0025] i) tin
[0026] ii) copper
[0027] iii) zinc
[0028] iv) silver
[0029] v) silver plated on copper
[0030] vi) oxides of the above.
[0031] As the filter unit is replaced, the water treating substance is automatically replaced, and need not be separated from the filter or separately inserted into the replacement filter; saving time and energy, as well as avoiding the problem of inadvertent non-placement of water treating substance into the filter.
[0032] These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
[0033] FIG. 1 is a plan view of a spa or pool apparatus into which the filter unit is integrated;
[0034] FIG. 2 is an enlarged elevational view of one filter unit;
[0035] FIG. 3 is an end view taken on lines 3 - 3 of FIG. 2 ;
[0036] FIGS. 4 and 4 a are side views showing two modes of water flow into and out of the filter unit;
[0037] FIG. 5 is a schematic view of water flow into and out of a filter unit;
[0038] FIG. 6 is an enlarged elevation, taken in cut-away section, through a filter unit, showing a center section;
[0039] FIG. 7 is an endwise axial view taken on line 7 - 7 of FIG. 6 ;
[0040] FIG. 8 is a cut-away elevation similar to FIG. 6 ;
[0041] FIG. 9 is an endwise axial view taken on lines 9 - 9 of FIG. 8 ;
[0042] FIG. 10 is a schematic side view of a modified filter incorporating the invention;
[0043] FIG. 11 is an end view taken on lines 11 - 11 of FIG. 10 ;
[0044] FIG. 12 is a schematic enlarged plan view of a texture water treating filter media incorporating the invention;
[0045] FIG. 13 is a view like FIG. 10 showing a modification;
[0046] FIG. 14 is an end view taken on lines 14 - 14 of FIG. 13 ; and
[0047] FIG. 15 is a schematic enlarged view of external textured, water treating structure on the FIG. 13 filter.
DETAILED DESCRIPTION
[0048] The present invention is particularly applicable to a filter unit or structure 18 , as seen in FIGS. 1-9 .
[0049] In FIG. 1 , a pool or spa unit 10 includes an annular upright side wall 11 and a bottom wall 12 . The side wall may consist of multiple sections 11 a. The self-supporting side wall may consist of plastic material, as disclosed for example in U.S. Pat. Nos. 5,745,934 and 5,749,107. The side wall is shown to contain upper ducting 14 to supply water under pressure to jets at 14 a that supply water to the interior of unit 10 . Lower ducting 15 receives water from the body of contained water in the pool or spa, as under suction exerted by a pump indicated at 16 . The pump re-supplies water to ducting 14 , under pressure.
[0050] As seen in FIG. 4 , suction is exerted via a side opening 17 in side wall 11 to the interior of a filter unit 18 , for flowing pool or spa water through the cylindrical, porous filter element 19 of unit 18 , via side opening 17 to duct 15 . Unit 18 is easily replaceable, or connectible to wall 11 , as via sleeve 100 . FIG. 4 a shows the pump 16 a displacing water at 101 into the filter unit 18 via the connector 100 , to flow into the pool at 102 .
[0051] FIG. 5 shows a filter unit 39 in which water flow 40 enters sidewardly the filter unit, and exits endwise at 40 a. Such flow passes through filter media pleats 41 and then through opening 42 in internal tube 43 . The water then flows endwise in tube 43 to exit at 40 a. Water treating material may extend over, for example be coated on, all or part of the tube, walls 44 , end caps 49 and 50 , and pleats, for controlled exposure to pool or spa water, to control water treatment. See coatings 61 and 62 on end walls or caps 49 and 50 , coatings 63 on pleats, and coating 64 on the tube. Water flows axially and radially, and turbulently adjacent extended surfaces of the material.
[0052] The coating typically consists of one or more of the following:
[0053] i) bacterial inhibiting
[0054] ii) an algaecide
[0055] iii) an algaestat
[0056] iv) a sanitizer
[0057] v) a bacteriostat
Examples of i) are: Iodine, chlorine, bromine, copper, silver and several polymers Examples of ii) are: copper, silver, polyquats and quats Examples of iii) are: silver, copper and several polymers Examples of iv) are: chlorine, bromine, biguanides and iodine Examples of v) are: benzyl alcohol, chloramines B, chloramines T and several polymer
[0063] Other examples are bacteriostats and algaestats utilized in the medical and plastics industries, as for heart valves, replacement bone parts and items easily contaminated in public areas such as handles, knobs and other commonly touched devices.
[0064] See also the generalized filter unit or structure 70 in FIGS. 10-12 , with the water treating substance extensively coated at 71 - 73 on the perforated tube 74 , (or tube 74 manufactured out of such substance) and/or the end walls 75 and 75 a, and/or at 76 on the filter media pleats 77 . Such pleats spaced about the tube between walls 75 and 75 a may have a textured open weave (to pass water) woven construction, as shown in FIG. 12 , with warp and woof strands 77 a and 77 b consisting of thin ribbons of the water treating substance (as for example metal), and strands 78 a and 78 b consisting of other material (plastic for example). It is understood that the water treating material may extend over all or part of the tube, walls and pleats, with controlled exposure to pool or spa water, by filter position (for example), thereby to control water treatment.
[0065] The modified generalized filter unit or structure 80 in FIGS. 13-15 incorporates perforated tube 81 , end walls 82 , and filter media pleats 83 , as in FIGS. 10 and 11 , for maximum contact with water flow through the filter. A perforate wall such as a cage 84 extends about the pleats and may have a textured configuration as shown in FIG. 15 , with open weave water passing configuration. The cage consists of parallel strands 86 intersecting parallel strands or ribbons 87 of water treating substance, such as metallic ribbons, and support strands 88 of other material such as plastic.
[0066] In the above, the water treating bactericide or algaecide, may consist essentially of one or more of the following materials:
[0067] i) tin
[0068] ii) copper
[0069] iii) zinc
[0070] iv) silver
[0071] v) silver plated on copper
[0072] vi) oxides of i), ii), iii), iv), and v).
[0073] The treating substance may be layered or coated onto the filter structure, or may be integral with the filter structure.
[0074] FIGS. 6 and 7 show a filter unit as at 39 in FIG. 5 , wherein the center section, such as tube 43 , is itself constructed or manufactured of a sanitizing, algaecide, algaestat, bacteria inhibiting material, indicated at 54 .
[0075] FIGS. 8 and 9 show a filter unit, as at 39 in FIG. 5 wherein end caps 50 and 51 are themselves constructed or manufactured of a combination sanitizing, algaecide, algaestat, bacteria inhibiting material, indicated at 52 .
[0076] As respects FIGS. 1-15 , the invention also provides, in combination:
[0077] a) a tub having a sidewall to extend about a water receiving zone,
[0078] b) and a filter unit in said zone and having connection to support structure at the tub sidewall, such that the treating substance or coating, or manufactured element, is spaced from the tub sidewall and is exposed to water flow proximate the tub side wall, enabling ready removal and replacement with the filter unit.
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For use in a pool or spa, the combination comprising, filter structure in the path of pool or spa water flow, substance in direct contact with a surface or surfaces of said filter structure, to contact said flow, said substance characterized as being one of the following: i) bacteria inhibiting ii) an algaecide iii) an algaestat iv) a sanitizer. v) a bacteriostat
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[0001] This application is a non provisional of U.S. provisional patent application Ser. No. 60/615,502, entitled “Linear Compressor Controller”, filed on Oct. 1, 2004 and is hereby incorporated by reference.
FIELD OF INVENTION
[0002] This invention relates to a controller for a linear motor used for driving a compressor and in particular but not solely a refrigerator compressor.
SUMMARY OF THE PRIOR ART
[0003] Linear compressor motors operate on a moving coil or moving magnet basis and when connected to a piston, as in a compressor, require close control on stroke amplitude since unlike compressors employing a crank shaft stroke amplitude is not fixed. The application of excess motor power for the conditions of the fluid being compressed may result in such a free piston colliding with the cylinder head in which it is located.
[0004] In International Patent Publication no. WO01/79671 the applicant has disclosed a control system for free piston compressor which limits motor power as a function of property of the refrigerant entering the compressor. However in this and other free piston refrigeration systems overshoot of the piston may occur despite other measures and it may be useful to detect an actual piston collision and then to reduce motor power in response. Such a strategy could be used purely to prevent compressor damage, when excess motor power occurred for any reason. It could also be used as a way of ensuring high volumetric efficiency. Specifically in relation to the latter, a compressor could be driven with power set to just less than to cause piston collisions, to ensure the piston operated with minimum head clearance volume. Minimising head clearance volume leads to increased volumetric efficiency.
[0005] U.S. Pat. No. 6,536,326 discloses a control system for free piston machines which includes a feedback signal to reduce piston drive power when mechanical vibration due to piston-cylinder head collision are detected. A sensor such as a microphone is used to detect the mechanical vibrations.
[0006] In the prior art up until WO03/0443 65 discrete component sensors have been required to detect piston collisions. While WO03/044365 discloses measuring successive half stroke times and detecting a change it would be desirable if other sensorless techniques were available.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a linear motor controller which goes someway to achieving the above mentioned desiderata.
[0008] Accordingly in one aspect the invention consists in a method of controlling the stroke of a free piston linear compressor motor so as to minimise or avoid piston collisions at the extremities of said stroke. The method includes the steps of:
[0009] monitoring the motor back EMF,
[0010] detecting zero-crossings of said motor back EMF,
[0011] monitoring the slope of the back EMF waveform in the vicinity of said zero crossings,
[0012] detecting discontinuities in waveform slope, and
[0013] incrementally reducing motor input power upon detection of a slope discontinuity.
[0014] In a second aspect the invention consists in a free piston linear compressor motor having a stroke controlled so as to minimise or avoid piston collisions at the extremities of said stroke. The motor has a wound stator and a co-acting armature which is mechanically coupled to said piston. Means are provided to monitor the motor back EMF in the stator windings. A zero crossing detector means detects zero-crossings of the monitored back EMF. There are also means for determining the slope of the back EMF waveform in the vicinity of the detected zero crossings, and for determining discontinuities in the back EMF waveform slope. A motor input power controller supplies current to stator windings and reduces motor input power upon a slope discontinuity being determined.
[0015] Preferably said slope monitoring comprises measuring and storing the value of the back EMF at predetermined intervals and calculating the slope of the back EMF waveform between successive predetermined intervals to produce succession of slope values.
[0016] Preferably said slope monitoring comprises comparing the latest measured slope with the measured slope at the same point in the immediately preceding cycle.
[0017] Preferably said slope monitoring comprises comparing the latest measured slope with the average of the measured slopes at the same point of a predetermined number of immediately preceding cycles.
[0018] Preferably said discontinuities in back EMF waveform slope are detected by successively comparing each said calculated slope values with a predetermined value and if said predetermined value is exceeded over a predetermined number of slope values indicating a slope discontinuity.
[0019] Preferably said back EMF slope discontinuities which are detected are those which represent an increase in slope on rising back EMF and a decrease in slope on falling back EMF.
[0020] Preferably said back EMF slope discontinuities which are detected are those which represent an increase in slope on a falling back EMF.
[0021] To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
[0022] The invention consists in the foregoing and also envisages constructions of which the following gives examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] One preferred form of the invention will now be described with reference to the accompanying drawings in which;
[0024] FIG. 1 is a diagrammatic longitudinal section of a linear compressor controlled according to the present invention,
[0025] FIG. 2 is a graph of compressor motor back EMF versus time,
[0026] FIG. 3 is a graph of motor “constant” versus axial displacement of the piston for a short stator motor,
[0027] FIG. 4 is a graph of motor back EMF versus time for a small and a maximum stroke length,
[0028] FIG. 5 is a flow chart of the collision detection avoidance process used in the invention, and
[0029] FIG. 6 is a block diagram of a controller employing the process of FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention provides methods detecting piston head collisions in a free piston reciprocating compressor powered by a linear motor. One such is the type shown in FIG. 1 . This motor configuration has a reduced size compared to the conventional linear motor of the type described in U.S. Pat. No. 4,602,174. The reduced size keeps the efficiency high at low to medium power output at the expense of slightly reduced efficiency at high power output. This is an acceptable compromise for a compressor in a household refrigerator which runs at low to medium power output most of the time and at high power output less than 20% of the time (this occurs during periods of frequent loading and unloading of the refrigerator contents or on very hot days).
[0031] While in the following description the various embodiments of the present invention are described in relation to a cylindrical linear motor it should be appreciated that these methods are equally applicable to linear motors in general and in particular also to flat linear motors, see for example WO 02/35093, the content of which are incorporated herein by reference. One skilled in the art would require no special effort to apply the control strategy herein described to any form of linear motor.
[0032] The compressor shown in FIG. 1 , involves a permanent magnet linear motor connected to a reciprocating free piston compressor. The cylinder 9 is supported by a cylinder spring 14 within the compressor shell 30 . The piston 11 is supported radially by the bearing formed by the cylinder bore plus its spring 13 via the spring mount 25 . The bearings may be lubricated by any one of a number of methods as are known in the art, for example the gas bearing described in WO 01/29444 or the oil bearing described in WO 00/26536, the contents of both of which are incorporated herein by reference. Equally the present invention is applicable to alternative reciprocation systems. For example while below a compressor is described with a combined gas/mechanical spring system, the embodiments of the present invention can be used with an entirely mechanical or entirely gas spring system.
[0033] The reciprocating movement of piston 11 within cylinder 9 draws gas in through a suction tube 12 through a suction port 26 through a suction muffler 20 and through a suction valve port 24 in a valve plate 21 into a compression space 28 . The compressed gas then leaves through a discharge valve port 23 , is silenced in a discharge muffler 19 , and exits through a discharge tube 18 .
[0034] The compressor motor comprises a two part stator 5 , 6 and an armature 22 . The force which generates the reciprocating movement of the piston 11 comes from the interaction of two annular radially magnetised permanent magnets 3 , 4 in the armature 22 (attached to the piston 11 by a flange 7 ), and the magnetic field in an air gap 33 (induced by the stator 6 and coils 1 , 2 ).
[0035] A two coil version of the compressor motor is shown in FIG. 1 , which has a current flowing in coil 1 , which creates a flux that flows axially along the inside of the stator 6 , radially outward through the end stator tooth 32 , across the air gap 33 , then enters the back iron 5 . Then it flows axially for a short distance 27 before flowing radially inwards across the air gap 33 and back into the centre tooth 34 of the stator 6 . The second coil 2 creates a flux which flows radially in through the centre tooth 34 across the air gap axially for a short distance 29 , and outwards through the air gap 33 into the end tooth 35 . The flux crossing the air gap 33 from tooth 32 induces an axial force on the radially magnetised magnets 3 , 4 provided that the magnetisation of the magnet 3 is of the opposite polarity to the other magnet 4 . It will be appreciated that instead of the back iron 5 it would be equally possible to have another set of coils on the opposite sides of the magnets.
[0036] An oscillating current in coils 1 and 2 , not necessarily sinusoidal, creates an oscillating force on the magnets 3 , 4 that will give the magnets and stator substantial relative movement which is most efficient when the oscillation frequency is close to the natural frequency of the mechanical system. This natural frequency is determined by the stiffness of the springs 13 , 14 and mass of the cylinder 9 and stator 6 . The oscillating force on the magnets 3 , 4 creates a reaction force on the stator parts. Thus the stator 6 must be rigidly attached to the cylinder 9 by adhesive, shrink fit or clamp etc. The back iron is clamped or bonded to the stator mount 17 . The stator mount 17 is rigidly connected to the cylinder 9 .
[0037] Experiments have established that a free piston compressor is most efficient when driven at the natural frequency of the compressor piston-spring system of the compressor, However as well as any deliberately provided metal spring, there is an inherent gas spring, the effective spring constant of which, in the case of a refrigeration compressor, varies as either evaporator or condenser pressure varies. The electronically commutated permanent magnet motor already described, is controlled using techniques including those derived from the applicant's experience in electronically commutated permanent magnet motors as disclosed in WO 01/79671 for example, the contents of which are incorporated herein by reference.
[0038] When a linear motor is controlled as described in WO01/79671 it is possible that the compressor input power increases to a level where the excursion of the piston ( 11 , FIG. 1 ) results in a collision with the head of cylinder ( 9 , FIG. 1 ).
[0039] The present invention detects the onset of such collisions, or even when a collision is about to occur from the shape of the motor back EMF waveform.
[0040] When a collision is detected the magnitude of the motor current is reduced. The reductions to the current and thus input power to the motor are reduced incrementally. Once the collisions stop, the current value is allowed to slowly increase to its previous value over a period of time. Preferably the period of time is approximately 1 hour. Alternatively the current will remain reduced until the system variables change significantly. In one embodiment where the system in WO01/79671 is used as the main current controller algorithm, such a system change might be monitored by a change in the ordered maximum current. In that case it would be in response to a change in frequency or evaporator temperature. In the preferred application of the present invention it is envisaged that the WO 01/79671 algorithm be used with the present invention providing a supervisory role which would lead to an improved volumetric efficiency over the prior art.
[0041] The physical phenomena from which the present invention resides will now be outlined with reference to FIGS. 2 and 3 .
[0042] When the piston moving at a velocity, ν, hits the cylinder head (assuming it is made from the same material), an elastic stress wave is propagated with a magnitude, σ i , determined by the relation
σ i =ν·√{square root over (ρ i·E )}
where ρ i and E are the density and Young's Modulus respectively of the piston cylinder material.
[0043] The stress, σ i , acts on the contact area, A i for a length of time determined by the time it takes for the stress wave to travel the length or the piston and return after reflecting at the far end. Therefore there is a force, F i , acting on the piston, given by
F i =σ i ·A i
for a reasonable time.
Since the forces on the piston rod of a linear compressor must balance, then:
m·a+c·ν+k·x+P·A+F i =0
where
m is the piston mass c is the viscous drag coefficient k is the spring stiffness a is the piston acceleration x is the piston position P Pressure
and
A P Piston Area
This can be rearranged to give the acceleration;
a = F i + k · x + c · v + P · A k m
[0051] Thus the collision force, F i , significantly increases the deceleration of the piston and this is reflected in the shape of the back emf versus time curve i.e. the sudden change of slope shown in FIG. 2 .
[0052] Conventional linear motors are designed so that there is a linear relation between back emf and velocity.
i.e. emf=α.ν
In contrast the “short stator” configuration of the preferred form of motor (disclosed in WO 00/79671) has a design where the value of α varies with the position
i.e. emf= f ( x ). v
[0053] If the motor design is such that there is a “kink” or discontinuity in the function f(x), as shown by the arrow on FIG. 3 , this kink will show up in the back emf curve at larger strokes. FIG. 4 shows the effect of the kink from FIG. 3 on the back emf curve as the stroke increases from 12 mm to 14 mm.
[0054] In an alternative embodiment (see FIG. 7 ) this kink can also be achieved by adding a sensing coil in series with the windings. This coil generates an emf only when a permanent magnet on the motor armature gets close to it. The magnet may be specifically for this purpose or it may be one of the existing magnets. This emf adds to the emf generated by the main windings just prior to the zero crossing as shown in FIG. 7 .
[0055] A method for determining kinks or discontinuities in the back EMF induced in the stator windings of the motor and for the subsequent control of the motor input power to avoid piston collisions is illustrated in flowchart form in FIG. 5 . In practice it is convenient to implement this method of control using a programmed microprocessor. The flowchart of FIG. 5 shows the essential logic of the processor program.
[0056] The motor and control system employing the present invention is shown in block diagram form in FIG. 6 . The function of the present invention is encapsulated within block 101 which provides an input to the motor input power adjusting means 102 which is primarily controlled by the algorithm disclosed in WO 01/79671. The motor control of the present invention overrides the basic motor control algorithm only upon calculations indicating a collision or near collision of the piston.
[0057] Digitised back EMF signals are applied to an input of microprocessor 103 and routine determines 110 the times when the back EMF waveform is zero or a corresponding periodic value. If zero crossing is detected a decision is made 111 whether a sufficient period has passed following the instance of zero crossing. In the preferred embodiment this time period is 100 microseconds. If not then the back EMF value is measured and stored 112 . If more than 100 microseconds has passed then sufficient data has been collected to calculate the slope of the back EMF curve over that 100 microsecond period 113 . A routine 114 is then executed to determine if there has been any discontinuity in measured slope values. That is, if the slope departs from a value determined from the suction and discharge pressures (or variables which are well correlated with these parameters e.g. evaporating temperature and frequency) for a predetermined number of consecutive 100 microsecond cycles then a discontinuity is determined. Since this is indicative of a piston collision a signal is sent to power controller 102 to reduce input power and thereby reduce the stroke of the motor armature and piston to reduce the potential for collisions. The motor input power will be reduced incrementally and a number of iterations of the process described could take place in some instances before the slope discontinuity determining routine ceases to indicate a slope discontinuity and decision step 115 inhibits further signals to the motor input power controller.
[0058] By the above secondary control means and by employing a motor design for the compressor having the “short stator” configuration or the sensing coil technique previously referred to, piston collisions with the compression cylinder bead can be reduced and damage obviated.
[0059] It will also be appreciated the present invention is equally applicable to a range of applications. It is desirable in any free piston reciprocating linear motor to limit or control the maximum magnitude of reciprocation. For the present invention to be applied the system requires a restoring force eg: a spring system or gravity, causing reciprocation, and some change in the mechanical or electrical system which causes a change in the electrical reciprocation period when a certain magnitude of reciprocation is reached.
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A sensorless method and apparatus for detecting piston collisions in a free piston linear compressor motor. The waveform of the back EMF induced in the motor stator windings is analysed for slope discontinuities and other aberrations in a time window centred on the back EMF zero-crossings. Waveform slope artefacts are indicative of piston collisions and cause the motor power to be decremented in response.
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RELATED APPLICATIONS
This application is a continuation of, and claims priority to, U.S. patent application Ser. No. 12/340,194, filed on Dec. 19, 2008, which claims priority to Australian Provisional Patent Application No. 2007907032, having a filing date of Dec. 20, 2007, both of which are incorporated herein by reference in its entirety.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[Not Applicable]
MICROFICHE/COPYRIGHT REFERENCE
[Not Applicable]
FIELD OF THE INVENTION
The present invention relates to a method of gaming, a game controller and a gaming system.
BACKGROUND OF THE INVENTION
Gaming systems which implement games that include an element of skill are known to provide players with enjoyment. However, a problem with such gaming systems is that if players exercise sub-optimal skill, the overall return to player can be less than intended. Further, the return to skilled players will be more than to less skilled players. Accordingly, it is sometimes a requirement to provide optimal play instructions to direct players how to obtain an optimal outcome. While this allows the same return to be made to all players, it lessens the enjoyment of those players who derive enjoyment by learning to exercise optimal skill.
Accordingly, a need exists for an alternative gaming system.
BRIEF SUMMARY OF THE INVENTION
In a first aspect, the invention provides a method of gaming comprising:
conducting a game requiring a player to make a choice between at least one optimal action and at least one sub-optimal action having a lower return to player than the optimal action such that the difference between the sub-optimal action and the optimal action represents a lost return to player;
receiving a player choice of an action; and
conducting a trial for an award in which the probability of success is controlled to provide an expected return to player from the trial that compensates the player for the lost return to player in response to determining that the choice is a sub-optimal action.
In an embodiment, the expected return to player is equivalent to the lost return to player and the trial is only conducted when the choice is a sub-optimal action.
In an embodiment, the method comprises conducting a normal trial for the award in response to a player choosing an optimal action such that a trial is conducted irrespective of the action and the expected return to player is increased when the choice is a sub-optimal action.
In an embodiment, the award is a progressive jackpot.
In an embodiment, the method comprises adding the lost return to player to a pool of the progressive jackpot.
In an embodiment, the choice is made as part of a game round and any trial is conducted prior to any further game round.
In a second aspect, the invention provides a game controller for a gaming system, the game controller arranged to:
conduct a game requiring a player to make a choice between at least one optimal action and at least one sub-optimal action having a lower return to player than the optimal action such that the difference between the sub-optimal action and the optimal action represents a lost return to player;
receive a player choice of an action; and
conduct a trial for an award in which the probability of success is controlled to provide an expected return to player from the trial that compensates the player for the lost return to player in response to determining that the choice is a sub-optimal action.
In an embodiment, the expected return to player is equivalent to the lost return to player and the trial is only conducted when the choice is a sub-optimal action.
In an embodiment, the game controller is arranged to conduct a normal trial for the award in response to a player choosing an optimal action such that a trial is conducted irrespective of the action and the expected return to player is increased when the choice is a sub-optimal action.
In an embodiment, the award is a progressive jackpot and the game controller comprises a jackpot odds adjuster arranged to adjust the probability of success at the jackpot based on the player choice.
In an embodiment, the game controller is arranged to add the lost return to player to a pool of the progressive jackpot.
In an embodiment, the game controller is arranged such that the choice is made as part of a game round and any trial is conducted prior to any further game round.
In a third aspect, the invention provides a gaming system comprising:
a player interface comprising a display and an instruction input mechanism; and
a game controller arranged to:
conduct a game requiring a player to make a choice between at least one optimal action and at least one sub-optimal action displayed to the player on the display, the sub-optimal action having a lower return to player than the optimal action such that the difference between the sub-optimal action and the optimal action represents a lost return to player, and receive a player choice of an action from the input mechanism,
the gaming system further arranged to conduct a trial for an award in which the probability of success is controlled to provide an expected return to player from the trial that compensates the player for the lost return to player in response to determining that the choice is a sub-optimal action.
In an embodiment, the expected return to player is equivalent to the lost return to player and the trial is only conducted when the choice is a sub-optimal action.
In an embodiment, the gaming system is arranged to conducting a normal trial for the award in response to a player choosing an optimal action such that a trial is conducted irrespective of the action and the expected return to player is increased when the choice is a sub-optimal action.
In an embodiment, the award is a progressive jackpot and the gaming system comprises a jackpot odds adjuster arranged to adjust the probability of success at the jackpot based on the player choice.
In an embodiment, the gaming system is arranged to add the lost return to player to a pool of the progressive jackpot.
In an embodiment, the gaming system is arranged such that the choice is made as part of a game round and any trial is conducted prior to any further game round.
In an embodiment, the game controller is arranged to conduct the trial.
In an embodiment, the gaming system comprises a jackpot controller in data communication with the game controller and arranged to conduct the trial.
In a fourth aspect, the invention provides computer program code which when executed implements the above method.
In a fifth aspect, the invention provides a computer readable medium comprising the above program code.
In a sixth aspect, the invention provides a data signal comprising the above program code.
In a seventh aspect, the invention extends to transmitting the above program code.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
An exemplary embodiment of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a block diagram of the core components of a gaming system;
FIG. 2 is a perspective view of a stand alone gaming machine;
FIG. 3 is a block diagram of the functional components of a gaming machine;
FIG. 4 is a schematic diagram of the functional components of a memory;
FIG. 5 is a schematic diagram of a network gaming system;
FIG. 6 is a further block diagram of a gaming system; and
FIG. 7 is a flow chart of an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, there is shown a gaming system having a game controller arranged to implement a game where players can seek to exercise skill to take optimal actions but if they take sub-optimal actions they are compensated by a chance or an increased chance to win an award. In an embodiment, all of the player return lost by sub-optimal choices is added to a jackpot pool and the players chances of winning a jackpot from the jackpot pool are adjusted to provide an expected player return equivalent to the lost return such that the player return is the same irrespective of a player's choices.
General Construction of Gaming System
The gaming system can take a number of different forms. In a first form, a stand alone gaming machine is provided wherein all or most components required for implementing the game are present in a player operable gaming machine.
In a second form, a distributed architecture is provided wherein some of the components required for implementing the game are present in a player operable gaming machine and some of the components required for implementing the game are located remotely relative to the gaming machine. For example, a “thick client” architecture may be used wherein part of the game is executed on a player operable gaming machine and part of the game is executed remotely, such as by a gaming server; or a “thin client” architecture may be used wherein most of the game is executed remotely such as by a gaming server and a player operable gaming machine is used only to display audible and/or visible gaming information to the player and receive gaming inputs from the player.
However, it will be understood that other arrangements are envisaged. For example, an architecture may be provided wherein a gaming machine is networked to a gaming server and the respective functions of the gaming machine and the gaming server are selectively modifiable. For example, the gaming system may operate in stand alone gaming machine mode, “thick client” mode or “thin client” mode depending on the game being played, operating conditions, and so on. Other variations will be apparent to persons skilled in the art.
Irrespective of the form, the gaming system comprises several core components. At the broadest level, the core components are a player interface 50 and a game controller 60 as illustrated in FIG. 1 . The player interface is arranged to enable manual interaction between a player and the gaming system and for this purpose includes the input/output components required for the player to enter instructions and play the game.
Components of the player interface may vary from embodiment to embodiment but will typically include a credit mechanism 52 to enable a player to input credits and receive payouts, one or more displays 54 , a game play mechanism 56 that enables a player to input game play instructions (e.g. to place bets), and one or more speakers 58 .
The game controller 60 is in data communication with the player interface and typically includes a processor 62 that processes the game play instructions in accordance with game play rules and outputs game play outcomes to the display. Typically, the game play instructions are stored as program code in a memory 64 but can also be hardwired. Herein the term “processor” is used to refer generically to any device that can process game play instructions in accordance with game play rules and may include: a microprocessor, microcontroller, programmable logic device or other computational device, a general purpose computer (e.g. a PC) or a server.
A gaming system in the form of a stand alone gaming machine 10 is illustrated in FIG. 2 . The gaming machine 10 includes a console 12 having a display 14 on which are displayed representations of a game 16 that can be played by a player. A mid-trim 20 of the gaming machine 10 houses a bank of buttons 22 for enabling a player to interact with the gaming machine, in particular during game play. The mid-trim 20 also houses a credit input mechanism 24 which in this example includes a coin input chute 24 A and a bill collector 24 B. Other credit input mechanisms may also be employed, for example, a card reader for reading a smart card, debit card or credit card. A player marketing module (not shown) having a reading device may also be provided for the purpose of reading a player tracking device, for example as part of a loyalty program. The player tracking device may be in the form of a card, flash drive or any other portable storage medium capable of being read by the reading device.
A top box 26 may carry artwork 28 , including for example pay tables and details of bonus awards and other information or images relating to the game. Further artwork and/or information may be provided on a front panel 29 of the console 12 . A coin tray 30 is mounted beneath the front panel 29 for dispensing cash payouts from the gaming machine 10 .
The display 14 shown in FIG. 2 is in the form of a video display unit, particularly a cathode ray tube screen device. Alternatively, the display 14 may be a liquid crystal display, plasma screen, any other suitable video display unit, or the visible portion of an electromechanical device. The top box 26 may also include a display, for example a video display unit, which may be of the same type as the display 14 , or of a different type.
FIG. 3 shows a block diagram of operative components of a typical gaming machine which may be the same as or different to the gaming machine of FIG. 2 .
The gaming machine 100 includes a game controller 101 having a processor 102 . Instructions and data to control operation of the processor 102 are stored in a memory 103 , which is in data communication with the processor 102 . Typically, the gaming machine 100 will include both volatile and non-volatile memory and more than one of each type of memory, with such memories being collectively represented by the memory 103 .
The gaming machine has hardware meters 104 for purposes including ensuring regulatory compliance and monitoring player credit, an input/output (I/O) interface 105 for communicating with peripheral devices of the gaming machine 100 . The input/output interface 105 and/or the peripheral devices may be intelligent devices with their own memory for storing associated instructions and data for use with the input/output interface or the peripheral devices. A random number generator module 113 generates random numbers for use by the processor 102 . Persons skilled in the art will appreciate that the reference to random numbers includes pseudo-random numbers.
In the example shown in FIG. 3 , a player interface 120 includes peripheral devices that communicate with the game controller 101 comprise one or more displays 106 , a touch screen and/or buttons 107 , a card and/or ticket reader 108 , a printer 109 , a bill acceptor and/or coin input mechanism 110 and a coin output mechanism 111 . Additional hardware may be included as part of the gaming machine 100 , or hardware may be omitted as required for the specific implementation.
In addition, the gaming machine 100 may include a communications interface, for example a network card 112 . The network card may, for example, send status information, accounting information or other information to a central controller, server or database and receive data or commands from the central controller, server or database.
FIG. 4 shows a block diagram of the main components of an exemplary memory 103 . The memory 103 includes RAM 103 A, EPROM 103 B and a mass storage device 103 C. The RAM 103 A typically temporarily holds program files for execution by the processor 102 and related data. The EPROM 103 B may be a boot ROM device and/or may contain some system or game related code. The mass storage device 103 C is typically used to store game programs, the integrity of which may be verified and/or authenticated by the processor 102 using protected code from the EPROM 103 B or elsewhere.
It is also possible for the operative components of the gaming machine 100 to be distributed, for example input/output devices 106 , 107 , 108 , 109 , 110 , 111 to be provided remotely from the game controller 101 .
FIG. 5 shows a gaming system 200 in accordance with an alternative embodiment. The gaming system 200 includes a network 201 , which for example may be an Ethernet network. Gaming machines 202 , shown arranged in three banks 203 of two gaming machines 202 in FIG. 5 , are connected to the network 201 . The gaming machines 202 provide a player operable interface and may be the same as the gaming machines 10 , 100 shown in FIGS. 2 and 3 , or may have simplified functionality depending on the requirements for implementing game play. While banks 203 of two gaming machines are illustrated in FIG. 5 , banks of one, three or more gaming machines are also envisaged.
One or more displays 204 may also be connected to the network 201 . For example, the displays 204 may be associated with one or more banks 203 of gaming machines. The displays 204 may be used to display representations associated with game play on the gaming machines 202 , and/or used to display other representations, for example promotional or informational material.
In a thick client embodiment, game server 205 implements part of the game played by a player using a gaming machine 202 and the gaming machine 202 implements part of the game. With this embodiment, as both the game server and the gaming device implement part of the game, they collectively provide a game controller. A database management server 206 may manage storage of game programs and associated data for downloading or access by the gaming devices 202 in a database 206 A. Typically, if the gaming system enables players to participate in a Jackpot game, a Jackpot server 207 will be provided to perform accounting functions for the Jackpot game. A loyalty program server 212 may also be provided.
In a thin client embodiment, game server 205 implements most or all of the game played by a player using a gaming machine 202 and the gaming machine 202 essentially provides only the player interface. With this embodiment, the game server 205 provides the game controller. The gaming machine will receive player instructions, pass these to the game server which will process them and return game play outcomes to the gaming machine for display. In a thin client embodiment, the gaming machines could be computer terminals, e.g. PCs running software that provides a player interface operable using standard computer input and output components.
Servers are also typically provided to assist in the administration of the gaming network 200 , including for example a gaming floor management server 208 , and a licensing server 209 to monitor the use of licenses relating to particular games. An administrator terminal 210 is provided to allow an administrator to run the network 201 and the devices connected to the network.
The gaming system 200 may communicate with other gaming systems, other local networks, for example a corporate network, and/or a wide area network such as the Internet, for example through a firewall 211 .
Persons skilled in the art will appreciate that in accordance with known techniques, functionality at the server side of the network may be distributed over a plurality of different computers. For example, elements may be run as a single “engine” on one server or a separate server may be provided. For example, the game server 205 could run a random generator engine. Alternatively, a separate random number generator server could be provided. Further, persons skilled in the art will appreciate that a plurality of game servers could be provided to run different games or a single game server may run a plurality of different games as required by the terminals.
Further Detail of Gaming System
FIG. 6 shows a gaming system of an embodiment where the compensatory award is provided by adjusting the odds of a player winning a jackpot. To play a game round the player operates the instruction input mechanism 56 to place a wager. The outcome generator 622 generates a game outcome based on game rules 641 using random number generator 621 .
The game rules 641 require the player to make a choice between a set of possible actions. The number of different actions can vary depending on the implementation of the game and can be, for example, a selection between different options. The player operates choice selector 56 A of instruction input mechanism 56 to input their choice. The choice processor 623 receives the input choice input and determines whether the player has selected to take an optimal action or a sub-optimal action.
The choice processor 623 provides the choice to the prize award module 624 . The prize award module 624 determines what prize applies based on the choice and the prize table 642 (as well as the previously determined game outcome if this affects the prize) and updates the meters 643 accordingly.
The choice processor 623 advises the jackpot module 625 whether the player has made an optimal or sub-optimal choice and the amount of any lost return to player resulting from the choice. The action of the jackpot module 625 varies depending on whether a player has made an optimal choice or a suboptimal choice. In this embodiment, each player has a chance to win the jackpot in each game round and accordingly if a player makes an optimal choice, the jackpot module 625 determines whether they have won a prize from the jackpot pool 644 in accordance with the normal odds of winning Those normal odds of winning may depend, for example, on the size of a player's bet
If the choice processor 623 determines that a player made sub optimal choice it determines the amount of credits that the player has foregone by the sub-optimal choice and advises the pool incrementer 626 which adds the amount of credits to the jackpot pool 644 . It will be appreciated in this embodiment the jackpot is a progressive jackpot which allows the pool to be incremented.
A person skilled in the art will appreciate that the amount of lost return can be represented in a number of different ways including as an amount in currency. The choice processor 623 also advises the jackpot module 625 that the player is made of sub-optimal choice. The odds adjustor 625 A adjust the odds of winning the jackpot in order to compensate the player for the lost amount of credits. The jackpot controller module 625 then determines using random number generator 621 whether the player has won the jackpot. Accordingly, players who make sub-optimal choices have a greater chance of winning the jackpot. Persons skilled in the art will appreciate that the jackpot controller module 625 could be provided by a separate device in data communication with the game controller, for example at jackpot server 207
In an alternative embodiment only players who make sub-optimal choices get access to a chance to win the jackpot in this particular part of the game. Other players may have a chance to win the jackpot in other parts of the game.
It will be appreciated that the determination of whether the player has won the jackpot is made by the jackpot module 625 as part of the game round such that compensation is targeted specifically at players who make the sub-optimal play. Merely increasing the jackpot pool with any loss returned to player could result in players who are more skilled in obtaining a better return to player and less skill.
The method is summarised in FIG. 7 and involves starting a game round 710 and offering a player choice of some action 720 , for example a decision to make, where they must make a selection. The method then involves determining whether the action is optimal 730 and if it is optimal conducting a normal jackpot trial 740 and awarding any prizes 780 . If the action is not optimal the method involves adding the lost credit to the jackpot pool 750 , adjusting the odds for jackpot wins 760 and conducting an adjusted jackpot trial 770 and awarding prizes if any before proceeding to the start of another game round. Other features of the method will be apparent from the above description of the gaming system.
Persons skilled in the art will appreciate that the probability of winning is adjusted in accordance with the lost return to player. Thus the expected return to player of the jackpot is compensates for the lost return to the player. Further, it is possible to offer players a game of skill without providing optimal play instructions. Thus, players who derive enjoyment by learning the optimal plays for a game while other players who do not learn the optimal plays are not disadvantaged.
Persons skilled in the art will also appreciate that the method of the embodiment could be embodied in program code. The program code could be supplied in a number of ways, for example on a computer readable medium, such as a disc or a memory (for example, that could replace part of memory 103 ) or as a data signal (for example, by downloading it by transmitting it from a server).
EXAMPLES
Example 1
A game has a free game multiplier that is randomly generated, either ×2 or ×4 multiplier with even probability. Thus, the average result is ×3. The player has an option of repeating the selection and so the player gets a second chance to hit the ×4 if their original result was ×2. Hence the optimal play would be to repeat the selection if the player receives ×2. If the player refuses to repeat the selection then they have rejected an average multiple at ×3 and taken an average multiplier at ×2. The loss is equivalent to an average multiplier at ×1. This amount in credits (i.e. what the player would win without the multiplier) is forwarded to the jackpot pool and a probability for winning the jackpot could be cast immediately such that the expected return from the jackpot for this hapless player is exactly the return lost through the poor decision.
Example 2
In this example, a fixed value prize is available to be awarded as compensation—a feature is worth a total value of $30 and the feature comprises 30 skill events worth $1 each. Player A only wins $20 in the feature. To maintain player return, the player A needs to be paid $10. In this game, a prize of $40 is available as a randomly awarded prize. The player has lost $10 so the player needs a 1 in 4 chance of winning the $40. Player B plays the same game but has less skill and wins only $10 in the skill feature. The player has “lost” $20. The fixed prize is $40 so the player needs a 1 in 2 chance to win the fixed prize. The game adjusts the probability of winning the prize accordingly.
Example 3
In this example a progressive prize is available to be awarded as compensation. Using the example above, the player has “lost” $10 due to lack of skill but a regulator requires that the player have access to be able to win that amount to ensure fairness. The $10 amount is added to a progressive meter. (The addition can be to the visible meter or the amount can be broken in to parts with some of the amount going to a hidden meter to fund future start ups and some of it going to the visible meter) The visible progressive meter reads $15. Half of the lost amount is added to the visible meter and the other half goes to the hidden meter. The visible meter now reads $20 and the hidden meter has increased by $5. The player needs to be given a chance to win $10. The available prize is $20 on the progressive meter. So the player is given a 1 in 2 chance of winning the progressive meter. The player is successful and the player is paid the $20 and the meter resets to $5 from the hidden meter. Time passes and the visible progressive meter now reads $20. Player B has “lost” $20 of which $10 goes to the visible meter and $10 to the hidden meter. The visible meter now reads $30. Player B is given a 2 in 3 chance of winning the progressive meter.
It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention. in particular, various of the above features may be combined to form further embodiments.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
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A method of gaming comprising: conducting a game requiring a player to make a choice between at least one optimal action and at least one sub-optimal action having a lower return to player than the optimal action such that the difference between the sub-optimal action and the optimal action represents a lost return to player; receiving a player choice of an action; and conducting a trial for an award in which the probability of success is controlled to provide an expected return to player from the trial that compensates the player for the lost return to player in response to determining that the choice is a sub-optimal action.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority to U.S. provisional application No. 61/624,534, filed on Apr. 16, 2012, and hereby incorporates the subject matter of the provisional application in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of composite textiles, particularly to yarns, tows and structural members suitable for manufacturing fiber reinforced composites. This invention enables the production of robust pre impregnated yarns that are easily wound onto spools and processed on conventional textile machinery such as a Maypole braiding machine without difficulty.
2. Brief Description of Related Art
Several process techniques are commonly used for making fiber reinforced composites. These include:
1. Weaving, braiding, or winding of yarns (or tows) into flat fabric or shaped tubular preforms followed by saturation of the preform by liquid resin and then curing to harden the resin,
2. The fabric preforms in 1) may be stacked and painted with liquid resin, one layer at a time, stacked wet in a mold to make a solid shape, then cured under a vacuum bag or in an autoclave to harden the resin.
3. Fabric preforms in 1) may be vacuum or pressure infused with liquid resin followed by curing to harden the resin.
4. The yarns/tows may be resin impregnated (or be pre-impregnated yarns) before braiding or weaving and then cured afterwards. The resin may be partially cured before braiding and then curing is finished after braiding.
5. The yarns or tows may be resin impregnated and then used directly in a process called filament winding to make a structure, usually over a mold or mandrel, and subsequently cured to harden the resin,
6. The yarns or tows may be resin impregnated and pulled through a heated die to shape and cure the composite simultaneously (in a process called pultrusion).
7. The fibers may be chopped and sprayed simultaneously with liquid resin onto a mold. The mixture is then cured in place.
The list above is not intended to be all inclusive, and curing may or may not require heat. Liquid resin is a complex mixture of monomers, prepolymers and catalysts. Resin is usually viscous, thus limiting its ability to flow and thoroughly impregnate thick layers of compacted fiber.
The subject of this invention is included in technique number 4 above—large prepreg yarns are created from an assembly of small, thoroughly infused prepreg yarns, held together by a fibrous or polymer jacket. The large prepreg yarns are then braided or woven into a shaped composite preform and subsequently cured by heating. The prepreg yarn may be partially cured before braiding or weaving.
Fibers are infused with a polymer resin and cured to harden in order to generate a composite material. This process is relatively simple for making thin composites, but problems arise when a laminate or yarn is thick. It is difficult to infuse resin through a thick material completely to the center. To mitigate this problem, manufacturers have developed prepreg materials, which have the resin already present in the material. After making a structure, there is no required infusion, and the structure can be cured directly. Using prepreg materials will ensure that resin fills the entirety of the composite material, for maximum strength and reliability. However, prepreg yarns are particularly sticky, and therefore not generally considered suitable for braiding, weaving, or a number of other manufacturing processes.
In addition, two of the most used fibers for composite manufacture are carbon and glass. Both these fibers suffer from being excessively brittle and fragile. They break easily when subjected to abrasion in textile processing. While resin saturation of the fibers improves the abrasion resistance, it is still not good, and the resin saturation comes at the price of stickiness.
Yarns which are components in fiber reinforced composites must be thoroughly saturated with (typically a viscous) resin to make the composite. Since saturation is difficult for large assemblies of fibers, the fibrous assembly must therefore be small, or flattened into a wide, thin ribbon in order for the resin to penetrate thoroughly. These units of saturated fibers are called prepreg yarns or prepreg tows. As fiber reinforced composites are all composed of fibers infused and surrounded by a matrix resin, and given the difficulty of infusing large fiber bundles, one objective of this invention is the production of a large, thoroughly resin infused fiber bundle or yarn suitable for composite manufacture.
To make a larger yarn or structural unit, the small, resin-saturated assemblies of fibers may be combined into parallel bundles, but these bundles need to be held together. Twisting of a fiber bundle is the most common method of ensuring that fibers remain with the fiber bundle, but twisting lowers alignment of fibers in the axial direction of the yarn and reduces fiber strength. Some constraint such as a braided, wrapped or extruded overlayer can allow the fibers to remain in axial alignment while maintaining the integrity of the fiber bundle. Although the extruded overlayer is a common method of constraining a core of fibers (particularly wire) and is included in the invention, the braided or wrapped construction of the overlayer produces a more flexible yarn structure than an extruded overlayer. The winding onto spools and the interlacing on conventional equipment is more difficult with the extruded overlayer. On the other hand, the extruded overlayer is better at containing the prepreg yarn core than a braid or wrap. It is one purpose of this invention to produce very large prepreg yarns which maintain both structural integrity (a contained core with aligned filaments and no splitting), and sufficient flexibility to allow processing on conventional textile manufacturing equipment like a braiding machine
The core fibers must be contained in such a way that they are permitted to move freely around the carrier eyelets and pulleys while preserving their parallel orientation along the axis of the yarn. Another objective of this invention is to provide a jacket of minimum weight to protect, contain, and efficiently consolidate the core fibers
A particular difficulty of converting the prepreg yarns or tows into a composite structure is the stickiness of the prepreg yarn, which creates difficulty in braiding or weaving. Therefore filament winding is the preferred method of assembling the prepreg yarns or tows into a composite preform. However, the filament wound structure suffers from the lack of yarn interlacing, making the final cured composite structure subject to splitting and delamination. Another purpose of this invention is to produce a prepreg yarn that can be easily converted to an interlaced fabric or shaped preform by braiding or perhaps weaving on typical textile fabrication machinery.
Preferred fibers for reinforcing composites are often carbon and glass, because of their strength and stiffness. As both of these fibers are brittle and suffer from failure caused by abrasion, another object of this invention is the protection of these brittle fibers from abrasion damage.
Fibers are strongest in their own axial direction, but not necessarily in their other directions. Generally, when individual fibers are made into a yarn or rope, it is necessary to impart some amount of twist, in order to keep the fibers together, at least during the processes of making yarn, winding on spools and conversion into a textile structure. In the resulting yarn geometry, the axial direction of the yarn is not the same as the axial direction of many or all of the fibers. The result is a proportional reduction in strength based on the pitch of the fibers. It is another purpose of this invention to produce a braidable prepreg yarn wherein almost all of the fibers are aligned close to the yarn axis.
Both weaving and braiding provide interlaced structures. Weaving typically produces a flat fabric, while braiding can produce either flat or cylindrical fabric. Further, the cylindrical braided structure can be easily shaped to polygon structures, and is easily varied in cross sectional area and shape during braiding. Braiding is often the most desirable method for producing shaped thin composites. Therefore the products produced by this invention are particularly useful in producing braided structures.
Braided structures range in size from medical sutures and shoestrings to large marine ropes for securing ships and drilling platforms. Our examples are manufactured on typical textile braiding machines. It is anticipated that the yarn size produced by this invention will be scalable so that as the size of the braiding machine carriers and bobbins increase, the yarn size that is braidable will also increase.
DESCRIPTION OF THE PRIOR ART
Braiding around a core of axially aligned fibers is not new. One can find dozens of examples in a typical hardware store, in the form of ropes, clothes lines, and any number of cables including some made of metal wire. Specialized ropes for mountain climbing consist of axially aligned high strength fiber in the core, surrounded by an abrasion resistant braided jacket. The structural elements of braided rugs are often a braided jacket surrounding a core of fibers, which may not be aligned in the axial direction of the yarn.
Elastic yarns in clothing like socks usually consist of axially aligned elastomeric fibers covered by a wrapping of cotton yarn to minimize the friction (stickiness) between the yarn and the human body.
The subject of this invention is described above—large prepreg yarns created from an assembly of small, thoroughly infused prepreg yarns, held together by a fibrous or polymer jacket. The large prepreg yarns are then braided or woven into a shaped composite preform and subsequently cured by heating. The prepreg yarn may be partially cured before braiding or weaving.
The patent art suggests wrapping of biaxial, Maypole braiding around a resin saturated yarn (U.S. Pat. Nos. 3,644,866, 2,684,318, 7,132,027, and EP 1401378) but an uncritical application of these techniques will not produce a large, robust, braidable yarn. The structural features necessary for winding a yarn on spools, passing it over guides, eyelets, and rollers and sliding it between other yarns at the braid point or the fell of the cloth in weaving—all without damage—requires close attention to the fine details of the manufacturing process and how the yarn interacts with it. In particular, a biaxial braided jacket over a large prepreg yarn will not allow sufficient flexibility unless the braid angle is somewhat less than the compressive jammed state. On the other hand, if the braid angle moves substantially away from the compressive jammed state, the jacket tends to open up and the prepreg core pops out of the jacket as the yarn is bent over guides and small rollers.
A normal triaxial braid is somewhat better than a biaxial braid in that the axials restrain the core within the jacket better than the biaxial braid. The most efficient way of containing the core within the jacket seems to be the true triaxial braid in which the axials interlace with the helicals (U.S. Pat. No. 5,899,134). Both axial constructions restrain the core better at lower cover factor (lower weight) than the biaxial braid.
The prior art ignores these characteristics of a braided jacket over core construction, and without attention to these details (as revealed in this invention); the manufacture of a robust braidable yarn is not possible. Previous inventions and the associated literature (U.S. Pat. No. 7,132,027) do not specify or discuss the aforementioned structural features necessary for the covering layer to perform the intended purpose of the currently disclosed yarn structure. Perhaps this is because the previous art does not anticipate a large yarn that is spoolable, braidable or weavable. Indeed the claims of U.S. Pat. No. 7,132,027 anticipates the use of the braiding of dry yarn rather than prepreg, as the saturation of yarn with resin is listed as a step after braiding in the patent.
BRIEF SUMMARY OF THE INVENTION
The present invention discloses a braidable prepreg yarn. It contains two basic components; a core containing fiber and resin, and a protective jacket. The core is comprised of a number of prepreg tows. Prepreg tows are commercially available as resin infused fiber bundles containing 3000 to 12000 individual fibers or more. A tow with 3000 individual filaments is identified as a 3K tow. The inventors have used carbon fiber, but others such as glass, para-aramid, liquid crystal polyester (LCP), and any other high strength fiber may be used. These tows already include a requisite amount of resin that will cure and give strength and stiffness to the yarn. The prepreg tows are typically 40-70% fiber by volume. The individual fibers comprising each tow are all essentially axial fibers, with no substantial twist. This provides the maximum axial strength for the tow.
Several tows are compacted together to form a dense core. If the resin were not already present, it would not be expected that resin would be able to penetrate the dense collection of fibers and reach the center of the core. The large core is composed of very many, densely packed, axial fibers. It is very strong in the axial direction, but susceptible to buckling and splitting, as well as abrasion damage during braiding. In fact, the core is often too sticky to braid well. The fibers stick to each other and will not slide past one another to form a compact braid. Also the resin is sticky and adheres to various points of contact on the braiding machine. For these reasons, a protective jacket is placed over the core. Three embodiments of the protective jacket are envisioned:
1. a braided jacket,
2. a fiber-wrapped jacket, and
3. an extruded thermoplastic jacket.
For embodiments 1 and 2 of the protective jacket, the strength of the jacket fiber is not as important as for the core. The jacket fibers should protect the core and so the core fibers should not break easily. The jacket should provide abrasion resistance for the core. The protective jacket should also contain the stickiness of the core, allowing the assembly to slide over machinery parts and other yarns without sticking. If the protective jacket is braided or wrapped fibers, there should be sufficient resin in the core that it bleeds through the jacket and bonds the structural members together at their intersecting points in the composite structure. In embodiment 3, the solid thermoplastic coating will contain the stickiness and provide the bonding between the structural elements provided that the curing temperature is sufficiently high to melt the thermoplastic jacket resulting in a strong polymer weld between the structural members at their intersection points. Nylons are the preferred thermoplastic jacket materials, but polyolefins, polyesters, and other thermoplastic jackets are envisioned to be acceptable jacket materials. Thermoplastic fibers, if used in braided or wrapped jacket, may also be melted to form a bond between the prepreg yarns.
The protective jacket braided by the inventors might be a conventional Maypole braid, a braid with axials, or a true triaxial braid (U.S. Pat. No. 5,899,134). A conventional braid at close to 100% coverage, significantly reduces the stickiness of the yarn, holds in most of the resin, and provides a high level of abrasion resistance. An open, true triaxial braid (U.S. Pat. No. 5,899,134) can offer sufficient protection, limit the stickiness, and allow more resin to leave the prepreg to assist in the bonding of yarns at joints. Jackets hold the core in a more circular cross section making it a stiff member, able to transmit large compressive axial and bending loads far better and more efficiently than a flat tape cross section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevated side view of a core of a jacketed yarn;
FIG. 2 shows an elevated cross section view of the yarn of a jacketed yarn;
FIG. 3 is a side perspective view of a schematic of a braider forming the jacketed yarn of FIG. 2 ;
FIG. 4 shows an elevated side view of an alternate embodiment of the jacket of FIG. 2 ;
FIG. 5 shows an elevated side view of an alternate embodiment of a jacketed yarn; and
FIG. 6 shows an elevated side view of an alternate embodiment of the jacket of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , the core ( 101 ) of the yarn ( 100 ) is shown. The core ( 101 ) may be comprised of a plurality (i.e. one or more) of prepreg tows ( 103 ). The tows ( 103 ) are arranged essentially axially, with no significant component of twist. Each tow ( 103 ) is further comprised of many small diameter fibers ( 102 ), and each fiber ( 102 ) is also oriented substantially axially with respect to the tow ( 103 ), and therefore with respect to the core ( 101 ) as well. The tows ( 103 ) are compacted together in order to maximize the density of the core ( 101 ). This compaction will assist in providing stability to the core ( 101 ). It is shown that the tows ( 103 ) are compacted in the core ( 101 ) to a polygon shape, often a substantially hexagonal cross section (see FIG. 2 ). As a result, the tows ( 103 ) are arranged within the core ( 101 ) in a close packed configuration which often gives them the appearance of being a hexagonal close packed structure, which indicates a high density for the material. This density requires that the tows ( 103 ) already include resin (not shown), because it is very difficult to infuse resin through such a thick and dense core ( 101 ).
Continuing to look at FIG. 1 , an embodiment of prepreg yarn ( 100 ) is not shown. Generally, a yarn ( 100 ) cannot be made entirely of axial fibers such as axial fibers ( 102 ). Axial fibers with no twist have little or no cohesion to one another, and therefore separate very easily. They are susceptible to buckling, and they are also susceptible to breaking. The core ( 101 ) as shown in FIG. 1 is preferably contained as described in more detail below.
Looking now at FIG. 2 , the jacketed yarn ( 100 ) is shown in a circular cross-section view, which includes the core ( 101 ) surrounded by a protective jacket ( 118 ). The number of axial fibers or filaments ( 102 ) in the core ( 101 ) cross section easily numbers 36000 or more and cannot be represented to scale in size or number, so FIG. 2 is a schematic representation of the cross section. The jacket ( 118 ) provides not only protection, but also binds the tows ( 103 ) of the core ( 101 ) together, helps to contain the resin (not shown) that is pre-impregnated into the tows ( 103 ) during subsequent textile processes, and limits the stickiness of the yarn ( 100 ) as a whole. The jacket ( 118 ) in most embodiments should be made of high-performance fibers, which can include aramids, polyethylene fibers, or LCP. In one or more alternative embodiments, the jacket ( 118 ) may be formed from prepreg tows ( 103 ), for example serving as the axial fibers ( 102 ). Conventional nylons, polyesters and other thermoplastics may also be used in the jacket ( 118 ). There are numerous embodiments for the jacket ( 118 ) and only a few embodiments are listed herein. The inventors use various braids to accomplish multiple embodiments, but wrapping (see FIG. 6 ), extruding, and other methods can also be utilized. The method used does not substantially change the invention, alternative embodiments are contemplated within the scope of the instant invention, and may be selected based on the features needed case by case. The embodiment of the jacket ( 118 ) includes helical wrapping and interlacing yarns ( 105 ) and that follow helical paths that are either clockwise or counterclockwise around and about axial fibers ( 104 ) that are laid in the structure or wrapping, helical yarns ( 105 ).
FIG. 3 represents a schematic of the equipment used to assemble one or more embodiments of the prepreg fibers ( 102 ) into the core ( 101 ) and construct a braided jacket ( 118 ) around the core ( 101 ). The equipment preferably consists of a braiding machine, a take up stand spool ( 106 ) and driver ( 107 ), a yarn creel ( 110 ) feeding both core fibers ( 102 ) and axial fibers ( 104 ) and a Maypole braider ( 109 ) with carriers and bobbins ( 113 ) all braiding to produce a jacketed prepreg yarn ( 100 ).
FIG. 4 , represents one embodiment for the jacket ( 118 ), a conventional biaxial Maypole braid ( 115 ) over the core ( 101 ). Such a braid is straightforward and simple. The coverage of the core ( 101 ) with an embodiment of jacket ( 118 ) approaches 100%. The full coverage of core ( 101 ) soaks up more of the resin (not shown) that exudes from the core ( 101 ) during curing and perhaps reduces the bonding between fibers ( 104 , 105 ) at crossover intersections. The full coverage jacket ( 118 ) also minimizes the stickiness and abrasion suffered by the core ( 101 ). The danger is that full coverage may result in the compressive jammed state and stiffen the yarn ( 100 ). It is important that the braided jacket ( 118 ) not be in the compressive jammed state (see for example Structural Analysis of a Two - dimensional Braided Fabric , Q. Zhang, D. Beale, S. Adanur, R. M. Broughton, R. P. Walker, Vol. 88(1), 1997), as the yarn may exhibit too much stiffness to be wound on the braider bobbins ( 113 ) for the subsequent formation of the composite preform. On the other hand, as the braid angle decreases from the compressive jammed state, the braided jacket ( 118 ) is more likely to open up during bending around yarn guides and allow the core ( 101 ) to pop out of the protective jacket ( 118 ). (The braid angle is defined as the acute angle between the yarn axis and the braiding yarns). It will be appreciated by those skilled in the art that the natural compression jammed state diameter of the jacked jacketed braid ( 118 ) should not be greater than the diameter of the core ( 101 ).
Looking now at FIG. 5 , another preferred embodiment of jacket ( 118 ) includes an open true triaxial braid jacket ( 119 ) over the core ( 101 ). In this embodiment, the jacket ( 119 ) is made as an open braid, such as a true triaxial braid. The axial fibers ( 104 ) actually interlace ( 120 ) with the helical fibers ( 105 ). The axial fibers ( 104 ) may consist of prepreg tows ( 104 ), Since the braided jacket ( 119 ) is open, the coverage is much less than 100%. This configuration may be desired for a number of reasons. The open braid will allow some of the resin to escape from the core ( 101 ) during curing. The escaping resin (not shown) serves the purpose of bonding fibers ( 104 , 105 ) together at their intersections to produce a composite structure. Anywhere two fibers ( 104 , 105 ) come in contact, for example at intersection points ( 117 ), joints need to be formed to stabilize the composite structure. The amount of resin will be enough to bond the joints between the fibers ( 104 , 105 ) if one pays attention to the fiber volume fraction in the prepreg. It is important to provide sufficient coverage with the open braided jacket ( 119 ) so that the yarn ( 100 ) does not become too sticky to braid and the core ( 101 ) does not pop out of the protective jacket ( 118 , 119 ). The open jacket ( 119 ) reduces total weight.
Looking now at FIG. 6 , one other notable embodiment of jacket ( 118 ) includes wrapping the core ( 101 ) with a radial wrapping device which dispenses yarn ( 121 ) in a helical path around the core ( 101 ). This embodiment offers a very fast way to produce an embodiment of jacketed yarn ( 122 ). The preferred embodiment is to include two radial wrapped fibers ( 105 ) around the core ( 101 ) in opposite directions. The coverage is adjustable, within similar limits and with similar results as described above with the open or closed braided jacket respectively ( 119 ) or ( 118 ).
Additional embodiments and techniques are considered, which are not shown. For example, an additional method to produce the protective jacket ( 118 ) is extrusion, as in the manner of a PVC insulated electrical wire. The down side (i.e. disadvantage) of extrusion coating is that the solid coating will produce a stiffer yarn ( 100 ) than a braid or fiber wrapped core ( 101 ). An extruded layer of a polymer, such as nylon, will provide complete coverage of the core ( 101 ). This will contain all the resin present in the core ( 101 ), ensuring that no strength is lost and that the yarn ( 100 ) is not sticky. After the yarn ( 100 ) is produced, it is used in manufacturing a structure. The extruded layers of multiple yarns will be in contact with one another. The structure will then be heated to cure the resin. During or after the resin is cured, the extruded layers may fuse together, either by a chemical welding process or by briefly heating the structure to the extruded layer's melting point until the material just begins to flow, and then cooling it again. This may result in a very strong bond, much stronger than the bond produced by resin.
The following examples are intended as illustrative aids and should not be construed to limit the scope of the instant invention in any way.
Example 1
A core ( 101 ) of 12 strands of 3 k prepreg tow ( 103 ) containing 60% of Hexcel HexTow® AS4D fiber impregnated with 40% UFXXX TCR™ epoxy resin thermal cure epoxy resin (supplied by TCR composites) was pulled through the center of a 32 carrier horizontal Wardwell Maypole braider ( 109 ). The braider ( 109 ) was loaded with 16 packages of 200 den Vectran™ fibers which was braided at full coverage around the core ( 101 ). The jacketed yarn ( 100 ) was cured at 300 F for 3 hours. The cured yarn ( 100 ) was observed under light microscopy, was cross sectioned and observed under scanning electron microscopy. The structure of the core ( 101 ) was close packed with minimum voids. Tensile strength was essentially as expected from the amount of carbon fiber in the core ( 101 ) and the strength of the fibers in the jacket ( 118 ).
The uncured yarn ( 100 ) was wound onto a braider bobbin ( 113 ) for subsequent use on a Maypole braiding machine ( 109 ). The yarn ( 100 ) was further evaluated by braiding into an open composite structure before curing at 300 F for 3 hours. The yarn was found to exude sufficient resin during curing to form a bond between the braided yarns at their crossover points during curing.
Example 2
A core ( 101 ) of 12 strands of 3 k prepreg tow ( 103 ) containing 60% of Hexcel HexTow® AS4D fiber impregnated with 40% UFXXX TCR™ thermal cure epoxy resin (supplied by TCR composites) was pulled through the center of a 32 carrier horizontal Wardwell Maypole braider ( 109 ). The braider ( 109 ) was loaded with 8 packages of 200 den Vectran™ yarn and 4 strands of axial fibers ( 104 ) arranged to create the true triaxial braid ( 119 ). The braided jacket ( 119 ) exhibited which was braided at full coverage around the core ( 101 ). The jacketed yarn ( 101 ) was cured at 300 F for 3 hours. The cured yarn ( 101 ) was observed under light microscopy, was cross sectioned and observed under scanning electron microscopy, tested for tensile strength and bending, and torsion. Although the jacket ( 119 ) was lighter weight, the strength of the yarn ( 100 ) was about the same as in Example 1.
The yarn ( 100 ) was wound onto a braider bobbin ( 113 ) for subsequent use on a Maypole braiding machine ( 109 ). The yarn ( 100 ) was further evaluated by braiding into an open composite structure before curing at 300 F for 3 hours. The yarn was found to exude sufficient resin during curing to form a bond between the braided yarns at their crossover points during curing.
REFERENCES CITED
Jensen, M. J., Jensen, D. W., Howcroft, A. D., Continuous Manufacturing of Cylindrical Composite Lattice Structures, TEXCOMP10 Recent Advances in Textile Composites, edited by Christophe Binetruy, Francois Boussu, 2010, p. 80-87
Structural Analysis of a Two-dimensional Braided Fabric. Q. Zhang, D. Beale, S. Adanur, R. M. Broughton & R. P. Walker, Journal of The Textile Institute, Volume 88, Issue 1, 1997, pages 41-52
U.S. Pat. No. 2,684,318, April 1950, Meek et al.
U.S. Pat. No. 3,007,497, November 1961, Skobert et al.
U.S. Pat. No. 3,644,866, January 1971, Deardurff
U.S. Pat. No. 5,899,134, May 1999, Klein et al.
U.S. Pat. No. 7,132,027, November 2006, Jensen
European Patents
EP 1401378 B1, August 2008, Lassila et al.
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A composite prepreg yarn designed and constructed is a very large, strong yarn with resin infused throughout, which can be used to prepare composite preforms via conventional Maypole braiding or other textile processes. The invention increases the loads that can be transmitted by the cured yarn in a composite structure, decreases the stickiness that can prevent their use in braiding and other textile processes, provides protection to the high-strength fibers from abrasion that is encountered during and after composite preform manufacturing via braiding.
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BACKGROUND OF THE INVENTION
The invention relates to fuel injection pump for internal combustion engines including a pump pressure chamber and a fuel storage compartment held at relatively low pressure and a fuel supply or suction conduit through which the pump aspirates fuel from the storage compartment to the pressure chamber in normal operation. An electromagnetic valve is provided to obturate the fuel suction conduit in order to arrest the engine.
In known fuel injection pumps of the general type described above, restarting the internal combustion engine is impossible after the electrical system has been turned off since the magnetic valve obturates the suction conduit.
This factor can be very undesirable when the engine is installed in water-borne vehicles or in land vehicles in which long uninhabited stretches of road must be traversed.
OBJECT AND SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a fuel injection pump which does not suffer from the above-mentioned disadvantage of inability to restart the engine, while including fuel control by electromagnetic valving.
This object is attained, according to the invention, by providing a normally-open electromagnetic valve permitting fuel to flow from the fuel suction compartment into the pump pressure chamber. When the magnetic armature is actuated against the force of the valve spring, it is aided by the pressure difference existing between the fuel suction compartment and the pump pressure chamber.
The invention will be better understood as well as further objects and advantages become more apparent from the following detailed description of a preferred embodiment taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial longitudinal section through a distribution injection pump according to the invention; and
FIG. 2 is an enlarged illustration of the construction of the magnetic valve in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, there is shown a fuel injection pump for multi-cylinder, internal combustion engines including a housing 1 in which is rotatably carried a drive shaft 2. Co-rotating with drive shaft 2 is a frontal cam plate 3 provided with a plurality of cam lobes 4 which cooperate with locally-fixed rollers 5. The rotation of the drive shaft 2, due to means not shown, causes rotation of the frontal cam plate 3 which is transmitted by a coupling member 6 to a pump piston 7 which is thereby made to undergo simultaneous reciprocating and rotating motion while being pressed on the cam plate 3 by spring means not shown. The number of cam lobes 4 and hence the number of piston strokes per revolution is equal to the number of cylinders in the engine.
The piston 7 moves in a bore 10 within a cylindrical bushing 9, closed on top by a valve carrier 8, thereby defining a working pressure chamber 11. An axial bore 12 in the valve carrier 8 connects the pressure chamber 11 with a blind chamber 13 which is connected by a line 14 to the cylindrical bore 10 in the bushing 9. The axial bore 12 may be obturated by a valve member 16 loaded by a spring 15. The connecting line 14 terminates radially into the cylindrical bore 10, and an annular groove 17 located on the circumference of the pump piston and a longitudinal groove 18 connected thereto create a communication between the terminus of the connecting line 14 and sequential ones of the individual pressure lines 20 during each compression stroke of the piston. The pressure lines 20 lead to individual engine cylinders (not shown) and are equal in number to the number of engine cylinders.
During each compression stroke of the piston 7, fuel is delivered through the axial bore 12, which opens the valve member 16, and hence into the chamber 13, the connecting line 14 and through the distribution groove 18 to one of the pressure supply lines 20. During the downward, suction stroke of the piston, fuel flows from a slightly pressurized pump suction chamber 22 through a suction line 23 into the bore 10. The fuel flow from the suction chamber is controlled by a number of longitudinal grooves 24 on the pump piston, equal in number to the number of pressure lines 20. During the compression stroke of the piston, the rotation of the piston interrupts the communication between the suction line 23 and the longitudinal grooves 24 so that the entire fuel quantity supplied by the piston is delivered to one of the pressure lines 20. The suction conduit 23 is further controllable by an electromagnetic valve 25, as will be explained in detail below.
The amount of fuel delivered to the engine is controlled by changing the fuel flow from the pressure chamber 11 to the suction chamber 22 through a blind bore 26 in the pump piston 7 which connects with a transverse bore 27. Cooperating with the transverse bore 27 is a fuel quantity setting member 28, embodied as an annular slide displaceable on the outside surface of the pump piston, whose position determines the point of time at which the transverse bore 27 is opened when the pump piston moves upwardly, thus creating a communication between the pressure chamber 11 and the pump suction chamber 22. From this point on, the supply of fuel to the pressure line 20 is interrupted. By changing the position of the annular slide 28, the fuel quantity actually delivered to the engine may thus be adjusted.
The adjustment of the fuel quantity is performed by the engagement of a ball head 31 of a control lever 30 engaging a recess 32 in the annular slide 28. The control lever pivots about a point 34 whose position can be changed by an eccentric 35. The other end of the control lever 30 is engaged by a control spring in opposition to the force of an r.p.m. signal generator. The bias tension of the control spring may be adjusted with an arbitrarily settable lever. When the engine r.p.m. increases, the r.p.m. signal generator acts to reduce the injected fuel quantity, whereas the spring urges the lever in the direction of increasing fuel quantity. The equlibrium position, which defines the actual injected fuel quantity, can be adjusted by the above-mentioned lever.
The magnetic valve 25 has a casing 37 on which are provided external screw threads which engage complementary threads in the fuel pump housing 1. An armature 38 is connected by a rod 36 with a movable valve member 40. A spring 41 loads the valve member 40 so as to maintain the valve in the open condition when deenergized. Mutually opposite end faces of the armature 38 and a core 39, respectively, are conical, to provide favorable magnetic flux conditions when the coil 42 is energized. Energizing the magnetic coil 42 obturates the suction conduit 23 and thus stops the engine. When the electrical system of the internal combustion engine is turned off, the magnetic valve 25 re-opens so that, during restart or during a possible failure of the electrical system, fuel can again be supplied from the suction compartment 22 to the pump pressure chamber 11.
In a particularly favorable feature of the invention, shown in FIG. 2, the non-magnetic rod 36 is connected to the armature 38 made of magnetic material in a press-fit, while being inserted in a bore 43. Furthermore, the movable valve member 40 has a flange 44 which supports the spring 41 and also serves as a stroke-limiting stop by cooperating with the end of the core 39 which faces it. At the end nearest the valve seat, the magnet core 39 extends through the casing 37 and serves as support for a sealing ring 46 disposed between the core 39 and an interior surface of the pump housing 1. The magnetic valve 25 may be threadedly disengaged from the housing 1 and the threaded opening 47 may be obturated by a threaded plug in the event that the control of fuel flow through suction conduit 23 is not required. The end 48 of the movable valve member 40 is provided with an elastic sealing material 49, preferably of rubber-like consistency, and preferably vulcanized directly onto the armature tip 40.
On the side remote from the valve seat, the magnetic valve casing 37 is enclosed by a cover 57 which has a central aperture carrying an electric contact screw 52 which is insulated by plastic rings 53 with respect to the cover 57 and the casing 37. An electrical connector 54 leads from the contact screw 52 to the magnetic coil 42. The cover has a projection 55 which engages the coil body to prevent a relative rotation of the coil 42 and the contact screw 52 or the cover 57, which might result in fracture of the conductor 54. The edge of the casing 37 is clamped or crimped around the adjacent edge of the cover 57, thereby fastening it permanently.
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A fuel injection valve for an internal combustion engine includes a fuel storage compartment and a pressure chamber from which a reciprocating pump piston delivers fuel to the engine's fuel lines. The fuel conduit between the storage compartment and the pressure chamber can be closed off by an electromagnetic valve. To permit engine operation even when the electrical system is non-functional, the magnetic valve is of the normally open type, held open by a spring. In the energized state, the valve closes off the fuel conduit and its closure is aided by the fuel pressure gradient across the valve.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to focusing screen devices suited for use in optical instruments which necessitate focus adjusting operation, such as photographic cameras, and more particularly to focusing screen devices which enable the observer to recognize the focus adjusting condition of the optical system by discrimination of whether or not the image is shifted at least in part.
2. Description of the Prior Art
Conventional focusing screens, such as those used in single lens reflex cameras, often use matted surfaces, microprisms, or split image prisms. Matted surfaces and microprisms have the disadvantage that the user must be experiened in discriminating between a sharp focus condition and an out-of-focus condition because the sharpness of the image formed thereon must be observed directly. On the other hand, a split-image prism does not require as much experience and focusing is comparatively simple. However, because the image is split at only one line segment when the image is out-of-focus, the operator can often not use it. To ensure proper operation, microprisms and split-image prisms are often incorporated into a single focusing screen. Such a focusing screen requires proper selection of one of the two possible focusing methods depending upon the given photographic situation. Thus, it is rather difficult for a beginner to master the technique of focusing with such a screen.
Moreover, there is a device in which two optical band grooves of saw-tooth-like or peak-like cross-section are arranged to face in different directions and to be mechanically reciprocatingly movable so that the field of the view of the finder is covered by either one of the band grooves at a time. Accordingly, as the two band grooves reciprocate, when the image is not in-focus, the image shifts to the left and right periodically. When a sharp focus condition is reached, the image is at a standstill. This method of achieving detection of an in-focus condition is disclosed in Japanese Patent Publication No. Sho 46-33496 (33496/1971). A device which makes it possible to detect when the image is in-focus by rotating the saw-tooth-like or peak-like cross-sectional grooves mechanically when the image is out-of-focus, and producing a standstill when the image is in-focus, is disclosed in Japanese Patent Publication No. Sho 47-20733 (20733/1972). These devices permit an operator to focus clearly and detect a proper focus simply even if the operator is a beginner.
However, because these devices require mechanical drive means to move the optical band grooves of the focusing screen, and, further, because the focusing screen travels through a large space, it is very difficult, if not nearly impossible, to incorporate such a device in a space as small as, for example, that available within a camera housing. Even if such incorporation is possible, as the focusing screen of the band grooves is driven, vibrations are produced. This raises the problem of the possibility that the focusing screen plane cannot be kept sufficiently stable to meet the particularly rigorous requirement for accuracy.
SUMMARY OF THE INVENTION
With the foregoing in mind, the present invention has for its general object to provide a novel and more advantageous focusing screen device which has overcome all the above-described drawbacks of the conventional devices.
An object of the invention is to provide an improved focusing screen device which enables an observer to realize the focus adjusting condition of the optical system with higher accuracy and reliability than was heretofore possible.
Another object of the invention is to provide a further improved focusing screen device which does not have a mechanical moving part, and therefore which is extremely adaptable to a minimization of the bulk and size of its body for a compactness. Since large components are no longer necessary, the device can be made ready for incorporation in an optical instrument such as a photographic camera despite the limitation of very little unoccupied interior space. Moreover, because of its operating without accompaniment of any mechanical vibrations and driving shocks, the device is stabilized against a change of the position of the focusing screen plane, and, therefore, a very large increase in the accuracy of focusing adjustment can be expected from its use.
To this end, according to the present invention, a focusing screen device includes light refracting means having plural sets each of a plurality of light refracting surfaces, each set of surfaces having a different light refracting direction and light control means including an electro-optical light control element for controlling the passage of light through each surface in each set, whereby when the light control element is controlled from outside, the focusing condition of the optical system is indicated in the form of whether or not the object image as a whole or in part changes its position, for example, continuously as a split line scans the image, and/or, for example, periodically, thus enabling an observer to recognize the focusing condition of the optical system with extreme clarity.
In a number of preferred embodiments of the present invention to be described more fully later, said focusing screen device operates in various modes separately or in combination, one of which is, in view of a more concrete and advantageous construction, that particularly when the optical system is out of focus, a vibrational motion is given to the image, thus performing a highly noticeable indication of the out-of-focus condition. Another mode is similar to the split-image type focusing screen, in that a split line is formed, but the position of the split line is continuously shifted, thus enabling an observer to discriminate the focusing condition of the optical system more clearly and easily than the conventional split-image type focusing screen. Still another mode is that when out of focus, the image is caused to travel along a path of a closed loop, thus giving an observer a very clear impression when the optical system is out of focus.
Though in these embodiments, the above-described light control means incorporates FE-TN (Field Effect-Twisted Nematic) type liquid crystal as said electro-optical element with polarizing plates or filters, it is of course possible to use an electro-chromic element or other suitable means as the control element.
These and other objects and features of the present invention will become apparent from the following detailed description of preferred embodiments thereof taken in connection with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of an optical system in a single lens reflex camera taken as an example of application of the focusing screen device of the present invention.
FIGS. 2 to 4 show a first embodiment of the present invention in which FIG. 2 is a sectional view of a focusing screen device, FIG. 3 is an exploded perspective view of the device of FIG. 2, FIG. 4(a) is a plan view of the polarizing plate of FIG. 3 in a position where no voltage is applied and pictorial representations of the view-field of the finder when in the out-of-focus and in-focus conditions, and FIG. 4(b) is a similar view and similar representations when a voltage is applied.
FIG. 5 is a perspective view of another example of the prism of FIG. 3.
FIGS. 6 to 8 show a second embodiment of the present invention in which FIG. 6 is an exploded perspective view of a focusing screen device. FIG. 7(a) is a diagram of a drive circuit for the liquid crystal of FIG. 6, FIG. 7(b) is a pulse timing chart of the various outputs of the ring counter of FIG. 7(a), and FIG. 7(c) is a pulse timing chart of the various outputs of the OR gates OR1 to OR7 of FIG. 7(a). FIGS. 8(a), 8(b) and 8(c) are plan views of the liquid crystal cells in operative conditions at time points t1, t2 and t3 in FIG. 7(c) respectively with their corresponding pictorial representations of the field of view of the finder.
FIGS. 9 to 13 show a third embodiment of the present invention in which FIG. 9(a) is an exploded perspective view of a focusing screen device, FIG. 9(b) is a perspective view in an enlarged scale of the prism elements of FIG. 9(a). FIGS. 10(a), 10(b), 10(c) and 10(d) are plan views of the prism element assembly in four different operative conditions where one of the faces of each prism element are respectively selected to pass light therethrough with the resulting pictorial representations of the field of view of the finder. FIGS. 11(a) and 11(b) are plan views of the paired transparent electrodes of FIG. 9 respectively. FIG. 12 is a diagram of a drive circuit for the liquid crystal cell of FIG. 9, and FIG. 13 is a pulse timing chart of the various output signals of the circuit portions of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 there is schematically shown a single lens reflex camera chosen as an example of an optical instrument to which the focusing screen device of the invention is applicable. FIG. 1 shows a photographic objective 1; a reflex mirror 2; a photographic film 3; a focusing screen 4; a condenser lens 5; a pentaprism 6; and an eye-piece 7. Light from an object to be photographed enters through the objective lens 1 and after reflection from the mirror 2 is focused on the focusing screen 4'. An image of the object formed on this focusing screen can be observed through the condenser lens 5, pentaprism 6 and eye-piece 7. When an exposure is made, the reflex mirror 2 is flipped upward so that the light entering through the objective 1 is focused through an opened shutter (not shown) on the film 3, and the film 3 is exposed to an image equivalent in sharpness to that on the focusing screen 4'.
FIGS. 2 to 5 show a first embodiment of the present invention where motion of the image is vibrational, and the blocking and unblocking of the light is carried out by a liquid crystal cell.
FIG. 2 shows an example of a practical focusing screen device of the present invention which can be substituted for the focusing screen 4' of FIG. 1, and FIG. 3 shows this device as disassembled. This focusing screen device is generally indicated as 4, and comprises, in a direction from the reflex mirror 2, a linear polarizing plate 4a, a glass substrate 4b with a transparent electrode 4b 1 formed thereon, a transparent insulating plate 4c containing a transparent liquid crystal material 4d in a central rectangular region thereof, a transparent electrode 4e 1 on the lower surface of a glass substrate 4e, a polarizing plate 4f having a plurality of pairs of polarizing elements 4f 1 and 4f 2 different in the direction of polarization from each other by 90°, and a prism plate 4g having an alternating arrangement of two prism elements 4g 1 and 4g 2 of different orientation from each other in correspondence to the above-described polarizing elements 4f 1 and 4f 2 . The above-described two transparent electrodes 4b 1 and 4e 1 on the glass substrates 4b and 4e are positioned in contact with the respective surfaces of the liquid crystal cell 4d. It is noted here that as the liquid crystal material 4d, use is made of, for example, FE-TN (Field Effect-Twisted Nematic) type material.
The transparent electrodes 4b 1 and 4e 1 are supplied with an alternating voltage as shown in FIG. 2 at the left hand lower corner thereof. When the voltage is at zero value, the polarized face of light from the polarizing plate 4a is rotated in passing through the liquid crystal 4d depending upon the oriented state of the liquid crystal molecules, finally through 90° before it reaches the polarizing plate 4f. On the other hand, when a voltage is applied, the liquid crystal molecules take the homogeneous orientation so that the polarized light from the polarizing plate 4f does not rotate in passing through the liquid crystal to the polarizing plate 4f. There are two directions of polarization of the polarizer elements 4f 1 and 4f 2 in the polarizing plate 4f. The direction for the elements 4f 2 is the same as that of the linear polarizer 4a, and the direction for the elements 4f 1 is the same as that resulting from the rotation by the liquid crystal 4d, that is, the direction of polarization through 90°. These two directional polarizer elements in each pair 4f 1 and 4f 2 are associated with the respective prism elements 4g 1 and 4g 2 of the same directionality.
The operation of the focusing screen device of such construction will be described below.
With no potential applied across the transparent electrodes 4b 1 and 4e 1 , the liquid crystal cell 4d rotates the plane of polarization through 90° so that only those of the polarizer elements which have the different direction of polarization which differs by 90° from that of the polarization of the polarizing plate 4f, in this instance, elements 4f 2 pass the polarized light. As shown in FIGS. 4(a)-(i), therefore, only the areas corresponding to the prism elements 4g 2 aligned with said polarizer elements 4f 2 appear white on a dark background at the other prism elements 4f 1 . Then, when a potential is applied, the polarized light from the polarizing plate 4a is incident upon the opposite polarizing plate 4f without the change in the plane of polarization, so that only the polarizer elements 4f 1 having the same direction of polarization as that of the polarizing plate 4a open to pass the polarized light. As shown in FIGS. 4(b)-(i ), therefore, the other prism elements 4g 1 in the prism plate 4g aligned with said polarizer elements 4f 1 , when no voltage is applied, are then selected to refract the emerging light in the different direction. As a result, when switching on and off (that is, supply and cut off) of the alternating voltage applied across the transparent electrodes 4b 1 and 4e 1 of the liquid crystal cell 4d is repeated, at a rate detectable the human eye (for example, a few Hz), the incident light Io on the focusing screen device 4 as it passes therethrough is directed to Io' and Iv' depending upon whether the voltage is absent or present respectively, as shown in FIG. 2. The exiting light changes its direction alternately at the corresponding repetition rate to that of the voltage supply, while the image in the central target area is simultaneously shifted by a distance proportional to the degree of unsharpness as in the ordinary split-image type focusing screen. When the condition of best focus is reached, the image no longer changes its position. In more detail, with the out-of-focus condition, when the voltage takes zero value, an image of a subject at the center of the target area appears in the left hand half of the corresponding area of the view-field of the finder as shown in FIGS. 4(a)-(ii), and then when the voltage takes a certain value, that image appears in the right hand half as shown in FIGS. 4(b)-(ii). When the objective 1 is brought into best focus, that image comes to the center of the area and remains at a standstill regardless of the change of the voltage applied, as shown in FIGS. 4(a)-(iii) and 4(b)-(iii).
Though the above-described embodiment employs wedge prisms as the prism elements for light refraction, elongated roof or peak shaped prism elements as shown in FIG. 5 may be used to effect an equivalent result. That is, a number of roof type prism elements 4g'a are arranged side by side, and their left and right roofs or inclined surfaces 4g' 1 and 4g' 2 are aligned with respective polarizing elements 4f 1 and 4f 2 of the polarizing plate 4f. It is noted that the electric-optical light control element, use may be made, besides the liquid crystal cells, of an electro-chromic element or other suitable electro-optical transmittance control element. In the case of the electro-chromic elements, there is no need to use the polarizing plates, thereby giving an advantage that the brightness of the image on the focusing screen device is correspondingly increased.
FIGS. 6 to 8 show a second embodiment of the present invention where the image in the target area is split into two parts along a horizontal line, and this horizontal line or split line is vertically moved at a moderate speed so that the observer can realize whether or not the image is split more distinctively.
FIG. 6 shows this second embodiment of the focusing screen device as comprising similar parts to those of FIG. 3 except that the patch of one of the electrodes of the liquid crystal cell 4d is divided into a number of mutually insulated strips to the total number of prism elements 4g 1 and 4g 2 in the plate 4g, as transparent electrodes SG1 to SG16, and that the polarizing plate 4f' has only one uniform polarizing area of which the direction of polarization is perpendicular to that of polarization of the polarizing plate 4a.
FIG. 7(a) shows a drive circuit for the liquid crystal cell. FIG. 7(a) shows a pulse generating circuit PG1; a frequency dividing circuit 10; a ring counter 11; OR gates OR1 to OR7 connected to the outputs of said ring counter 11; inverting circuit IN11 to IN18 connected to the output Q1 of the above-described ring counter 11 and the outputs of the above-described OR gates OR1 to OR7 respectively; an inverting circuit IN1 connected to the output of the above-described pulse generating circuit PG; and analogue switches ASW1 to ASW16. The analogue switches ASW1, ASW3, ASW5, ASW7, ASW9, ASW11, ASW13 and ASW15 are fed at their "one" inputs with the output of the above-described pulse generating circuit PG1, and at their other or control inputs with the output Q1 of the above-described ring counter 11 and the outputs of the OR gates OR1 to OR7 respectively. On the other hand, the analogue switches ASW2, ASW4, ASW6, ASW8, ASW10, ASW12, ASW14 and ASW16 each are fed at their "one" inputs with the output of the above-described inverter circuit IN1, and at their control inputs with the outputs of the above-described inverters IN11 to IN18 respectively.
Also shown are inverting circuits IN21 to IN28, the inverting circuit IN21 having an input which is connected to both of the outputs of the above-described analogue switches ASW1 and ASW2, the inverting circuit IN22 having an input which is connected to both of the outputs of analogue switches ASW3 and ASW4, the inverting circuit IN23 having an input which is connected to both of analogue switches ASW5 and ASW6, the inverting circuit I24 and I27 likewise having inputs which are connected to successive pairs of outputs of analogue switches, and the inverting circuit IN28 having an input which is connected to the both of the outputs of analogue switches ASW15 and ASW16.
The transparent divided electrodes SG1-SG16 are associated with the liquid crystal shown in FIG. 6, together with the transparent common electrode 4e 1 . The transparent electrode strip SG1 is connected to both of the outputs of the above-described analogue switches ASW1 and ASW2, the electrode strip SG3 to both of the outputs of the above-described analogue switches ASW3 and ASW4, the electrode strips SG5, SG7, SG9, SG11 and SG13 are likewise connected to the respective pairs of outputs of the analogue switches, and the electrode strip SG15 to both outputs of analogue switches ASW15 and ASW16.
On the other hand, the transparent electrode strips SG2, SG4, SG6, SG8, SG10, SG12, SG14 and SG16 are connected only to the outputs of corresponding inverting circuits IN21 to IN28.
The operation of the circuit of such construction is as follows:
The pulse generating circuit PG1 produces a train of pulses which are applied to the frequency divider 10. Responsive to the output of the frequency divider 10, the ring counter 11 produces pulse trains at its output Q1 to Q9 as shown in the timing chart of FIG. 7(b). Therefore, at the outputs of OR gates OR1 to OR7 there appear pulses as shown in the timing chart of FIG. 7(c). Now, on consideration of which condition each of the outputs assumes at a time point t1, it is at this time point t1 that the output Q1 of the ring counter 11 and the output of the OR1 take low level (hereinafter referred to "0"), and the outputs of the OR gates OR2 to OR7 take high level (hereinafter referred to "1"), and therefore that the outputs of the inverters IN11 and IN12 are "1" and the outputs of inverters IN13 to IN18 are "0". This leads to turn off the analogue switches ASW1, ASW3, ASW6, ASW8, ASW10, ASW12, ASW14 and ASW16 turning off, and the analogue switches ASW2, ASW4, ASW5, ASW7, ASW9, ASW11, ASW13 and ASW15 turning on. Therefore, applied to the transparent electrode strips SG1, SG3, SG6, SG8, SG10, SG12, SG14 and SG16 are pulses of opposite phase to that of the output pulse of the above-described pulse generating circuit PG1, and at this time, the electrode 4e 1 is fed with the output pulses of the generating circuit PG1 with the result that a substantial alternating voltage is applied to the liquid crystal areas L1, L2 and L13 to L18, and these liquid crystal areas are turned on. On the other hand, applied to the transparent electrode strips SG2, SG4, SG5, SG9, SG11, SG13 and SG15 are pulses of the same phase as that of the output pulses of the above-described pulse generating circuit PG1, and this applied pulse is of the same phase as that of the pulse applied to the electrode 4e 1 with the result that the voltage applied to the liquid crystal areas L11, L12, L3 to L8 is no longer alternating, and therefore these liquid crystal areas are turned off. The ON and OFF states of the entire surface of the liquid crystal cell are shown in FIGS. 8(a)-(i). Since the liquid crystal surface areas L1 to L8 and L11 to L18 correspond to the prism elements 4g 1 and 4g 2 in the plate 4g, the image appears to be split along a horizontal line coincident with the boundary between the liquid crystal areas L12 and L3 as shown in FIGS. 8(a)-(ii).
Next, at a time point t2 in FIG. 7(c), the analogue switches ASW1 to ASW16 change their ON and OFF positions with the result that the liquid crystal areas L1, L2, L3 and L14 to L18 are turned on, and the liquid crystal areas L11, L12, L13 and L4 to L8 are turned off, as shown in FIGS. 8(b)-(i). The appearance of the image is shown in FIGS. 8(b)-(ii). Then, at a time point t3, the liquid crystal assumes the ON and OFF states as shown in FIGS. 8(c)-(i) and the image appears with its split line as shown in FIGS. 8(c)-(ii).
As is evident from the above, depending upon the output periods of the ring counter 11, as shown in FIGS. 8(a), (b) and (c), the boundary line of the split image continues to go on shifting successively. Thus, an effective splitting of the image is realized. Upon adjustment of the position of the objective 1 so as not to produce a split image, the objective 1 can be sharply focused.
A third embodiment of the present invention will next be described by reference to FIGS. 9 to 13. This third embodiment operates to detect an out of focus condition by imparting into the image a circulating movement.
FIG. 9(a) shows a focusing screen device according to this third embodiment as disassembled. What is different from FIG. 3 appears in the electrode structure of the liquid crystal cell and the prism structure. These will be described more fully later.
Also the polarizing plate 4f" is constructed in the form of a uniform polarizer with the direction of polarization being the same as that of the polarizer 4a.
FIG. 9(b) shows the details of a prism element assembly on the prism plate 4g" shown in FIG. 9(a). This prismed area is made up from prism elements each in the form of a regular square pyramid. In this example, the four faces of the prism element are associated with respective light control portions of the light control means operating in such a manner that light is allowed to pass through all the prism elements at their one faces, while being simultaneously blocked at all of their other faces at a given time. The positions of the light emergent faces change by rotating about the element axis, thus the entering light as it emerges caused to deviate to four different directions at an angle with the axis. When the image is not in best focus, it is caused to move in a square path from corner to corner. The larger the degree of unsharpness, the longer is the length of the side of the square path. When the condition of best focus is reached, the image no longer moves. In this case, it is required that one cycle of progressive opening and closing operation of the four light shutter elements for each prism element takes a sufficient time for the eye to perceive the motion of the image and to realize when the image stops.
FIG. 10 shows a great number of regular square pyramid prism elements arranged in a matrix in the above-described focusing screen device 4 in four operative conditions, along with the pictorial representations the resultant field of view of the finder at FIGS. 10(a), (b), (c) and (d). FIG. 10(a) shows a light arrangement when the first faces 4g"1 of all the prism elements are white, and the position an image of an object at the center of the target area takes when the condition of best focus is not yet reached at (ii) and has been established at (iii). FIG. 10(b) shows another light arrangement when the second faces 4g" 2 of all the prism elements are while on a dark background of the other three faces, and what position the same object image takes when in the out of focus and in-focus conditions at (ii) and (iii) respectively. FIG. 10(c) shows another light arrangement when the third faces 4g" 3 of the prism elements are while on a dark background of the other three faces, and what position the same object image takes when in the out of focus and in-focus conditions at (ii) and (iii) respectively. FIG. 10(d) shows another light arrangement when the fourth faces 4g" 4 of all the prism elements are while on a dark background of the other three faces and what position the same object image takes when in the out of focus and in-focus conditions at (ii) and (iii) respectively. And, when the light arrangement is transferred from the first prism face 4g" 1 to the second prism face 4g" 2 , then therefrom to the third prism face 4g" 3 , then therefrom to the fourth prism face 4g" 4 , and then to the first prism face 4g"a, and so on, the image moves in tracing a square path to circulate about the center of the area of the view-field as the image is not in focus. As the degree of unsharpness increases, the total length of the path increases. As the image approaches the best focus, the path is decreased in the length, finally to a point at which the image gets standstill, as the position of the objective lens 1 is so adjusted.
Here, FIGS. 11(a) and 11(b) show an example of the electric-optical light control element assembly usuable with the prism element assembly of FIG. 10. This light control element assembly is constructed in the form of a liquid crystal cell. In FIG. 11(a), X1 and X2 show saw-tooth-like transparent electrodes formed on one glass substrate in mating relation with each other. In FIG. 11(b), Y1 and Y2 show another pair of saw-tooth-like transparent electrodes formed on the opposite glass substrate in mating relation with each other. And a liquid crystal fills the space between the transparent electrodes X1 and X2-carried glass substrate and the transparent electrode Y1 and Y2-carried glass substrate. When to assemble these two glass substrates, it is required that the inclined boundary between the two transparent electrodes X1 and X2 indicated at 21 and the inclined boundary between the two transparent electrodes Y1 and Y2 indicated at 22 cross each other. When to assemble such liquid crystal light shutter element assembly with the prism element assembly, it is required that each regular tetragon 20 defined by the opposed two of the saw teeth of the transparent electrodes X1 and X2 is just aligned to the base of the corresponding one of the regular square pyramid prism elements.
FIG. 12 shows a drive circuit for the above-described liquid crystal cell. In the figure, PG2 is a pulse generating circuit; 31 is a constant voltage forming circuit having an output terminal which is connected to a series connected circuit of three resistors R1, R2 and R3 of equal resistance value to one another. IN21 is an inverting circuit connected to the output of the above-described pulse generating circuit PG2; 32 is a frequency dividing circuit connected also to the above-described pulse generating circuit PG2. ASW11 to ASW18 are analog switches, the analog switches, the analog switches ASW11, ASW13, ASW16 and ASW18 being fed at their control inputs with the output of the above-described inverter circuits IN21 and the analogue switches ASW12, ASW14, ASW15 and ASW17 being fed at their control inputs with the output of the above-described pulse generating circuit PG2. Again, the analogue switches ASW11 and ASW15 are fed at their inputs with a voltage V3 from the junction of the above-described resistors R2 and R3, the analogue switches ASW12 and ASW16 at their inputs with a voltage V2 from the junction of the above-described resistors R1 and R2, the analogue switches ASW13 and ASW17 at their inputs with a voltage V1 from the output of the above-described constant voltage forming circuit 31, and the analogue switches ASW14 and ASW18 at their inputs with earth voltage E. 33 and IN22 are a 90° phase delay circuit and an inverting circuit respectively each connected to the above-described frequency dividing circuit 32. IN23 is an inverting circuit connected to the output of said 90° phase delay circuit. ASW21 to ASW24 are analogue switches, the analogue switches ASW21 and ASW23 being connected at their one inputs each to both of the outputs of the above-described analog switches ASW11 and ASW12, while the analog switches ASW22 and ASW24 are connected at their one inputs each to the both of the outputs of the above-described analog switches ASW13 and ASW14. Again, the control inputs of analog switches ASW21 and ASW24 are connected to the output of the above-described inverting circuit IN23, and the control inputs of analog switches ASW22 and ASW23 are connected to the output of the above-described 90° phase delay circuit 33.
ASW31 to ASW34 are also analog switches, the analog switches ASW31 and ASW33 being connected at their one inputs each to the both outputs of the above-described analog switches ASW15 and ASW16, while the analog switches ASW32 and ASW34 are connected at their one inputs each to both of the outputs of the above-described analog switches ASW17 and ASW18. Again, the analog switches ASW31 and ASW34 have control inputs which are connected to the output of the above-described frequency dividing circuit 32, and the analog switches ASW32 and ASW33 have control inputs which are connected to the output of the above-described inverting circuit IN22.
Applied to the above-described transparent electrode XI are both of the outputs of the analog switches ASW33 and ASW34, and to the transparent electrode X2 are both of the outputs of the analog switches ASW31 and ASW32. Also applied to the above-described transparent electrode Y1 are both of the outputs of the analog switches ASW21 and ASW22, and to the transparent electrode Y2 are both of the outputs of analog switches ASW23 and ASW24.
The operation of the circuit of such construction will next be described by reference to the pulse timing chart of FIG. 13. The pulse generating circuit PG2 is assumed to produce a train of pulses shown on line PGW in FIG. 13. Then, as the combined output of analog switches ASW11 and ASW12 there is produced a train of pulses of low voltage level shown on line YOFF; as the combined output of analog switches ASW13 and ASW14 a pulse train shown on line YON; as the combined output of analog switches ASW15 and ASW16 a pulse train shown on line XOFF; and as the combined output of analog switches ASW17 and ASW18 a pulse train shown on line XON. On the other hand, at this time, the frequency dividing circuit 32 and inverting circuit IN22 produces trains of pulses at a divided frequency shown on lines BN1 and BN1 respectively. Also the 90° phase delay circuit 33 and the inverting circuit IN23 produces pulse trains at the same frequency but delayed in phase by 90° as shown on lines BN2 and BN2 respectively.
As the combined output of analog switches ASW21 and ASW22 there is produced a pulse voltage at Y1' which is applied to the transparent electrode Y1; as the combined output of analog switches ASW23 and ASW24 there is produced a pulse voltage at Y2' which is applied to the transparent electrode Y2; as the combined output of analog switches ASW31 and ASW32 there is produced a pulse voltage at X2' which is applied to the transparent electrode X2; and as the combined output of analog switches ASW33 and ASW34 there is produced a pulse voltage at X1' which is applied to the transparent electrode X1.
Therefore, applied across the transparent electrodes: X1-Y1, X2-Y1, X2-Y2, and X1-Y2 are the respective pulsating voltages of which the amplitudes vary with time and of which the phases are deviated from each other by 90° as shown on lines X1'-Y1', X2'-Y1', X2'-Y2' and X1'-Y2' in FIG. 13 respectively. Since the V1 is so adjusted that the liquid crystal is turned on by the pulse voltage 2V1 (P-P value), and off by the pulse voltage 2V3 (P-P value), as the liquid crystal areas between the pairs of transparent electrodes are deviated in phase from each other, they are periodically turned on and off. The turning on of only those of the liquid crystal areas which lie between the transparent electrodes X1-Y1 corresponds to FIG. 10(b); the turning on of only those of the liquid crystal areas which lie between the electrodes X2-Y1 corresponds to FIG. 10(c); the tuning on of only those of the liquid crystal areas which lie between the electrodes X2-Y2 corresponds to FIG. 10(d); and the turning on of only those of the liquid crystal areas which lie between the transparent electrodes X1-Y2 corresponds to FIG. 10(a). As such is a manner of operation, when the image is not in focus, the image appears to circulate.
Though this embodiment has been described as using the regular square pyramid configuration of the prism element, the present invention is not confined thereto. Otherwise configured prisms may be used provided for regular polyhedron whatever. It is however noted that as the number of faces in a single prism element increases and the pyramid approaches a right circular cone, though the motion of the image becomes smooth, the brightness of the image on the focusing screen device gradually decreases. Therefore, there is a compromise between the number of faces and the image brightness. In general, the square pyramid or thereabout will be optimum.
As has been described in greater detail, according to the focusing screen device of the present invention, all the drawbacks of the conventional focusing screen such as awkward appearance of the image and particularly the difficult assessment of the condition of best focus of the optical system are moped up, and it is made possible for the observer to realize the focus adjustng condition of the objective lens by a very novel and advantageous method with a higher accuracy and reliability than was heretofore possible. Further, there are many additional advantages that because of the unnecessity of using particular mechanical moving parts, a further minimization of the bulk and size of the entire body and a compactness can be very readily facilitated, and there is never required a supplemental large-scale device, so that the focusing unit can be easily incorporated in a photographic camera or like optical instrument of which the interior space is extremely limited, and that since any mechanical vibrations are never accompanied, the focusing screen device is very stable and therefore a very high precision of focus adjustment can be expected from its use.
It is noted that the focusing screen device of the present invention may be modified in various ways within the scope and spirit of the present invention. Therefore, it is to be understood that the present invention is of course not limited to the features of the embodiments thereof.
As an example, for the second embodiment described in connection with FIGS. 6 to 8, the periodic shift of the image in the first embodiment described in connection with FIGS. 2 to 4 may be adapted. For this purpose, it is required to provide a circuit comprising a frequency divider (output: a few Hz) A, an inverting circuit B, AND gates C and D and an OR gate E as shown by imaginal lines in FIG. 7(a) so that the output pulse from the pulse generating circuit PG1 and the output pulse of the inverting circuit IN1 are alternately applied to the electrode 4e1. It is noted here that this circuit portion can be also used in driving the liquid crystal cell in the first embodiment described in connection with FIGS. 2 to 4. That is, concretely speaking, the output pulse of the pulse generating circuit PG1 is applied to either one of the electrodes 4b1 and 4e1, and the other is fed with the ouput pulse of the OR gate E.
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A focusing screen device for use in a photographic camera or other suitable optical instrument includes a light refracting structure having a number of sets of light refracting surfaces. Each set of surfaces provides a different light refracting direction than that of the other sets. A light control assembly including an electro-optical element controls the passage of light through each surface of each set. The focusing condition of the optical system of the camera then is perceived by observing whether or not an object image changes its position, as a whole or in part, after light from the object passes through the device. For example, the position of the image may change continuously or periodically as a split line scans the image. Accordingly, the observer is able to recognize the focusing condition of the optical system with extreme clarity.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The invention is related to an actuator comprising a housing, a motor, an actuating member and a screw mechanism providing a linear movement of the actuating member with respect to the housing in response to a rotational movement of the motor, said screw mechanism comprising a screw and a nut one of which is rotatably supported with respect to the housing.
2. Description of Related Art
Such actuator is known from WO-A-9603301. The actuator comprises a screw mechanism, consisting of a screw and a nut which engage each other by means of rollers having circumferential grooves. Such actuator provides a well defined axial displacement, and also a certain degree of reduction. Thus, a fairly, small axial displacement is obtained in response to a considerable rotation of the screw. Consequently, the screw may exert a considerable axial force on the actuating member.
The proper operation of the screw mechanism can be assured as long as the screw, nut and rollers are subject to a well-defined, axial load. In such case, all components are loaded in accordance with their design requirements; moreover, the load may then reach a considerable level without causing damage to the screw mechanism.
A very unfavorable case however occurs when the screw mechanism is subjected to loadings having a transverse or radial component. The screw, nut and rollers are not designed to accommodate the transverse load components, and will be damaged.
The same occurs in case the actuator is loaded by a bending couple, which is always associated with such transverse forces.
SUMMARY OF THE INVENTION
The object of the invention is to provide an actuator as described before, in which the problems related to transverse or radial loadings are circumvented or at least alleviated. This object is achieved in that the screw mechanism and the actuating member engage each other through a resilient intermediate pressure means. The resilient intermediate pressure means is able to transfer the required actuating force from the screw mechanism onto the actuating member. Thus, its stiffness in axial direction should be rather high. In particular, the stiffness should be maintained at a level where the required force/displacement relationship still provides the possibility to obtain the desired actuating force.
On the other hand, said resilient intermediate pressure means is not as stiff as a direct connection between the screw mechanism and the actuating member. This adapted stiffness has the advantage that extreme loadings, which have a certain transverse component or bending moment, are not directly and fully transmitted towards the screw mechanism. The resilient aspect of the force transmission between the screw mechanism and actuating member makes these transverse or bending loadings less severe or even absent.
According to a first possible embodiment of the invention, the screw mechanism and the actuating member engage each other through spring elements. The spring elements may provide an asymmetric stiffness distribution with respect to the axis of the screw mechanism. The asymmetric character of the spring elements may be obtained in several ways, e.g. by more or stiffer springs at one side of the axis of the actuating member and the screw mechanism than at the opposite side.
The advantage of an asymmetric layout of the spring elements is that it may anticipate an asymmetric loading pattern under full loading. An example of a non-aligned loading, which increases with the load level, is to be attributed to flexing of the claw piece in the application of an actuator in a disc brake.
According to a second possibility, the screw mechanism and the actuating member engage each other by means of a resilient pressure pad.
Such pressure pad may have a relatively small thickness compared to its lateral dimensions. It can therefore easily be accommodated between the actuating member and the screw mechanism, within narrow space constraints.
The pressure pad preferably comprises two generally parallel wall members, said wall members being mutually connected along their circumference and enclosing a closed internal space.
The actuating member may be carried out as a piston, said piston being accommodated in a cylinder which forms a bore in the housing of the screw mechanism. Thus, the intermediate resilient pressure member is supported against the inside of the piston head.
According to a further development, the resilient intermediate pressure means engages a load measuring device. In particular, the load measuring device senses the pressure of the fluid.
The pressure developed in the fluid provides a reliable measure of the force exerted by the actuator. Possible a non-axial or excentric loadings will not hamper the measurement of the overall axial loads to which the actuator is exposed. Thus, a reliable measurement is obtained.
If convenient, the internal space of the pressure pad is connected to a measuring channel, the free end of said channel being provided with the load measuring device. Thereby, the actual measurement, e.g., by a piezoelectric sensor, may be carried out a particular location which is for instance shielded from the area where the actuating member is located (heat, moisture).
The invention is also related to a brake caliper comprising a housing, a motor, an actuating member and a screw mechanism providing a linear movement of the actuating member with respect to the housing in response to a rotational movement of the motor, said screw mechanism comprising a screw and a nut, one of which is rotatably supported with respect to the housing. The screw mechanism and the actuating member engage each other through a resilient intermediate pressure means for pressing the brake pads onto the brake disc.
The resilient intermediate pressure means of the brake caliper may engage a load measuring device as well. The internal space of the pressure pad is connected to a measuring channel, the free end of said channel being provided with the load measuring device.
The actual load measuring device (e.g. a piezoelectric sensor) may now be situated at a location where the influence of the heat developed by the friction between the brake pads and the brake disc, is reduced.
The measuring channel may extend through the screw of the screw mechanism, the load measuring device being situated at the end of the screw which is opposite the pressure means. Furthermore, the load measuring device comprises a load cell or load sensor, the electric signal line thereof extending through thee internal space of the motor towards a connector or the like on the housing.
Preferably the fluid is a temperature resistant thermal oil.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained further with reference to the embodiments shown in the figures.
FIG. 1 shows a first embodiment of a brake caliper comprising an actuator according to the invention.
FIG. 1 a is an enlarge view of the actuating member illustrated in FIG. 1, having springs.
FIG. 2 shows a second embodiment.
FIG. 2 a is an enlarged view of an actuating member illustrated in FIG. 2, having a pressure pad.
FIG. 3 shows a third embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The brake caliper shown in FIG. 1 comprises a claw piece 1 , having a flange 2 supporting brake pad 3 , and a housing 4 carrying brake pad 5 . Between the brake pads 3 and 5 , a brake disc 6 is accommodated.
Brake pad 5 is moveable towards, and away from, the other brake pad 3 by means of an actuator 7 which comprises an electric motor 8 , a reduction gear mechanism 9 , and a screw mechanism 10 . The motor 8 has a stator 11 and a rotor 12 , which rotor 12 is connected to a tubular connecting member 13 carrying a sun gear wheel 14 . The sun gear wheel 14 engages satellite gear wheels 15 , which are accommodated on carrier 16 . The satellite gear wheels 15 also engage the fixed ring gear wheel 17 . The carrier 16 , in particular shaft 18 thereof, engages the screw mechanism 10 by means of tubular intermediate 19 . The tubular intermediate member 19 is supported rotatably within the tubular connecting member 13 by means of bearings 20 , 21 . The tubular intermediate member 19 is connected to nut 22 of the screw mechanism 10 which by means of rollers 23 engages screw 24 . Screw 24 is held non-rotatably, but can move in an axial direction. The nut 22 forms a unity with the inner ring of the four point contact ball bearing 30 , the outer ring 31 of which is supported in the housing 4 .
The screw 24 engages the actuating member 25 , in such a way that by means of the screw mechanism 10 the brake pad 5 can be moved towards, and away from, the other brake pad 3 .
During a braking action, the brake pads 3 , 5 , may exhibit some play transverse with respect to the axis of screw mechanism 10 . Thereby, the screw mechanism 10 , in particular screw 24 thereof, may be loaded in a non-axial or non-aligned way.
In order to counteract the effects of such non-axial loadings, the surfaces 26 and 27 of the actuating members respectively the screw 24 engage each other by means of relatively stiff springs 28 and relatively flexible springs 29 , whereby a locally different stiffness is obtained.
The stiffness ratio of these springs is selected in such a way that they simulate a flexing which is opposite to the flexing of the brake caliper, which flexing occurs as a result of the clamping forces by means of which the brake pads engage the brake disc. Thus, the caliper flexing is reversed or counteracted in order to obtain an axial load on the screw mechanism.
FIG. 1 a is an enlarged view of the actuating member 25 as illustrated in FIG. 1, connected to the screw 24 by springs 28 and 29 . As discussed previously, the springs 28 and 29 counteract the effects of non-axial loading that would be transmitted to the screw 24 in their absence.
The embodiment according to FIG. 2 corresponds to some extent to the embodiment of FIG. 1 . The connecting member 13 , which carries sun gear wheel 14 , is now supported with respect to the housing by means of bearings 33 , 34 .
Furthermore, the carrier 16 , which carries satellite gear wheels 15 which engage both the sun gear wheel 14 and the ring gear wheel 17 , is connected to the nut 22 of the screw mechanism 10 . This nut 22 at the same time constitutes the inner ring of the four point-ball bearing 30 , the outer ring 31 of which is supported in the housing 4 .
Nut 22 engages screw 24 by means of rollers 23 . The screw is held against rotation, but is able to move in an axial direction. Thus, upon rotation of the nut 22 , the screw 24 moves backward and forward, thus moving the brake pads 3 , 5 onto each other and onto the brake discs 6 , or moving them away from each other.
The actuating member is carried out as piston 35 , which slidably held within the cylinder space 37 in the housing 4 . By means of a groove nut connection 38 , 38 ′, the piston 35 is held non-rotatably, but slidably.
By means of further groove/nut connection 39 , 39 ′, screw 24 is also held non-rotatably, but slidably, with respect to piston 35 .
The screw engages piston head 40 by means of the interposed pressure pad 36 . This pressure pad 36 has two parallel walls 41 , connected at the circumference 42 , e.g. by means of welding. The internal space enclosed between the parallel walls 41 is filled with a pressure medium 43 , e.g. a hydraulic fluid.
In case, as a result of the braking action, the brake pad 5 would tilt somewhat, and thereby causes somewhat misalignment between the axis of the piston 35 and the screw 24 , pressure pad 36 may accommodate this misalignment. In this way, the screw 24 is still mainly loaded in axial direction, thus allowing a proper function of the screw mechanism 10 .
FIG. 2 a is an enlarged view of the actuating member or piston 35 as illustrated in FIG. 2, having a pressure pad 36 . As discussed previously, the pressure pad 36 may accommodate misalignment between the axis of the piston 35 and the screw 24 .
In the third embodiment, shown in FIG. 3, a load measuring device 50 has been applied. This may for instance be a piezoelectric sensor. The load measuring device 50 is connected to a measuring channel 51 , which is connected to the internal space 52 of the pressure pad 53 .
Through a signal cable 54 , the load measuring device 50 is connected to a control unit for further processing of the data thus obtained. As shown in the figure, the signal table 54 is guided through the internal hollow space of the electric motor 7 .
The internal space 52 and the measuring channel 51 may be filled with a thermal oil which is resistant to the high temperatures which may develop as a result of the friction between the brake pad 5 and the brake disc 6 . Furthermore, a ceramic pad 55 may be arranged between the pressure pad 53 and the head of the piston 35 , so as to thermally insulate the thermal oil as a further precaution.
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Apparatus for providing a linear movement to an actuating member while preventing axial loadings from being transmitted from the actuating member to an engaging member, such as a screw. A pressure pad or springs are interposed between an actuating member and an engaging member such that axial loadings are prevented from being transmitted from the actuating member to the engaging member due to the resilient effect of the springs or pressure pad.
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This is a continuation, of application Ser. No. 101,028, filed Dec. 23, 1970, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to the making of molded bodies from ligno-cellulose particles, and more particularly to a method of making such bodies.
Molded bodies made from ligno-cellulose particles are already known. Such particles may be in the form of chips and fibers and have suitable binder material or materials added to them whereupon they are subjected to compression in a suitable die or mold to receive the configuration desired. It is conventional to provide one mold having a cavity and another mold or die which can enter into this cavity and which presses between itself and the surfaces bounding the cavity the mixture of particles and binder to the desired configuration.
The problems with this known molding of such particles exist if the finished body is for instance to have two surfaces which include a steep angle with one another, such as surfaces on obliquely inclined side walls of hollow bodies including trough-shaped containers or the like, of flanges or arms on profiled-cross-sectioned bodies, of plate- or strip-shaped parts of molded bodies, and the like. In circumstances with the angle between the adjacent surfaces and the direction in which molding pressure is applied, is sufficiently large, no difficulties exist because the mixture of ligno-cellulose particles and binder is simply made to the required thickness in accordance with the desired compression ratio, and then introduced into the mold cavity in suitable manner, for instance manually or by means of a mechanical device. Thereupon, the molding operation is carried out.
Problems arise if the size of the angle, that is the dispersing angle, included between the inclined surfaces and the direction in which pressure for molding purposes is exerted, is exceeded; then these bodies must be produced in such a manner that the mixture is first introduced into an area which is defined, for example, between the surfaces of a core and the pressure surfaces of lateral dies with a quantity of the mixture which is intended for forming the horizontal or substantially horizontal surfaces of the body is usually placed upon the upwardly facing surfaces of this core. Now, suitable dies are moved into the mold from above and from one or more sides until the material has been compressed to the desired extent. It is also possible to insert certain portions of the mold or die into the cavity from above and other ones from below, simultaneously or in a predetermined sequence. These approaches are not entirely satisfactory because they are very complicated and expensive, especially because the dies utilized must be accurately constructed to insure proper operation of the molding apparatus. Also, the number of different dies and molding tools is relatively large which increases the cost of an apparatus utilized for such purposes.
Attempts have been made to solve the problem if the body to be molded is to be a hollow body, by molding the body piecemeal. This is done by molding individual portions of the body which can be molded in flat or substantially flat shape, and the thus-obtained blanks which are produced in a cold-molding stage, are subsequently joined in a hot-molding process to combine them and form of them an integral hollow body. However, this is quite clearly very complicated and requires a large number of individual tools so that this approach is expensive. Aside from this it will be appreciated that the application of this approach is limited to hollow bodies whose configuration lends itself to the initial manufacture of flat or substantially flat blanks which can then be subsequently united, and it is clear that there are many configurations of hollow bodies to which this approach is simply not applicable.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome the aforementioned disadvantages.
More particularly it is an object of the present invention to provide an improved method which makes it possible to mold a body having one or more surfaces which extend at a steep angle to an adjoining surface which may be horizontal or substantially horizontal during the molding, and in which these surfaces form substantially the boundary surfaces of plate-shaped or wall-shaped parts of the body.
It is a concomitant object of the invention to provide such a method which can be carried out without requiring expensive special-purpose dies and without requiring complicated additional molding steps.
Another object of the invention is to provide such a method which permits the molding of such bodies having a relatively complicated shape.
In pursuance of the above objects, and others which will become apparent hereafter, one feature of the invention resides, briefly stated, in a method of making a molded body from ligno-cellulose particles in a cavity provided in one of two die sections and having an open side, a surface opposite the open side, and an exposed face extending between the open side and the surface and defining with the latter a steep angle. This method comprises the steps of introducing into the cavity a mixture of ligno-cellulose particles and binder material, inserting the other die section into the open side and effecting relative movement of the die sections in a sense advancing the other die section past the exposed face and towards the surface. During such movement, the mixture between the other die section and the exposed face is maintained against displacement in direction towards the surface bounding the cavity.
Resort to the present invention provides the advantage that even if there is a very steep angle included between the exposed face and the surface bounding the cavity, the individual particles of the mixture to be converted into the molded body will remain in their positions during the molding operation without being taken along towards the surface by the other die section during the relative movement of the two die sections. This insures that the mixture will be compressed at all times to the required ratio.
It will be appreciated that in the molding of bodies having such surfaces which are so steeply inclined with reference to one another as pointed out above, the primary difficulty results from the fact that even if the surface of the inserted--as yet uncompressed-mixture is horizontally oriented or has a small angle of inclination to the direction of movement performed by the two die sections, the downwardly moving die section has the tendency to carry along the mixture in the direction of its movement towards the surface bounding the cavity opposite the open side of the latter, instead of merely compressing the mixture. The reason for this is that the fibrous consistency and the provision of the adhesive binder in the mixture causes the particles of the mixture to interengage everywhere with each other and to adhere to each other. Thus, when the material is carried along between the upper die section and the exposed face in the cavity, irregular distribution of the mixture takes place and the finished molded body will be insufficiently compressed in some locations and excessively compressed at other locations. This problem is overcome according to the present invention by preventing the material from being carried along, and this is achieved by giving the exposed face of the mold cavity and the face in the other die section which will subsequently be juxtaposed with the exposed face of the mold cavity, different surface consistencies or configurations. According to one embodiment of the invention this may be achieved by making one of these faces smooth whereas the cooperating face is stepped. This has the result that the fibrous mixture will be held back by each of the steps which will normally extend transversely of the direction of movement of the dies, and will be separated by the edges of the individual steps from the adjacent material adhering thereto which is pressed further downwardly without being taken along by such material. The more sharply the outer edges of the individual steps are defined, the more effective the construction will be. It is preferable that the upwardly facing surfaces or face portions of the individual steps, that is the face portions which face the open side of the cavity, and also the face portions which extend substantially parallel to the direction of movement, preferably extend at right angles to each other or enclose an angle of less than 90°.
The mixture to be molded may of course be introduced in various different ways into the cavity, either manually, or mechanically by means of a dispersing or pouring apparatus of known construction. If the material is introduced into the mold cavity in such a manner that the thickness of the layer of mixture in the mold varies, for instance in such a manner that the lower portions of the mold cavity are covered by a thickness of material which is greater than that in the upper portions, this must be taken into account to obtain a uniform compression ratio, by so designing the mold cavity that the angle between the direction in which pressure is exerted and the inclined face which is smooth is larger than the angle between the direction of pressure and an imaginary line which intersects the edges of the individual steps in the stepped face. The wall thickness of the part of the finished molded body which is provided with the steeply inclined face will then gradually increase, for example from its upper to its lower end, and the horizontal or substantially horizontal wall portion in which this inclined wall terminates for instance at the lower end, is then of a greater thickness than similar also horizontal wall portion into which the upper end of the inclined wall terminates.
For purposes of the present invention it is, of course, immaterial which of the two die sections move with reference to the other, and whether one die section moves upwardly or the other downwardly, or whether they both move towards one another during the molding operation.
If, for example, the present invention is utilized for producing a hollow body by means of a female die having in its cavity a stepped exposed face and a male die having smooth outer surfaces and which during the molding operation moves into the cavity of the female die, the molding mixture may first be introduced into the cavity so that it fills the latter entirely and even projects upwardly beyond the open side of the mold cavity to the extent necessary to obtain subsequently the desired compression ratio. The upper surface of the thus-introduced mixture will then be so shaped that it has a horizontal plane. In this case the male and female dies must be so designed so as to comply with the earlier-mentioned conditions if the same compression ratio is to be attained at all points. It is naturally then necessary not only to assure that the wall thickness of the finished molded body increases in the direction towards its bottom, but also that the greatest thickness of the bottom part be taken into account in so far as the length of the male die is made smaller than the depth of the cavity in the female die, so that the lower bottom face of the male die is spaced at a greater distance from the corresponding surface at the bottom of the mold cavity in the female die when the upper edge of the male die remains spaced from the upper edge of the mold cavity when the compression or molding step is concluded. A hollow body thus produced has a gradually increasing wall thickness and the thickness of its bottom wall is greater than the thickness of the side wall at the upper end thereof.
If it is desired to avoid too great a differential in the thickness of the side wall, or if it is desired to obtain a uniform wall thickness at all points, the mixture may be filled into the mold cavity in such a manner that it will first form a planar upper surface, whereupon a quantity of the mixture is again removed--for instance manually--to obtain a trough-shaped recess formed in this upper surface. In this case the finished molded body produced will have such a configuration that its wall thickness increases only slightly in the direction in which pressure is exerted during the molding step, or that the wall thickness is even uniform throughout.
Of course, in the interest of speed and economy it is preferable to introduce the mixture to be molded not manually, but mechanically, for instance by means of a spreading machine or by means of a blower. In this case the male tool or die is removed far enough from the cavity in the female die so that the lower portion of the cavity may be covered with a screen of a suitable type, the surface of which is of such a shape that the surface of the material or mixture which is blown into the cavity corresponds to the desired compression ratio to be attained. In this case attention must be given to the fact that the admissible angle of slope will not be exceeded, in order to prevent the material of the mixture from sliding downwardly when the screen is removed. If the mixture is blown into the cavity under a certain pressure, the admissible angle of slope may be made relatively steep because the binder-coated particles will probably then adhere sufficiently to each other.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary vertical section through a two-section die or mold for carrying out the method according to the invention;
FIG. 2 is a fragmentary enlarged detail view of a portion of a different mold similar to that of FIG. 1;
FIG. 3 is a view similar to FIG. 2 illustrating still a further mold;
FIG. 4 is a view similar to FIG. 3 illustrating yet another mold;
FIG. 5 is a vertical section through the female mold part shown in FIG. 1, but illustrating it as filled manually with mixture to be molded;
FIG. 6 is a view similar to FIG. 5 but illustrating the female mold section as covered with a screen and with the mixture blown into the mold section;
FIG. 7 is a vertical section similar to FIG. 6 showing the material at the end of the molding step;
FIG. 8 is a fragmentary vertical section of a further two-part mold;
FIG. 9 is a fragmentary vertical section through the female mold section of FIG. 8, with the mixture to be compressed blown into the mold cavity;
FIG. 10 shows the male and female mold sections of FIG. 8 at the end of the compression step for compressing material which has been introduced according to FIG. 9;
FIG. 11 is a view similar to FIG. 10 but showing an embodiment in which a molded body of substantially uniform wall thickness is to be produced;
FIG. 12 is a fragmentary vertical section illustrating a further embodiment of the invention; and
FIG. 13 is a view showing molds used in FIG. 12 at the end of a compression operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before entering into a detailed discussion of the drawing it is pointed out that in the various illustrated embodiments of molds--which are shown to permit a better explanation of the novel method--it is arbitrarily assumed that the body to be molded has a conical foot which is molded onto a horizontal plate and forms an upwardly open hollow body. The lowermost tool of the respectively illustrated two-section mold forms a female die having a cavity into which, after the required molding mixture is introduced, the corresponding male die is either moved downwardly from above whereas the lower die or female die is held in a fixed position, or wherein conversely the lower die is pressed from below upwardly against the upper male die which is held in fixed position. In the subsequent description it is assumed for purposes of explanation only that the upper male die is moved from above downwardly into the fixed or stationary lower female die.
With these comments in mind, and considering firstly FIG. 1, it will be seen that the lower female die section is identified with reference numeral 1 whereas the upper downwardly moving male die section is identified with reference numeral 2. The female die section 1 has a mold cavity 1a having an upwardly directed open side and the direction of pressure, that is the direction in which the male die 2 is moved into the mold cavity 1a, is indicated by the arrow a.
In accordance with the present invention, the lateral face bounding the mold cavity 1a is stepped and each of the thus-provided steps 11 has a surface 111 which extends in parallelism or substantially in parallelism with the direction a, and is thus substantially vertical. A substantially horizontal surface 112 cooperates with and extends at substantially a right angle to the respective surface 111. Conversely, the surfaces of the male die which are to enter the mold cavity 1a are not stepped, but instead are entirely smooth.
As the drawing shows, the lateral face 21 of the relatively conical upper male die 2 is inclined at an angle α which is larger than the angle β included between the direction a of molding pressure and the direction of an imaginary line x which connects the free edges of the individual steps. The lower pressure surface 22 of the male die 2 is rounded in substantially spherical configuration and merges smoothly into the lateral face 21. The total length L of the active part of this male die 2 is shorter by a predetermined distance than the depth T of the mold cavity 1a so that the thickness of the lateral wall of the hollow element which is produced during the molding operation increases in downward direction whereas the bottom wall of the finished molded body will have the greatest thickness.
As shown in FIG. 2, each upwardly directed surface 112 of the respective steps 11 may extend exactly normal to the direction of pressure a so that the angle γ included between each such surface 112 and the surface 111 of the preceding step 11 amounts to 90°.
In some cases, however, it is of advantage to utilize the embodiment illustrated in FIG. 3. Here, the angle γ' included between the surfaces 111 and 112 is less than 90° and with such a configuration the individual particles of the molding mixture are more reliably prevented from sliding downwardly along the face provided with the steps 11 in the direction of pressure a, when the male die 2 moves into the mole cavity 1a. Thus, the molding mixture on the upper side of the surfaces 112 will be actually and fully compressed at this particular point. It is pointed out, however, that an angle of more than 90° between the adjacent surfaces 112, 111 of two successive steps 11 should be definitely avoided, because the particles of the molding mixture would then not be reliably prevented from sliding downwardly in the direction a during the molding operation.
As shown in FIG. 4, it is also possible to so configurate the surfaces 111 that they do not extend directly parallel to the direction of pressure a, but instead are inclined at a certain angle to this direction. In this case it is of great importance that they substantially horizontal surfaces 112 of the individual steps 11 will not be included so that the particles of the molding material will not have the tendency to slide along the direction of the arrow a, and the angle γ should therefore not be larger than 90°.
FIG. 2 shows that the outer free edges 35 of the individual steps 11 should preferably be made as sharp as possible. On the other hand, the inner edges 38 between the successive steps 11 are preferably slightly rounded in order that the corresponding edges formed on the finished molded body will be more resistant to chipping or breaking off.
In the embodiment of FIG. 5 I have illustrated a lower female die 1 in which the mold cavity 1a is filled with molding material which in this embodiment is assumed to have been introduced manually. To prevent the bottom part of the finished molded body from becoming too thick, and to prevent the lowest portions of the finished molded body from becoming excessively compressed, the upper surface 3 of the molding mixture which has been introduced into the molding cavity--and which would normally be planar--is provided at 3' with a depression which is formed by removing manually a part of the molding mixture above the center of the mold cavity 1a, after the latter has been filled with the mixture.
For economic reasons and for others it is of course advisable not to utilize manual filling, and it is preferable not even to use a spreading machine for the filling purposes, especially if the mold is of a relatively complicated shape. Instead, it is preferred to insert the molding mixture by blowing it into the mold while the upper surface configuration of the mixture which can be formed is limited during the blowing process by a screen of a suitable shape which can subsequently be removed before the molding operation is carried out. This is shown in FIG. 6 wherein a screen 4 is shown superimposed above the upper open side of the mold cavity 1a in the lower die 1. The material is blown into the mold chamber or cavity 1a between the screen 4 and the female die 1. Preferably, the walls of the screen 4 are inclined substantially similarly to the external shape of the upper die 2, and in any event at angles not exceeding the angle at which the molding material might slide downwardly of its own accord, that is the slope angle. If the wall bounding the mold cavity 1a is inclined at a suitable angle, the molding mixture can be blown into the cavity in such a manner that when the hollow molded body has been finally compressed, it will have a uniform density and also a uniform wall thickness.
After the mold cavity in the lower female die 1 has been filled, either in the manner shown in FIG. 5 or in the manner shown in FIG. 6, the upper male die 2 is moved downwardly into the lower female die 1 and the molding mixture is compressed in accordance with the dimensions of the upper and lower dies, as illustrated in FIG. 7. In that Figure it will be seen that the thickness of the walls of the finished molded body 5 increases in the direction towards the bottom of the body, that is in the direction of the pressure a.
In FIG. 8 I have illustrated another embodiment of the invention in which it is assumed that a molded element of a U-shaped cross-section is to be produced, which is open at both ends and which has a smooth outer surface and an inclined inner surface of any desired shape. In this embodiment the lower female die 1 has such a mold cavity configuration that the inner surface forms a core 102 similar to a male die and extending in the longitudinal direction of the U-shaped cross-section. The lateral surfaces bounding the cavity forms steps 150 provided in accordance with the present invention. Each of these steps 150 has a surface 151 extending in substantial parallelism with the direction of pressure a and an upwardly facing surface 152 facing oppositely the direction a. Both of these surfaces of each step 150 extend substantially at a right angle to each other in the same manner as previously discussed, but the steps may also be of a shape substantially as described with reference to FIGS. 2-4 if desired.
To limit the size of the molding cavity the latter is defined by plane vertical surfaces 103 which extend substantially parallel to the central plane of symmetry of the U-shaped cross-section, and by smooth plane surfaces 103' extending normal to the surfaces 103 and connected with the core 102. The upper die in this case is a female die 101 of downwardly open trough-like shape with smooth surfaces, with the trough-like configuration being open at opposite longitudinal ends and adapted to be moved into the molding cavity defined by the walls 103 and 103' and the steps 150.
If it is assumed that the mold cavity is filled to such an extent with molding mixture that the upper side thereof forms a planar surface the central part of which covering the pressure surface portion 102 in the lower die forms a layer the thickness of which is in accordance with the desired rate of compression of the finished molded product. In this case the upper die 101 must of course be so designed that to obtain a uniform compression ratio the finished product will have a gradually increasing wall thickness, the greatest thickness of which is located along the free edges of the two legs of the U-shaped cross-section. This means that the depth of the recess 101a in the upper die 101 must be smaller than the height of the upwardly projecting part 102 of the lower die, and the lateral inner surfaces of the upper die 101 must be inclined relative to the direction of pressure a at an angle which is larger than the imaginary line connecting the outer edges of the individual steps 150 in the lower die.
As already pointed out, the molding mixture may be blown into the mold while the lower die is covered by a screen. In this case the screen may be so designed that the U-shaped cross-section may be made of any other wall thickness as long as the admissible pouring angle will not be exceeded. FIG. 9 illustrates the lower die as containing molding mixture which is blown into it, with the upper open side of the lower die covered by a screen 104 having such a configuration that the upper surface of the molding material blown into the lower die and identified with reference numeral 102 will have a shape somewhat similar to the shape of the lower die. After the material has been blown in, the screen 104 is removed and the upper die 101 is then moved downwardly into the lower die, thereby carrying out the molding operation until the molding mixture has been compressed to the desired extent and the two dies have reached the relative positions illustrated in FIG. 10. The thus-compressed molding mixture then forms a solid body 105 having the configuration illustrated in FIG. 10.
It goes without saying that if the binder component of this mixture is of the heat-setting type, the compressed body 105 may at the same time be cured by heating in known manner.
If it is desired to make the thickness of the walls of the molded body 105 uniform, instead of having the thickness of the side legs increase towards their free edges, the embodiment of FIG. 11 may be resorted to. Here, the angle included between the direction of pressure a and the lateral surfaces bounding the cavity in the upper die 101x must correspond exactly to the angle between the direction of pressure a and the imaginary line intersecting the edges of the individual steps in the lower die 102. The resulting molded body 105x will then have the shape shown in FIG. 11. It is pointed out, however, that a uniform wall thickness may also be obtained even if the different parts of the lower die are filled to different heights, for example as shown in FIG. 9. In this case, however, an unequal compression ratio at different points must be accepted; thus, in such a case the density of the material in the compressed body would increase toward the bottom of the hollow molded body, or else it would increase toward the free edges of the arms of the U-shaped cross-section as is the case in FIG. 8.
Coming, finally, to the embodiment illustrated in FIGS. 12 and 13, it wll be seen that this relates to a mold for producing a flat plate-shaped body one edge portion of which forms a wall projecting upwardly at an oblique angle, while the other end of this inclined wall is provided with an outwardly projecting horizontal part. Here, the lower die 202 is configurated as a female die and the upper die 201 as a male die. As shown in FIG. 12, the mold is in open position with the left part being broken away because it is not needed for an understanding of the invention. Steps 211 are provided in the oblique angled face of the lower die 202, and the upwardly directed face portions 221 of the individual steps 211 may incline with respect to their face portions 222--which extend substantially in the direction of pressure a--in accordance with the considerations outlined with reference to FIGS. 2, 3 or 4 as may be desired in each case. The lower die 202 is provided with a recess 225 and the upper die 201 with a corresponding projection to produce the outwardly projecting part on the upper end of the inclined wall of the finished body.
As the drawing shows, the upper die 201 has smooth surfaces and its obliquely inclined pressure face is disposed at the same angle to a horizontal plane as the imaginary line which extends through the free edges of the steps 211. The upper die 201 is designed so that the flat plate of the finished molded body will have a greater thickness than the upwardly inclined wall portion and the outwardly projecting part thereof.
As shown in FIG. 3, where the mold is shown in closed position at the end of the molding operation, the finished molded body is identified with reference numeral 250.
It is again emphasized as was done before, that the assumption that the lower die section is stationary and the upper die section moves downwardly with respect to it, which has been made for the illustrated embodiments, is purely for the sake of convenience and that the die sections may both move with reference to one another, or that the upper die section may be stationary and the lower die section may move upwardly with reference to it. Similarly, other modifications will offer themselves readily to those skilled in the art, for instance for the production of molded elements or bodies in which adjoining surfaces are inclined with reference to one another at a steep angle other than a right angle.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in the molding of bodies from ligno-cellulose particles, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can be applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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A two-section die is provided in one section with a cavity having an open side, a surface opposite the open side, and an exposed face connecting the open side and the surface and including with the latter a steep angle. The exposed face is provided with steps which extend transversely of the direction of movement performed by the second or male section of the die which is movable into the cavity for compressing a flowable mixture of ligno-cellulose particles and binder material placed into the cavity, and which has faces and surfaces juxtaposed with the respective face and surface of the cavity so as to compress between them the mixture; the pourable mixture is retarded against displacement in direction towards the surface during such movement, due to the presence of the steps.
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This is a continuation application of PCT/AT02/00120, filed on Apr. 23, 2002.
BACKGROUND OF THE INVENTION
The present invention relates to a method for drilling, in particular impact drilling or rotary percussion drilling, a hole in soil or rock material and fixing an anchorage in said hole, wherein a drill hole is formed by means of a drill bit mounted on a drill rod assembly while simultaneously introducing a jacket tube surrounding the drill rod assembly in a spaced-apart manner, as well as a device for drilling, in particular impact drilling or rotary percussion drilling, holes in soil or rock material and producing an anchorage, wherein a drill bit mounted on a drill rod assembly makes a drill hole and a jacket tube surrounding the drill rod assembly in a spaced-apart manner and following the drill bit is provided.
In the context of producing a hole or drill hole in soil or rock material and the subsequent fixation of an anchorage or lining in the drill hole it is known, for instance, from WO 98/21439 and WO 98/58132 to introduce a jacket tube into the drill hole during the drilling procedure, for instance impact drilling or rotary percussion drilling, whereupon, after completion of the drilling procedure, part of the drill bit is optionally removed from the drill hole together with the drill rod assembly, while the jacket tube remains within the drill hole such that an anchor will subsequently be formed within the drill hole by filling a curing mass into the same. According to the configuration set out in WO 98/58132, the drill rod assembly may be provided with additional ribs and grooves on its outer periphery so as to ensure an accordingly good anchoring effect in case the drill rod assembly remains within the drill hole and is subsequently filled.
Alternatively, it is known to remove from the drill hole the drilling tool together with the drill rod assembly after the production of a drill hole, whereupon an anchor or anchoring means is introduced into the drill hole, wherein, for instance, from EP-B 0 241 451, U.S. Pat. No. 4,490,074, DE-AS 21 05 888, U.S. Pat. No. 4,310,266, EP-A 0 875 663 and other documents, configurations are known in which the tubular anchoring means to be introduced subsequently is kept by suitable retention elements at a diameter reduced relative to the final state, whereupon, after the complete introduction of the prestressed tube into the drill hole and removal of the retention means, the tube, which usually comprises a substantially longitudinally extending slot, expands, thus coming into abutment, or being pressed, on the drill hole wall in order to provide the required anchoring effect. That known prior art involves the drawback that, on the one hand, the drill hole has to be made in a first method step, whereupon, after the removal of the drilling tool plus drill rod assembly, the anchoring means is introduced into the optionally very long drill hole in a further method step, after which abutment on the drill hole wall is enabled by the removal of the respective retention means under widening of the outer diameter. It is immediately apparent that the two separate operating steps not only require accordingly more time, but that optionally the subsequent introduction of an anchoring means having a great length involves difficulties. Furthermore, it is to be anticipated that the removal of the drilling device together with the drill rod assembly and the subsequent introduction of an anchoring means is feasible only in comparatively firm soil or rock, where it must be safeguarded that no material will break into the drill hole, for instance, during the drilling procedure or after the removal of the drilling tool and prior to the final introduction of the anchoring means such that the drill hole will not be blocked, thus impeding the introduction of the anchoring means.
SUMMARY OF THE INVENTION
The present invention, therefore, aims to provide a method and a device of the initially defined kind, by which, with a simplified construction, an at least provisional securing is feasible during the drilling procedure and an anchorage to the inner wall of the drill hole can be obtained immediately upon completion of a drill hole.
To solve this object, the method according to the invention, departing from a method of the initially defined kind, is essentially characterized in that the jacket tube, which is formed with a longitudinal slot, is at least partially introduced in substantial abutment on the drill hole during drilling. Since the jacket tube, which is formed with a longitudinal slot, abuts at least partially on the wall of the drill hole during the production of the bore, at least provisional securing during the drilling procedure is feasible, whereby it is safeguarded by the provision of the longitudinal slot that the jacket tube is sufficiently elastic and resilient and, therefore, does not offer too much resistance against the introduction of the jacket tube by the aid of, for instance, a tensile or impact stress, even with an at least partial abutment on the wall of the drill hole. Moreover, the longitudinally slotted jacket tube ensures that an appropriate anchorage by the at least partial abutment on the wall of the drill hole will be obtained immediately upon completion of the bore such that time will be saved in the formation of such an anchorage as compared to known configurations in which the drill rod assembly was removed upon completion of a bore and a separate anchor was introduced into the drill hole. In addition, the method according to the invention can be applied irrespectively of the soil or rock material to be drilled, since the jacket tube is introduced directly during the production or formation of the drill hole, so that even with loose rock, where caving in would optionally have to be feared at least after the removal of the drilling tool and prior to the introduction of the anchorage, no difficulties as might occur with an anchorage to be provided subsequently will have to be feared, because the jacket tube introduced during drilling will itself always keep clear the passage cross section of the drill hole in loose rock. After the drill hole is completed, the drilling tool may either be removed at least partially with the drill rod assembly through the interior of the jacket tube remaining within the drill hole or may be left within the drill hole together with the drill rod assembly plus drilling tool to increase the anchoring effect, so that an anchoring effect not only will result from the abutment of the jacket tube on the inner wall of the drill hole, but the anchoring effect will be enhanced by the drilling tool and drill rod assembly remaining within the drill hole. When introducing the jacket tube, which is provided with a longitudinal slot, at least partially in abutment on the wall of the drill hole, it is to be anticipated further that, by the introduction of a scouring fluid into the region of the drill bit as known per se and the thus effected discharging of excavated material also in the region of the outer periphery of the jacket tube, an accordingly liquid or viscous material layer will be present, which will cause a lubricating or sliding effect during the introduction of the jacket tube. After the completion of the bore, and hence interruption of the continued supply of scouring fluid, it is to be anticipated that the friction between the outer periphery of the jacket tube and the inner wall of the drill hole will accordingly increase upon solidification of the material in the region of the outer periphery of the jacket tube such that an accordingly good anchoring effect of the jacket tube abutting on the inner wall of the drill hole will be obtained.
In order to support the anchoring effect of the jacket tube abutting at least partially on the inner wall of the drill hole already during its introduction, it is proposed according to a preferred embodiment that an expandable element is introduced into the interior of the jacket tube and expanded upon completion of the drill hole and removal of the drill rod assembly. Such an introduction of an expandable element optionally enables the jacket tube to be reliably fixed on the inner wall of the drill hole over partial regions, thus providing an enhanced anchoring effect.
In a particularly simple manner, an expandable element can be fixed in the interior of the jacket tube in that the expandable element is expanded by an impact stress as in correspondence with a further preferred embodiment of the method according to the invention. Such an expandable element not only ensures the reliable abutment of the jacket tube on the inner wall of the drill hole, but also acts against any reduction of the clear cross section of the jacket tube caused, for instance, by a compressive stress exerted by surrounding material or a tensile stress exerted in the longitudinal direction of the anchor formed by the jacket tube, since, by providing the longitudinal slot, tensile stresses acting in the longitudinal direction of the jacket tube that constitutes the anchorage, in particular, might otherwise result in a reduction of the anchor cross section of the jacket tube, whereby the anchoring effect would be accordingly reduced.
Depending on the surrounding material and hence on the nature of the jacket tube, it is preferably proposed for the introduction of the jacket tube during the drilling procedure that the jacket tube is introduced into the drill hole by exerting a tensile stress via a connection with the drill bit and/or an impact stress. According to the invention, the jacket tube may thus be coupled, for instance, with the drill bit in a suitable manner and introduced into the drill hole during the drilling procedure merely by means of tensile stress. Particularly in the event of jacket tubes having larger material cross sections and hence elevated strengths, which are employed to provide an accordingly resistant anchorage, the jacket tube, however, may be additionally or alternatively introduced into the drill hole during the drilling procedure by exerting an impact stress so as to avoid excessive forces to be exerted on the drill bit in order to entrain the jacket tube.
In order to ensure proper introduction of the jacket tube during the drilling procedure, it is proposed in this context, according to another preferred embodiment, that at least one connection provided along the substantially longitudinally slotted jacket tube and defined by a predetermined breaking point is separated upon completion of the bore.
Particularly simple separation or breaking of the predetermined breaking point is preferably feasible according to the invention in that the separation or breaking of the predetermined breaking point is effected by a slight retraction of at least the impact shoe and jacket tube mounted thereon, as well as an actuation of the impact shoe. Thus, after the completion of the bore, the separation or breaking of the predetermined breaking point can be obtained under the expansion or spreading of the front end of the jacket tube, by a slight retraction of at least the impact shoe and optionally the annular drill bit mounted thereto, and the subsequent, second actuation of the impact shoe with the jacket tube held fast or mounted in the produced drill hole in an at least partially frictionally engaged manner, by an expansion of the internal diameter of the longitudinally slotted jacket tube by the impact shoe, for instance by providing mating bearing surfaces in the region of the front end of the jacket tube, so that, in the main, proper abutment of the outer diameter of the expanded jacket tube on the finished wall of the drill hole can be ensured.
In order to further increase the anchoring effect, particularly in the event of loose rock or in cooperation with an anchoring plate to be optionally fixed to the end projecting out of the drill hole, it is proposed according to a further preferred embodiment that a curing mass is filled into the interior of the jacket tube in a manner known per se upon completion of the bore. The curing material is able to penetrate into the surrounding material, in particular, in the front region as well as along the longitudinal slot of the expandable jacket tube, thus improving the anchorage of the jacket tube. By the penetration of the curing material and subsequent bracing with an anchor plate to be provided on the external end of the jacket tube, the fixation of optionally loosely layered soil or rock material can be obtained in addition.
To solve the objects set in the beginning, a device of the initially defined kind, moreover, is essentially characterized in that the jacket tube comprises a longitudinal slot substantially extending in the longitudinal direction of the jacket tube. By providing a jacket tube formed with a longitudinal slot, it is ensured that the jacket tube can be introduced into the drill hole at an accordingly low friction resistance and at least partially in abutment on the inner wall of the drill hole during the drilling procedure, whereupon an appropriate anchoring effect will be obtained upon completion of the drilling procedure by the immediate, at least partial abutment of the jacket tube on the inner wall of the drill hole.
In order to support the anchoring effect, it is proposed according to a preferred embodiment that an expandable element is introducible into the interior of the jacket tube and expandable in abutment on the inner wall of the jacket tube upon completion of the drill hole and removal of the drill rod assembly. Such an expandable element, which is expandable into abutment on the inner wall of the jacket tube, ensures the safe anchorage of the jacket tube within the drill hole, whereby such an expandable element will counteract, for instance, a cross-sectional reduction of the jacket tube, in particular in the event of a tensile stress exerted on the anchorage formed by the jacket tube, thus reliably maintaining the desired anchoring effect.
In order to provide a particularly favorable fixation of the expandable element in the interior of the jacket tube, it is proposed according to a particularly preferred embodiment that the expandable element is comprised of a sleeve which is expandable by an impact stress caused by the introduction of an especially conical element, wherein, in particular, if a plurality of expandable elements is provided in the interior of the jacket tube and in order to ensure proper positioning of the same, it is proposed according to another preferred embodiment that the jacket tube on its inner wall is provided with elevations or projections aimed to position the expandable element.
In order to enable a particularly simple introduction, it is preferably proposed that the jacket tube comprises at least one predetermined breaking point along its longitudinal slot extending substantially in the longitudinal direction of the jacket tube. Due to the at least one predetermined breaking point provided according to the invention along the longitudinal slot of the jacket tube, the jacket tube can be readily introduced into the drill hole during the drilling procedure, while the at least one predetermined breaking point is separated or broken upon completion of the drill hole in order to place the jacket tube in abutment on the inner wall of the drill hole so as to obtain the anchorage.
After the bore is completed, the at least one predetermined breaking point must be separable by the introduction of an appropriate force. On the other hand, the predetermined breaking point must, however, ensure sufficient strength during the drilling procedure, of the longitudinal slot extending substantially over the total length of the jacket tube. To this end, it is proposed according to another preferred embodiment that the at least one predetermined breaking point provided along the longitudinal slot of the jacket tube is formed by a weld bridging the longitudinal slot. By an appropriate positioning and configuration as well as optionally number of welds forming predetermined breaking points, different demands relating both to the resistance during the drilling procedure and the breaking or separation of the predetermined breaking point upon completion of the bore can be met.
For the proper introduction of the jacket tube during the drilling procedure, it is moreover proposed that the jacket tube, on its end facing the drill bit, is fixed to an impact shoe of the drill bit as in correspondence with a further preferred embodiment of the device according to the invention. In addition to introducing the jacket tube by exerting an impact stress by fixing the jacket tube to the drill bit or impact shoe, respectively, it may additionally be provided that an impact stress is exerted on the jacket tube end that projects out of the drill hole, which is feasible, in particular, with jacket tubes having elevated strengths.
In order to obtain a suitable anchoring effect of the jacket tube which is expandable upon completion of the bore, it is proposed according to a further preferred embodiment that the jacket tube is made of a prestressed material, in particular metal.
In order to complete the anchor, or increase the anchoring effect, in particular with partially loose layers of rock material, it is, moreover, preferably proposed according to the invention that upon completion of the drill hole an anchoring plate is fixable to the jacket tube on its end projecting out of the soil or rock material.
In order to ensure the proper haulage of the excavated rocks, it is, moreover, proposed according to a further preferred embodiment that the jacket tube, in the region of its end following the drill bit, in a manner known per se comprises at least one passage opening aimed to introduce the excavated soil or rock material into the interior of the jacket tube such that the excavated material can be discharged from the bore also in the free space, in particular annular space, defined between the drill rod assembly and the jacket tube.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be explained in more detail by way of exemplary embodiments schematically illustrated in the accompanying drawing. Therein:
FIG. 1 is a partially sectioned, schematic side view of a first embodiment of a device according to the invention for carrying out the method according to the invention;
FIG. 2 is a schematic section turned along line II—II of FIG. 1 in an enlarged illustration;
FIG. 3 is an illustration similar to that of FIG. 1 , of a modified embodiment of a device according to the invention for carrying out the method according to the invention;
FIG. 4 is another illustration similar to that of FIG. 1 , of a further modified embodiment of a device according to the invention for carrying out the method according to the invention;
FIG. 5 shows different steps during the realization of the method according to the invention using a device according to the invention, FIG. 5 a illustrating the procedure of making a drill hole by the method according to the invention in an illustration similar to that of FIG. 1 , FIG. 5 a showing the removal of the drill rod assembly upon completion of the drill hole, FIG. 5 c showing the introduction of an expandable element into the interior of the jacket tube upon completion of the drill hole and the removal of the drill rod assembly, and FIG. 5 d showing the procedure of expanding the expandable element; and
FIG. 6 is a schematic side view of another modified embodiment of a device according to the invention for carrying out the method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a drilling tool or drill bit generally denoted by 1 is connected through a connecting piece 2 as well as an impact shoe schematically indicated by 3 with a drill rod assembly 5 extending in the interior of a jacket tube 4 . The drill bit 1 is actuated by an impact drilling or rotary percussion drilling device not illustrated in detail and arranged outside the soil or rock material to be worked, whose surface is denoted by 6 , via the drill rod assembly 5 . The inner contour of a drill hole made by the drilling tool or drill bit 1 is schematically indicated by 7 in FIG. 1 .
As is apparent from FIG. 1 , the jacket tube 4 comprises a longitudinal slot 8 extending substantially in the longitudinal direction, as is also clearly apparent from the illustration according to FIG. 2 . From the illustration according to FIG. 2 , it is, furthermore, apparent that the sleeve 4 is made of a prestressed material, in particular metal, wherein said material in its relieved state outside the drill hole, which is shown in full lines, has a larger outer diameter than in its state within the drill hole, which is illustrated by thin, broken lines, the slot being denoted by 8 ′. The jacket tube 4 is, thus, introduced into the drill hole in a prestressed condition so as to ensure that the jacket tube 4 will at least partially abut on the drill hole inner wall 7 in order to thereby enable at least provisional securing already during the drilling procedure.
From FIG. 2 it is, furthermore, apparent that the drill rod assembly 5 is provided with a central passage channel 9 , via which a scouring fluid is introduced into the region of the drill bit 1 in order to discharge excavated material at least partially in the region of the outer periphery of the jacket tube 4 between the jacket tube 4 and the drill hole inner wall 7 , wherein a lubricating or sliding effect will be obtained by the introduction of the scouring fluid at the interface between the outer periphery of the jacket tube and the drill hole inner wall 7 . This lubricating or sliding effect accordingly reduces the friction resistance between the outer periphery of the jacket tube 4 and the drill hole inner wall 7 during the drilling procedure, while a frictionally engaged connection between the jacket tube 4 and the drill hole inner wall 7 can be obtained by curing upon completion of the drill hole 7 and hence interruption of the scouring agent feed into the region of the drill bit 1 .
In the embodiment represented in FIG. 1 , the introduction of the jacket tube 4 , which has a conically tapering outer shape in the region 4 ′ following the drill bit 1 , is effected by a tensile stress exerted on the jacket tube 4 via the impact shoe 3 .
In FIG. 1 , 10 serves to denote a transition sleeve which enables the fixation of an actuating means for impact drilling or rotary percussion drilling, which is not illustrated in detail.
In the modified embodiment depicted in FIG. 3 , the jacket tube 4 , in addition to the tensile stress applied by the impact shoe 3 , is subjected to an impact stress in the region of the anchor head 6 via the transition sleeve 10 such that the jacket tube 4 is introduced into the interior of the drill hole again denoted by 7 , both under a tensile stress and under an impact stress.
The jacket tube 4 again comprises a longitudinal slot 8 and is offset, or designed to have a reduced cross section, in partial regions of its outer periphery, such offset partial regions being denoted by 11 in FIG. 3 . Thus, only a partial abutment of the jacket tube 4 will be obtained, particularly during the introduction procedure, this being favorable to ensure a proper drilling progress, for instance in the event of a high friction resistance to be expected between the outer periphery of the jacket tube 4 and the drill hole inner wall 7 .
From the further modified embodiment according to FIG. 4 , it is apparent that the jacket tube 4 is introduced into the interior of the drill hole 7 merely by exerting an impact stress on the anchor head 6 by the aid of the transition sleeve 10 , while no tensile entrainment through a connection of the jacket tube 4 with the drill bit 1 is effected in this embodiment. Such an introduction of a jacket tube 4 by means of impact stress is feasible, in particular, in the event of an accordingly sturdier jacket tube or a jacket tube 4 exhibiting an elevated strength.
From the individual method steps illustrated in FIG. 5 , FIG. 5 a shows the formation or production of the drill hole 7 while introducing the jacket tube 4 in a manner, for instance, similar to that of the embodiment of FIG. 4 by exerting an impact stress on the anchor head 6 , without any connection being provided between the jacket tube 4 and the drill head 1 .
In FIG. 5 , an anchor plate 13 is each indicated in the region of the end projecting out of the soil or rock material 12 .
After the completion of the drill hole 7 as illustrated in FIG. 5 b the drill rod assembly 5 is removed from the drill hole 7 in the sense of arrow 14 , while the drill bit 1 remains within the drill hole 7 .
After the removal of the drill rod assembly, an expandable element generally denoted by 15 is introduced into the interior of the jacket tube 4 in the sense of arrow 16 . The expandable element 15 is comprised of a conically tapering sleeve 17 at least partially provided with a longitudinal slot 18 , whereby a conical element 19 can be introduced into the interior of the sleeve 17 .
After the introduction or insertion of the expandable two-part element 15 into the interior of the jacket tube 4 , for instance into the region of stops or projections 20 intended to position the expandable element, the conical element 19 is subjected to an impact stress via the transition sleeve 10 so as to cause the two-part expandable element 15 to be positioned on the desired site in the interior of the jacket tube and fixed to the inner wall of the jacket tube 4 .
This expandable element 15 upon introduction safeguards that no cross sectional reduction of the jacket tube 4 will occur, for instance, due to a compressive stress exerted by surrounding material or by applying a tensile stress in the sense of an extraction or separation movement of the anchorage, so that the desired anchoring effect will be reliably maintained. If a tensile stress is exerted on the anchor formed by the jacket tube 4 , a cross sectional reduction is feasible through the longitudinal slot 8 of the jacket tube 4 in the event no expandable element 15 is provided, whereby such a cross sectional reduction would deteriorate the anchoring effect.
Instead of providing positioning projections 20 , the expandable element 15 can also be brought into direct abutment on the drill bit 1 remaining within the drill hole 7 as indicated in FIG. 5 d . Moreover, it may be provided that a plurality of expandable elements 15 is introduced into the interior of the jacket tube 4 in order to obtain an appropriate support of the anchoring effect of the jacket tube 4 at different points. Such multiple expandable elements 15 can be arranged by appropriately designing, and mating with respective positioning projections 20 , in particular the conical sleeve 17 .
Alternatively or additionally to introducing the expandable elements 15 , it may be provided to fill the interior of the jacket tube 4 with a curable mass upon completion of the drill hole 7 and optionally removal of the drill rod assembly 5 .
In FIG. 6 , which illustrates a further modified embodiment, 1 serves again to denote a drilling tool or drill bit which is connected through a connecting piece 2 as well as an impact shoe schematically indicated by 3 with a drill rod assembly 5 extending in the interior of a jacket tube 4 , wherein the drill bit 1 is actuated by an impact drilling or rotary percussion drilling device not illustrated in detail and arranged outside the soil or rock material to be worked, whose surface is denoted by 6 , via the drill rod assembly 5 . The inner contour of a drill hole made by the drilling tool or drill bit 1 is again schematically indicated by 7 in FIG. 6 .
As is apparent from FIG. 6 , the jacket tube 4 again comprises a longitudinal slot 8 extending substantially in the longitudinal direction, wherein at least one predetermined breaking point 29 is provided along the longitudinal extension of the longitudinal slot 8 , said predetermined breaking point being formed, e.g., by a weld 29 . The jacket tube 4 in this case is fixed on the impact shoe 3 via an intermediate element and is entrained by the impact shoe 3 during the drilling procedure such that the jacket tube 4 formed with the longitudinal slot 8 is introduced into the drill hole 7 directly during the drilling procedure.
To remove the material excavated by the drill bit 1 , a passage opening 31 is provided in the front region of the jacket tube 4 , said passage opening 31 being formed by forming an enlarged clear passage cross section of the longitudinal slot 8 . Through this passage opening 31 , material worked off by the drilling tool 1 reaches the free space or annular space defined between the jacket tube 4 and the drill rod assembly 5 and is discharged on the end facing away from the drill bit 1 . If necessary, a second passage opening may be provided in the jacket tube 4 on the radially opposite partial region of the periphery, for instance, symmetrical with the passage opening 31 .
Upon completion of the bore, the expansion of the prestressed jacket tube 4 is caused by the breaking or separation of the weld defining the predetermined breaking point 29 , thus providing the desired anchoring effect.
Upon completion of the bore, the jacket tube 4 and at least the impact shoe 3 as well as drill bit parts mounted thereon, for instance the annular drill bit where a central drill bit and a radially surrounding annular drill bit are provided, are slightly retracted oppositely to the drilling or advancing direction 26 , whereupon, after said retraction, the impact shoe 3 is actuated once more via the drill rod assembly 5 , again in the direction of the drilling procedure 26 , thus separating the predetermined breaking point 29 .
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A method and a device for the drilling, in particular the percussive or percussive rotary drilling of a hole in earth or rock and for securing an anchorage in the hole. A bore hole is created by a drill bit mounted on a drill pipe and a sliding sleeve that surrounds the drill pipe at a distance is simultaneously introduced. A sliding sleeve configured with a longitudinal slit is introduced at least partially and rests substantially against the bore hole during the drilling, whereby a reliable anchorage can be achieved with a simple construction by the sliding sleeve with a longitudinal slit.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a rail vehicle, and more particularly a rail vehicle having a driver's cabin and at least one wagon that tilts during travel.
2. Description of the Prior Art
German Patent EP-A-0630781 discloses a rail vehicle having two car bodies in which their neighboring ends are supported on a common bogie and their outer ends are each supported on a drive bogie. The car bodies are substantially constructed the same and are arranged and supported on the common bogie symmetrically.
SUMMARY OF THE INVENTION
In the case of rail vehicles used for railway transport it is generally known to connect wagons to an independently operating locomotive, the bodies of which wagons tilt actively or passively when travelling through curves. The locomotive, used as the driving unit, has on this occasion at least two travelling gears, of which at least one is a driveable driving travelling gear. At the same time this driving unit is constructed without tilting technology, so that during the travel relatively large relative movements will occur between the driving unit and the following wagon body, since particularly passenger carriages have a different travelling pattern than a driving unit due to the high demands with regard to travelling comfort. This is also the case when the wagon bodies are not equipped with tilting technology. It is a disadvantage of this construction that the axle load on the driving unit is considerably greater than on the adjacent set of wheels of the adjoining wagon body.
The object of the invention is to provide measures for a rail vehicle having a driver's cabin and at least one wagon that tilts during travel, by which a compensation of the axle load is feasible in the region of the transition from the driving unit to the wagon body.
Accordingly, I have developed a rail vehicle having elastic support elements advantageously located between the traveling gear and the drive unit.
In a refinement of a rail vehicle according to the invention, by choosing the mounting position of the elastic support elements provided between the travelling gear and particularly the heavy driving unit, the axle load on the common travelling gear can be varied. The further the mounting position of the support elements of the driving unit is moved from one axle to the other axle in the direction of travel, the greater the axle load will be on the latter wheel axle. Since, as a rule, the wagon body is lighter than the driving unit, the mounting position for the wagon body, when viewed from above, is preferably above the wheel axle. If, accordingly, the mounting position of the support elements, carrying the driving unit, is moved towards the wagon body, the axle load on that set of wheels which is closer to the wagon body will increase and decrease correspondingly on that set of wheels which is closer to the driving unit. Consequently, an equalisation of the axle loads is feasible on the common travelling gear by appropriately choosing the mounting positions of the elastic support elements for the driving unit and the wagon body. Therefore the travelling gear has preferably a frame with two longitudinal beams extending in the direction of travel parallel to each other, on which the mounting positions can be chosen as a function of the supporting force required for the driving unit and the wagon body. In contrast to this, that end of the driving unit which is averted from it and is on the side of the driver's cabin is preferably mounted on a motor bogie.
The elastic support elements between the driving unit and the common travelling gear are constructed preferably as coil springs, which are particularly suitable for high loads. In contrast, the wagon body is supported on this common travelling gear preferably on two support columns provided transversely to the direction of travel at a distance next to each other, wherein on the top end of the support columns elastic intermediate layers, in particular pneumatic springs, are situated, on which the wagon body rests. At the same time the supporting positions of the wagon body are situated above the wagon body's centre of gravity, so that when travelling through a curve and at high speeds the wagon body can tilt relative the travelling gear by virtue of the centrifugal forces arising (Talgo technology).
The connection between the driving unit and the adjacent wagon body is facilitated by drawbars, which are connected by means of universal joints to the travelling gear on the one hand and to the driving unit and the wagon body on the other, so that forces occurring during braking, starting or in operation are transmitted not by the elastic support elements, but foremost by the travelling gear which is rigid at least in the longitudinal direction, without impairing the free mobility. At the same time the drawbar connected to the driving unit is preferably longer than the drawbar connected to the wagon body, while the latter extends almost horizontally and the drawbar on the side of the driving unit rises from the travelling gear towards the motor bogie in the front. When travelling straight, the drawbars are situated in a vertical plane which coincides with the longitudinal axis of the vehicle. The wheels of the individual sets of wheels are preferably fitted with a gauge-changing device, so that when the gauge changes the entire rail vehicle can be adjusted, especially when crossing borders. In addition to the secondary suspension formed by the elastic support elements, additional rubber-elastic intermediate layers may be provided between the wheel bearings and the frame of the travelling gear as primary suspension for the purpose of ensuring the quiet running of the entire travelling gear, constructed as a kind of Gresley twin coach system.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in detail in the following, based on a principal sketch of an embodiment. They show in:
FIG. 1 a rail vehicle with a driving unit and following wagon bodies,
FIG. 2 the travelling gear system between the driving unit and the adjacent wagon body in a principal side view, and
FIG. 3 the system according to FIG. 2 in a top view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, rail vehicle for railroad traffic at high speeds, which at its peak is at least 100 km/h, has a driving unit 1 and at least one following, adjacent wagon 2 , to which further wagons 3 may be attached. The driving unit 1 contains merely a driver's cabin 4 and electrical and mechanical components for the drive and control, wherein the drive is carried out via a motor bogie 5 with driving motor(s) provided in the region of the driver's cabin 4 . The relevant end of the driving unit 1 towards the adjacent wagon body 2 rests on a travelling gear 6 , which at the same time carries the adjacent end of the following wagon body 2 in the manner of a Gresley twin coach system. The opposite situated end of the wagon body 2 can be supported on a further adjacent wagon body 3 by means of an articulated coupling 7 , while in the region of the articulated coupling 7 a travelling gear 8 may be provided below the relevant end of the wagon body 3 . 1 . The wagon body 2 . 1 is used mainly for transporting passengers.
Referring to FIGS. 2 and 3, travelling gear 6 , which is common to the driving unit 1 and the wagon body 2 . 1 , has two axles 9 , 10 and, accordingly, two sets of wheels each with two rail wheels 11 . At the same time the axles 9 , 10 are mounted in a common travelling gear frame 13 , wherein in the direction of travel longitudinal beams 14 are provided, which are joined with each other in the region of the wheel axles 9 , 10 via a transverse beam 15 each, preferably rigidly. The distance between the axles 9 , 10 is in this case twice the diameter of the wheels 11 . The longitudinal beams 14 and the transverse beams 15 form the travelling gear frame 13 , wherein the beam pairs 14 , 15 are parallel to each other. That end of the driving unit 1 which is adjacent to the wagon body 2 . 1 is supported on the travelling gear 6 by elastic support elements 16 . These support elements 16 are formed by pairs of coil springs, wherein two coil springs each are erect behind each other on the longitudinal beams 14 in the longitudinal direction of the longitudinal beams 14 .
When viewed from above, the wagon body 2 . 1 is supported on the travelling gear 6 above the associated wheel axle 10 . For this purpose two support columns 17 are used, which stand at a distance next to each other transversely to the direction of travel and in particular on the longitudinal beams 14 , which columns also have elastic support elements 18 at their top ends, on which support elements 18 the wagon body 2 . 1 is supported by means of a bracket 19 . At the same time the brackets 19 are positioned so high that the wagon body 2 . 1 . is supported above the horizontal plane containing its centre of gravity. Consequently, due to the centrifugal forces the wagon body 2 . 1 can tilt passively so that its bottom region will swivel outwardly, thus the effect of the centrifugal force on the passengers and other goods being transported will be correspondingly reduced.
To keep the elastic support elements 16 , 18 as free as possible from the traction forces, which occur between the driving unit 1 and the wagon 2 especially during braking or acceleration, in the longitudinal centre of the travelling gear 6 , at both of its ends a drawbar 20 and 21 , respectively, is connected by means of universal joints, while the drawbar 20 , connected in the region of the axle 9 , is joined to the bottom 22 of the driving unit 1 via a link pin 23 also by means of a universal joint. This drawbar 20 extends from the travelling gear 6 inclined upwards toward the motor bogie 5 , while the drawbar 21 extends from the travelling gear 6 approximately horizontally towards a link pin 24 , which is fastened on the bottom 25 of the wagon body 2 . 1 . At the same time the universal joints of the drawbars 20 , 21 may be constructed as a ball joint or have rubber-elastic inserts. At the same time the drawbar 20 connected to the driving unit 1 is longer than the drawbar 21 connected to the wagon body 2 . 1 . In addition, between the wheel bearings of the axles 9 and the travelling gear frame 14 , a rubber-elastic intermediate layer 26 is provided, which serves the purpose of primary suspension and improves the quiet running of the travelling gear 6 .
By providing a common travelling gear 6 between the driving unit 1 and the wagon body 2 . 1 working as a Gresley twin coach system, the possibility will arise, particularly by displacing the mounting positions of the coil springs 16 away from the axle 9 on the side of the driving unit towards the following axle 10 on the side of the wagon, for the purpose of shifting the heavy load of the driving unit 1 even if partially towards the axle 10 associated with the wagon 2 , until an approximately even load on the axles 9 and 10 is achieved. In addition, the driving unit 1 may be supported by means of elastic support elements 16 , the working characteristics of which are considerably different from those of the support elements 17 , 18 used for the wagon body 2 . 1 . In addition, only one common travelling gear 6 needs to be provided for the ends of the driving unit 1 and the wagon body 2 . 1 which face each other, which simultaneously assumes the function of coupling to transmit the traction forces. Furthermore, with this arrangement a level control of the wagon body can be carried out without influencing the driving unit 1 , because the two vehicle portions are supported separately on the common travelling gear 6 ; in particular, such sets of wheels can be used in this case which are fitted with a gauge-changing device (Talgo-system). Incidentally, various add-on parts, like, for example shock-absorbers and the like, may be provided on the travelling gear 6 , to suit the prevailing requirements of the driving unit and/or of the following wagon 2 . At the same time the wheelbase is chosen to suit the constructive and weight requirements. Incidentally, for the purpose of achieving a balanced mass of the set of wheels on the axles 9 and 10 , the distance of the coil springs from the sets of wheels is determined by the mass of the driving unit to be supported, of the wagon body 2 . 1 and the distribution of the mass in the running gear itself.
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A rail vehicle with at least one driving unit and at least one adjacent wagon body that is capable of tilting during operation, where the tilting is provided by an assembly mounted on a travelling gear. The driving unit and the adjacent wagon body have their facing ends supported on a common travelling gear having at least two sets of wheels.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
This disclosure relates generally to the field of fluids used in subsurface wellbore, or pipeline cleaning. More specifically, the disclosure relates to the use of amphiphilic blends and friction reducers to enhance removal of sand and cuttings from wellbores, particularly after multi-zone fracturing operations.
Wellbores drilled through subsurface formations include vertical and “horizontal” wells, i.e., those that are highly inclined from vertical up to and exceeding 90 degrees from vertical. The objective of drilling such wells is to penetrate a large area of a subsurface formation or formations that exist in layers having approximately the same orientation with respect to vertical, that is, the formations are highly inclined with respect to vertical.
Some such formations include naturally or mechanically fractured zones, that is, zones where the formation has enhanced hydraulic permeability and conductivity due to tectonic stresses. Some fractured zones contain hydrocarbons in the form of oil and/or gas. A horizontal wellbore with fractured formation enhances the hydraulic interconnection of a large surface area of the formation to a single conduit, thereby making it economically feasible to produce the hydrocarbons.
It is also known in the art to stimulate such wellbores through such formations, as well as non-horizontal wellbores, after completion of the wellbore by hydraulic fracturing. Hydraulic fracturing may further enable hydraulic connection of the formation located at a substantial lateral distance from the wellbore, thus enhancing the productivity of the wellbore further. Hydraulic fracturing includes pumping a liquid suspension of “proppant”, which is a granular material whose grains are suitable to hold open a fracture created by the pressure of pumping the suspension into the formation after the pumping pressure is relieved.
Hydraulic fracturing may be performed in some wellbores in a plurality of individual zones isolated by seal elements disposed in the wellbore after the individual zone has been hydraulically fractured. It may be necessary to remove the mechanical obstructions, excess cuttings and other debris from the wellbore in order to gain access to the entire horizontal wellbore for fracturing. It may also be necessary to remove excess fracture proppant, other debris and to remove the seal elements from the wellbore after hydraulic fracturing operations are finished in order to produce hydrocarbons commercially from the wellbore. The removal of debris, seals, and excess proppant from horizontal wellbores is typically facilitated through the use of a coil-tubing rig or work-over rig equipped with a bottom-hole tool assembly designed for milling debris into small particles and/or flushing the obstructions up the wellbore annulus to the surface.
It is known in the art that fluid system additives can be used to enhance well-bore cleaning operations. Generally, friction reducers such as high molecular weight polymers of acrylates, acrylamides, and derivatives thereof can be added to the fluid system to reduce pressure pumping requirements and build viscosity in the fluid. Furthermore, sand and debris removal from horizontal wellbores may be performed with intermittently pumped high viscosity “pills” of gel disposed in a high viscosity, concentrated water solution. Typically, the gel is a xanthan, guar, polyacrylamide (or derivative thereof), cellulostic polymer (or derivative thereof), or other polymeric material, which may be the same as used to suspend the proppant in the hydraulic fracturing operation. It is believed that using the gel pill as described performs the function of a “liquid squeegee”, that is, to sweep the sand and other debris out of the wellbore by the function of the high-viscosity of the gel pill. It is further believed that high viscosity solutions are necessary to keep solid particles/debris in suspension as they travel through the annulus so as to prevent sedimentation and accumulation of solids within the wellbore behind the bottom-hole tool assembly, thereby reducing the probably of the debris causing the tubing and tools to become stuck in the wellbore.
Although the existing art provides means to enable horizontal well completions operations, the frequency of operational failures due to solids accumulation and production-related failures to do the debris left in the annulus after clean-out procedures creates the need for sand and debris removal fluids having higher solids removal efficiency than those known in the art.
SUMMARY
One aspect is a fluid composition for cleanout of wellbores drilled through subsurface formations that includes an effective amount of an amphiphilic chemical combined with an effective amount of a friction reducer in an aqueous solution of a base liquid. A remainder of the composition includes the base liquid.
Other aspects and advantages of the invention will be apparent from the description and claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of a horizontal well after hydraulic fracturing,
FIG. 2 shows cleaning out the wellbore of FIG. 1 using a coiled tubing system.
DETAILED DESCRIPTION
FIG. 1 is a cross section of an example wellbore 10 drilled through subsurface formations by a drilling rig 12 or similar device well known in the art disposed at the Earth's surface 11 . Although the example rig 12 shown is used on the land surface, the disclosed examples are equally applicable to marine drilling. The wellbore 10 may be initially drilled vertically or near vertically, and when approaching a target formation 14 , directional drilling equipment (not shown) may be used to change the trajectory of the wellbore at 10 A so that it ultimately follows the trajectory at 10 B of the target formation 14 .
The target formation 14 may be hydraulically fractured 20 . Portions of the wellbore at 10 B may be hydraulically isolated from each other using plugs 30 or similar mechanical seal devices to enable subsequent selective treatment, e.g., hydraulic fracturing of individual portions of the wellbore at 10 B.
After each such selective treatment, it may be required to clean out the excess fracturing proppant (e.g., sand) and to remove one or more of the plugs 30 . Referring to FIG. 2 , one example of such removal and cleaning operation may use a conduit contained on a coiled tubing unit 32 of types well known in the art to insert and withdraw a coiled tubing 32 from the wellbore 10 B. A distal end of the coiled tubing 34 may include an orienting device 36 , sensors 38 of various types known in the art, an hydraulic motor 40 such as a positive displacement motor or a turbine motor operated by flow of fluid through the coiled tubing 34 and a bit or mill 42 at the distal end. Additional tools may be included in the bottom-hole assembly to facilitate the clean out including but not limited to agitators, reverse jet annular velocity enhancers, and mechanical tractors. During cleanout operations, fluid is pumped into the coiled tubing 34 such as by using a fluid pump 44 , the motor 40 causes the bit or mill 42 to rotate, and cuttings and excess fracture proppant are lifted to the surface as the fluid exits the bit 42 and flows up an annular space between the coiled tubing 34 and the wall of the wellbore 10 B. The example shown in FIG. 2 is not meant to limit the types of conduit or conveyance apparatus that may be used in cleaning out a wellbore. Other types of conduit may include jointed tubing and drill pipe, and drilling rigs as in FIG. 1 or workover rigs may be used in such cleanout operations with equal effect.
In one example, the fluid may include an effective amount of an amphiphilic chemical blended with an effective amount of a friction reducer in an aqueous solution. The amphiphilic chemical may be a single compound or a mixture of compounds. Two non-limiting examples of the amphiphilic chemical may include 2-butoxyethanol at a concentration of 2.4 to 24 parts per million in the aqueous solution combined with acetic acid at concentrations of 6 to 24 parts per million in the aqueous solution. Another example of the amphiphilic chemical may be polydimethylsiloxane copolymer at a concentration of about 100 to 300 parts per million in the aqueous solution. An example of a friction reducer may include polyacrylamide, or an AMPS acrylamide polymer at a concentration of 70 to 150 parts per million in the aqueous solution. In the present context “aqueous” solution may be used to mean water or completion brine as the base liquid, or any other base liquid that is essentially non-reactive with the amphphilic chemical and the friction reducer. “Effective amount” with reference to the amphiphilic chemical and the friction reducer may mean an amount which optimizes the pressure pumping, flow rates, and removal of sand, debris and other particulate contaminants from the wellbore as a result of fluid flow out of the wellbore in the annular space between a conduit and the wall of the wellbore (explained below with reference to FIG. 2 ).
In use, the foregoing solutions may be used substantially as explained with reference to FIG. 2 . Testing has shown that substantially more fracture proppant and debris may be removed from a wellbore than using gel pills and larger amounts of friction reducer as known in the art.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein including but not limited to multi-stage vertical well completions and the clean out of pipeline systems where solids accumulations occur. Accordingly, the scope of the invention should be limited only by the attached claims.
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A fluid composition for cleanout of wellbores and pipe systems includes an effective amount of an amphiphilic chemical combined with an effective amount of a friction reducer in an aqueous solution of a base liquid. A remainder of the composition includes the base liquid.
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This application claims the benefit of U.S. provisional application number 60/095193, filed Aug. 3, 1998, and is a continuation in part of U.S. utility application number 08/905261, filed Aug. 1, 1997, which are both incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The field of the invention is diagnostics.
BACKGROUND OF THE INVENTION
In recent decades, advances in modem chemistry and more sophisticated instrumentation have led to a plethora of clinical tests. However, the equipment and the trained personnel needed to perform such tests led also to an increase in costs. To cut down on the costs related to clinical diagnosis, many physicians frequently outsource testing of blood and other specimens to centralized or specialized laboratories. Outsourcing clinical diagnostics, however, often increases the time between acquiring a sample and obtaining a test result. A delay in obtaining a test result is especially disadvantageous when time is a critical factor in differential diagnosis, for example, in the treatment of heart attacks, poisoning or strokes. Furthermore, a delay in obtaining test results adds to the overall cost.
The time span between acquiring a sample and obtaining a test result is not only of paramount importance in clinical diagnosis, but also in a variety of other fields. Such fields are, for example, environmental chemistry to detect a source of pollution, military field tests to detect poisonous gases, or criminological investigation to find traces of chemical markers. Time constraints, as well as the requirement to perform diagnostic tests at the place of sample collection led to the development of compact, self-contained test systems. Such self-contained test systems may be categorized into two different classes.
The first class may be characterized as qualitative test systems. Many qualitative test systems provide all required reagents, and a sample can be analyzed without further need of instrumentation. In U.S. Pat. No. 3,726,645 to Kaezmarek et al., U.S. Pat. No. 3,713,779 to Sirago et al., and U.S. Pat. No. 3,689,224 to Agnew et al., for example, small, flat hand-held test kits are described, in which a liquid or gaseous sample reacts with reagents provided by the test kit. A color change of an indicator reveals the presence of analyte. In these test kits, manual application of pressure is usually used to move and mix reagents; and the sample. In other test systems, for example in U.S. Pat. No. 4,806,316 to Johnson et al., the sample is propelled by gravity or a pressure difference. Again, a color change indicates the presence of analyte. In a further example, U.S. Pat. No. 4,859,421 to Apicella, additional elements in a test kit are described, such as one-way valves that allow only unidirectional flow of reagents. Furthermore, additional reagents for positive and negative controls may be provided.
The second class may be characterized as quantitative test systems. Quantitative test systems generally require a specialized instrument, commonly a photometer or fluorimeter. Such quantitative test systems utilize various ways of detection and various ways of how the sample is moved within the test device. In U.S. Pat. No. 4,963,498 to Hillmant et al., for example, a test system is described in which a blood sample is mixed with a reagent and subsequently drawn by capillary action into a flow path. Interactions between the reagents and the sample cause a change in flow rate. The flow rate is measured using a photocell, and the change in the flow rate is then correlated with the concentration of the analyte. In another example, U.S. Pat. No. 3,799,742 to Coleman describes a test system in which a sample is placed into a small test container. The sample is then manually pushed through a filter unit into a cuvette, where a color reaction takes place. The small test container is subsequently inserted into a reading device and the concentration of the analyte is calorimetrically determined. In U.S. Pat. No. 4,673,657 to Christian, a sample is placed into an assay card and forced to a detection zone by a roller bar. A pulse vacuum may firer move the sample repeatedly over the detection zone. The detection zone may specifically bind up to 250 analytes, and the analytes can then be automatically detected and quantified via an optical or magnetic detector.
Although various quantitative and qualitative test systems are known in the art, almost all test systems have a number of disadvantages. Typically, the assays performed in such systems are single-step assays, i.e., one sample is mixed with one reagent or set of reagents, and the result of the reaction is then measured. However, many modem diagnostic reactions employ multiple steps prior to the detection reaction, for example reduction of a sample to liberate disulfide bound thiols, or coupled enzymatic reactions to indirectly measure an analyte or secondary reactions for signal amplification.
Another disadvantage of many quantitative and qualitative test systems is that reaction of a sample with a substrate, and detection of the analyte, occur in the same location. This often poses problems when additional processing steps are required after the addition of reagents to the sample. Where samples are moved from one location to another within a test system, reproducible test conditions may be difficult to achieve.
Yet another disadvantage of known quantitative and qualitative test systems is that many of them utilize squeezable containers for storage and dispensing of reagent solutions. Despite the simple operation of squeezable containers, dispensing an accurate and precise amount of a reagent from a squeezable container is often problematic. Moreover, when an accurate and precise flow rate of a reagent is needed, squeezable containers may produce inaccurate and non-reproducible results.
Yet further, while many test systems are supplied with appropriate amounts of reagents, and typically follow relatively simple protocols, a problem frequently persists in that the accuracy and precision of test results become operator i.e. technique dependent. Such measurement is therefore often prone to errors.
Thus, many test systems are known in the art to qualitatively and quantitatively determine the presence of an analyte in a sample. However, current test systems tend to limit the complexity of a reaction sequence with which an analyte can be determined. Surprisingly, despite a growing number of new and useful diagnostic systems, there is no test system that permits a relatively quick and simple detection of an analyte in a sample that requires complex test procedures, without using sophisticated instruments. Therefore, there is still a need for methods and test systems that overcomes these limitations.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for automated sample analysis in which a plurality of actuators are involved in moving a sample from one compartment to another, and appropriate reactants are combined with the sample in one or more of the compartments.
The actuators are preferably contained in a device that also has a detector, data reduction capability, and a printer. Contemplated signal detectors include a photomultiplier tube, a photodiode, and a charge-coupled device.
Steps contemplated to be performed automatically include aliquoting the sample, diluting the sample, contacting at least a portion of the sample with a reagent having a substantially selective binding affinity towards the analyte, a buffer, an acid, a base, or a wash solution. Contemplated reactants include sense and antisense nucleic acids, antibodies, solid-phase substrates, chromophores, and amplifiers.
Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a disposable diagnostic container according to the present invention.
FIG. 2 is a plan view of an alternative disposable diagnostic container according to the present invention.
FIG. 3 is a plan view of another alternative disposable diagnostic container according to the present invention.
FIG. 4 is a plan view of another alternative disposable diagnostic container according to the present invention.
FIG. 5 is a perspective view of an analyzer that cooperates with the containers of FIGS. 1-4 to determine an analyte in a sample.
FIG. 6 is a schematic of actuators that can be used in conjunction with the containers of FIGS. 1-4 to determine an analyte in a sample.
DETAILED DESCRIPTION
FIG. 1 is a plan view of a disposable diagnostic container 10 according to the inventive subject matter, generally comprising a pouch having a sample inlet port 12 , a plurality of compartments 13 , 22 , 26 , 28 , 30 , and 32 , as well as passageway 16 coupling the inlet port 12 with compartment 13 , and portals 24 , 34 , 36 , 38 and 40 interconnecting the various compartments.
Container 10 is a relatively flat, laminated plastic pouch measuring about 8.5 cm by about 19 cm, and about one millimeter thick, in which the compartments, inlet port, passageway and portals are all defined by heat sealing. The nature and dimensions of the container, arrangement of compartments and interconnections, as well as the contents of the compartments will, of course, vary from embodiment to embodiment, and those skilled in the art will recognize that the embodiment of FIG. 1 is merely exemplary of an enormous number of such possible containers.
The size of the container, for example, largely depends on the volume of reactants to be contained, although it is contemplated that practical containers will typically be sized to define a volume in the range of between 50 μL and about 5 milliliters. Suitable containers may have many different shapes, so long as the shape permits contact of at least one side of the container with a plurality of actuators. Preferred shapes are flat, envelope-like shapes, but box-like, round, hemispherical, or even spherical shapes, are also contemplated.
The opposing top and bottom sheets forming container 10 may advantageously be formed from a thermoplastic material, including polypropylene, polyester, polyethylene, polyvinyl chloride, polyvinylidene chloride, and polyurethane. Such sheets are contemplated to have a relatively uniform thickness between about 0.05 mm to about 2 mm. The opposing sheets need not be fabricated from the same materials. For example, one sheet may comprise a reflective foil, and the other sheet may comprise a transparent or translucent plastic. The use of foil can help promote temperature stability, and can serve as an additional moisture and oxygen barrier. Foil can also enhance thermal transfer from a heating source to a sample or reagent.
Preferred containers are flexible, either in whole or in part. Flexibility as characterized herein is the capability of yielding to a reasonable force by temporarily changing shape without damaging the structure or material. A reasonable force, as used herein, is a pressure, typically below 5 lb/in 2 . For example, a preferred flat, envelope-like container is sufficiently flexible to be wrapped around an inch diameter cylindrical object without breaking or tearing the container. In another example, a portion of a container may advantageously be sufficiently flexible to displace a volume carried within that portion without rupturing the outer walls. The container may furthermore have a plurality of openings. The number of openings may vary considerably between at least one opening and twenty openings or more. Such openings may have a closing mechanism, be sealable or permanently open. Furthermore, some of the openings may be in liquid communication with each other, or may be used as a vent or an overflow. The container is furthermore characterized by having a plurality of compartments.
Container 10 also includes attachment holes 42 for mounting on alignment posts in an analyzer 400 . Alternative attachment devices or methods are also contemplated, including hooks, loops and other mounting attachments coupled to the container 10 at appropriate locations. It is further contemplated that container 10 may be devoid of mounting components.
One or more labels (not shown) may also be affixed to the container 10 . Labels may indicate identification marks, information relating to the type of diagnostic test being conducted, as well as patient information, test result data, or other information. The label(s) may optionally be removable, and may, for example, be removed from the container 10 to be placed in a patient's medical file, thereby eliminating the need for transferring data with attendant possibility for error.
Inlet port 12 serves as an entry point for receiving samples or other materials. Many configurations are contemplated, although it is preferable that the entry point uses some sort of common connection mechanism. For example, the entry point 12 in FIG. 1 is a female portion of a Luer lock mechanism. Alternative entry ports may be either simpler or more complex, and may contain a padding that can be punctured or pierced using a needle.
Contemplated entry points may also be placed elsewhere on a container other than as depicted in FIG. 1 . For example, a suitable entry point for a solid material may be formed as a simple slot in one of the sheets forming the top or bottom of the container. Such an entry point may be well suited for receiving a relatively solid piece such as a tissue or mineral sample, and may be sealable by a flap or tape mechanism.
Compartments 13 , 22 , 26 , 28 , 30 , and 32 are portions of container 10 that are fluidly separated from other portions of the container during at least some period of time. In general, compartments are separated from one another using at least one continuous element that contacts at least one of the walls of the container. For example, if the container is a cylinder, the continuous element could be a divider that is more or less perpendicular to the longitudinal axis of the cylinder, and contacts the inner circumference of the cylinder. Where the container is a flat bag, the continuous element may advantageously comprise a heat seal between opposing sides, in a form enclosing a defined space.
The volume of preferred compartments may advantageously vary between about 3% to approximately 90% of the total volume of the container. Such compartments may be filled with at sample, a reagent, or air, but the compartment may also have essentially no void volume. By way of example, compartment 22 may be designed to contain about 1 ml of a binding reactant, and wash compartment 28 may be designed to hold up to about 5 ml of a solvent solution.
At least some of the compartments may advantageously comprise a transparent portion through which a signal can be detected, or the progress of a reaction can be monitored. In such instances it may also be advantageous for an opposing surface to exhibit a reflective surface to improve signal detection. Compartments may also be shielded, for example against heat, light, or other radiation.
Compartments may have one or more openings, such as those at portals 34 , 36 , 38 , and 40 . Such openings may be in permanent liquid communication with the rest of the container, for example, by an incomplete wall surrounding the compartment. Openings may also be temporarily closed. For example, a breakable seal may form the opening, which separates the compartment from the rest of the container, until an opening force breaks the seal. Typically, the breakable seal is a chevron break point allowing a fluid to pass under about 5-15 psi. In another example, the opening comprises a one-way valve, which permits only a unidirectional flow of material when a pressure difference is applied between the ends of the valve. In yet a further example, the opening may be temporarily closed by a closing force. Typically, the closing force is delivered via a compression pad from outside the container, which effects a temporary physical separation of the compartment from the rest of the container.
Passageway 16 and portals 34 , 36 , 38 and 40 serve to fluidly connect various compartments and other spaces within the container, and with the external environment. The term “fluidly connect” specifically includes movement of any fluidizable composition, whether a liquid, gas, or fluidized solid. In many instances the fluid will be intended to move in a single direction only, but in other instances it may be advantageous to move at least a portion of a fluid in both forward and backwards directions.
In some cases compartments or other spaces may be separated by a barrier for a period of time, and it is contemplated that the barrier will at some point be breached. In such instances the separated compartments or other spaces are considered to be “fluidly connectable.”
FIG. 2 depicts an alternative configuration in which a container 100 has an entry slot 12 A instead of an entry port. The slot 12 A is preferably sealable such that a liquid sample placed into container 100 does not leak out. Entry slot 12 A can advantageously be located within a plastic or other ring 15 . Ring 15 can be attached to the container 100 and fitted with an attachable cover (not shown) such that any liquid inserted into entry slot 12 A does not leak out of the container.
FIG. 3 depicts an alternative configuration in which a container 200 includes an overflow compartment fluidly coupled, or fluidly coupleable to compartment 18 . Compartment 18 also contains a volumetric zone 14 that is externally partitionable to define a fixed volume to be used in a diagnostic test. For example, assuming the fixed volume is about 100 μl, fluid-receiving portion 18 can receive an input volume that is greater than about 100 μl, such as 150 μl. In this case, after receiving the 150 μl of sample, volumetric zone 14 can be externally partitioned such that the fixed volume, about 100 μl, is defined and then used for the diagnostic test with the excess volume, about 50 μl, being moved into overflow portion 20 . The excess volume moved into the overflow portion would not be used in the diagnostic test since only the fixed volume of a sample typically is used to perform the diagnostic test. This externally partitionable volumetric zone 14 provides a means for quantitatively analyzing a sample.
Partitioning volumetric zone 14 typically involves two steps. The first step involves using at least one movable object such as a compression pad to apply pressure to all the areas around the region defining the fixed volume with the exception of the area providing a fluid connection to the overflow portion 20 . This partially surrounds the region defining the fixed volume while allowing any excess volume to move into overflow portion 20 . The second step involves using at least one movable object such as a partitioning edge to separate the excess volume from the fixed volume. This completely surrounds the region defining the fixed volume. A compression pad and partitioning edge can be made from any material provided the fixed volume can be defined. It is noted that the positioning of the movable objects can be adjusted such that the applied pressure can define any particular volume as the fixed volume.
FIG. 4 depicts an alternative configuration in which a container 300 has additional compartments 102 , 104 , 106 and 108 . The overflow compartment 20 depicted in FIG. 4 will have the same configuration as depicted in FIG. 3 once a seal is placed along reference line B—B. In this embodiment compartments 102 , 104 , 106 , 108 have portions comprising reagent compartment 22 , reaction compartment 26 , substrate compartment 30 , and wash compartment 28 , respectively. Once a seal is placed along B—B, these compartment portions can become the reagent compartment 22 , reaction compartment 26 , substrate compartment 30 , and wash compartment 28 depicted in FIG. 3 . In addition, compartments 102 , 104 , 106 , 108 have removable delivery portions 110 , 112 , 114 , 116 , respectively. Further, compartments 102 , 104 , 106 , 108 have fluid input ports 118 , 120 , 122 , 124 , respectively. Thus, compartment 102 has a portion that corresponds to binding-reagent compartment 22 , a removable delivery portion 110 , and a fluid input port 118 ; compartment 104 has a compartment portion that corresponds to reaction compartment 26 , a removable delivery portion 112 , and a fluid input port 120 ; and so forth.
Container 300 can be fabricated as follows. With reference to FIG. 4, an appropriate fluid is inserted into the removable delivery portion through the fluid input port of each compartment. In an immunoassay, for example, a fluid containing at least one binding pair member can be inserted into removable delivery portion 110 of compartment 102 ; a fluid containing a solid material can be inserted into removable delivery portion 112 of compartment 104 ; a fluid containing a substrate can be inserted into removable delivery portion 114 of compartment 106 ; and a wash solution can be inserted into removable delivery portion 116 of compartment 108 . After inserting the appropriate fluid into each removable portion, the input port of each compartment can be sealed such that the inserted fluids remain within the compartment. This can be accomplished by heat sealing along reference line A—A. To help minimize the number of bubbles introduced into each compartment, each fluid can be positioned proximal to the compartment portion of each compartment before sealing the fluid input ports. To accomplish this, the container can be positioned such that gravity forces each fluid toward each compartment portion.
After sealing the fluid input ports, at least a portion of each fluid can be moved from the removable delivery portion of each compartment to the compartment portion of each compartment. Again, to help minimize the number of bubbles introduced into each compartment, each fluid can be positioned proximal to the compartment portion of each compartment before moving the fluids. Any process can be used to move the fluids from the delivery portion to the compartment portion. For example, gravity and/or pressure can be used to move the fluid into compartment portion of each compartment. Once at least a portion of each fluid is moved to the compartment portion of a compartment, that portion can be sealed from the delivery portion of each compartment such that the fluid within the compartment portion remains within the compartment portion. For example, a seal can be placed along reference line B—B. The delivering portion of each compartment can then be detached from the container by any suitable means, such as cutting along reference line B—B. In this case, detachment of the delivery portion of each compartment results in a diagnostic device as depicted in FIG. 3 .
In FIG. 5 an analyzer 400 generally comprises a main section 410 having a container receiving zone 412 with alignment posts 414 , a door 420 , multiple actuators 430 , a detector 440 , a printer 450 , and an interface 460 . Analyzer 400 is shown with an exemplary workpiece container 200 .
The main section 410 houses essentially all of the electronic or other circuitry needed to complete the contemplated tests. Of course, main section 410 can be designed using any suitable shape and dimensions, and can be formed from plastic, metal, or any other suitable materials.
Receiving zone 412 cooperates with door 420 to receive container 10 during the contemplated testing. In alternative embodiments a door is not needed at all, and the container can instead be inserted into an access slot. Alignment posts 414 may be configured in any suitable fashion, and can be eliminated altogether.
Actuator group 412 is used to deliver one or more forces to the container 10 , with the object of affecting some material with container 10 . Examples of actuators that may form part of group 412 are compression pads, roll bars, or wheels. Contemplated actuators may also have one or more additional functions, including heating, cooling, and delivering a magnetic force. For example, an actuator may heat inactivate an enzyme, or warm a reaction to a desired temperature. In another example, an actuator may be used to concentrate an analyte by binding it the surface of a magnetic bead. Actuators may also be employed to modify a volume occupied by fluids, solids, or air. The fluids may, for example, include a buffer, a sample, a reaction mixture, a reagent solution, etc. The solids may include paramagnetic beads, and the gases may include nitrogen or argon as protective agents, or CO 2 as a byproduct of a chemical reaction.
Where an actuator comprises a compression pad, the pad can be made from any material suitable for exerting an appropriate force to a portion of a container, in an appropriate pattern. Typically, a compression pad is a substantially flat surface, and has a shape corresponding to the shape of a compartment or passageway. Where an actuator is employed to otherwise seal a partition, a partitioning edge can be provided, preferably in the form of a wedge or a compression pad having a protrusion.
Detector 440 is essentially one, or any combination of signal detectors used to detect a signal generated through use of the container. Contemplated signal detectors include a photomultiplier tube, a photodiode, and a charge-coupled device. It is optional to include detector 440 in analyzer 400 .
Printer 450 is used to print information on any combination of human or machine-readable formats, including printing on a paper label or sheet. It is optional to include a printer in analyzer 400 .
Interface 460 can be any type of electronic or other means of exchanging information with another device. A typical interface is a common RS232 (serial) data port.
Not shown are other options for analyzer 400 , including a scanner than can detect a bar code, or other hand or machine written information included on a label.
FIG. 6 depicts further detail of the actuator group 412 described with respect to FIG. 5, and cooperates with the container 200 of FIG. 3 . It should be understood, however, that actuator group 412 could be employed with many different containers besides the specific configuration of container 200 , and that a generic actuator group can be employed with a very large number of containers and corresponding test protocols.
With reference to FIG. 6, actuator 412 has a series of compression pads that correspond to the various compartments of a diagnostic device, for example, device 200 depicted in FIG. 3 . Each compression pad can serve to apply external force to a particular region of the device such that fluid is moved. For example, a compression pad can be used to apply 5-50 psi of fluid pressure to a chevron break point within a compartment. Typically, two compression pads correspond to each compartment having a chevron break point. One compression pad is used to move fluid toward the chevron break point while the other is used to apply the force to move fluid through the chevron break point. In addition, the compression pad proximal to the chevron break point can be used to prevent movement of fluid between compartments, if necessary.
With reference to FIG. 6, actuator 412 has binding-reagent compartment compression pads V 01 , V 03 . Compression of binding-reagent compartment compression pad V 01 followed by compression of binding-reagent compartment compression pad V 03 can cause a fluid within binding-reagent compartment 22 of device 200 to pass through chevron break point 24 of device 200 . In addition, binding-reagent compartment compression pad V 03 can serve to prevent movement of fluid between compartments.
Actuator 412 also has volumetric zone compression pads V 03 , V 04 , V 07 , V 10 . Volumetric zone compression pads V 03 , V 04 , V 07 can serve to surround partially an area that defines a fixed volume of sample. Volumetric zone compression pad V 10 can serve to move a fluid from one compartment to another. In addition, actuator 412 has a partitioning edge V 08 that can serve to define a fixed volume. Partitioning edge V 08 can prevent fluid from moving between, for example, fluid-receiving portion 18 and overflow portion 20 of device 200 .
Actuator 412 also contains a reaction compartment compression pad V 09 . In addition to being able to move fluid from a reaction compartment, reaction compartment compression pad V 09 can rotate such that the magnetic force created by permanent magnet V 15 also rotates. A movable magnetic force can be used to move paramagnetic particles within a reaction compartment such that assay kinetics are increased. In addition, a magnetic force provided by permanent or electro-magnet can be used to hold paramagnetic particles in a particular location.
In addition, actuator 412 has substrate compartment compression pads V 06 , V 11 ; wash compartment compression pads V 05 , V 12 ; and waste-receiving compartment partitioning edge V 02 . These compression pads can be used to move fluid while waste-receiving compartment partitioning edge V 02 can be used to prevent fluid movement between, for example, reaction compartment 26 and waste-receiving compartment 32 of device 200 .
An analyzer apparatus can have any type of signal detection mechanism including, without limitation, a photomultiplier tube, photodiode, and charge-coupled device. With reference to FIG. 5, analyzer apparatus 400 has a photomultiplier tube 414 . In addition, shutter 416 can be used to protect photomultiplier tube 414 .
The analyzer can be programmable such that the compression pads and partitioning edges apply particular external force at particular times during the diagnostic test. In addition, the analyzer apparatus can have an alignment means (e.g., a plurality of pins) for positioning the diagnostic device. Further, the analyzer can have pressure sensors on either side of each compression pad and partitioning edge. These sensors can be used to determine and regulate the amount of pressure being applied. In addition, these sensors can be used to determine whether each compression pad and partitioning edge is working properly during operation.
The following methods are examples of operations during a test. These methods involve using device 200 with reference to the actuator components depicted in FIG. 6 . The number zero (0) means “off” or no external force applied and the number one (1) means “on” or external force applied.
V01
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To measure a fixed volume of a sample within volumetric zone 20 as a function of
time:
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To mix a sample with binding reagent compartment 22, incubate, and mix with
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To wash the paramagnetic particle:
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To add substrate from substrate compartment 30:
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Method of Use
In general, a sample is deposited into inlet port 12 under pressure, and travels to sample compartment 13 . Excess sample beyond the capacity of compartment 13 spills over into a spillage compartment 20 , which serves to aliquot the amount of sample in compartment 13 . A first reactant from compartment 22 is added to the sample, and after appropriate incubation the sample is shunted to reaction compartment 26 . Reaction chamber 26 may contain additional reactants, and still further more reactants can be added from substrate or other reactant compartment 30 . At one or more points in the processing stage the sample can be washed by a wash fluid from wash compartment 28 . Waste material is forced into waste compartment 32 . During these processes, various reactions take place with respect to an analyte within the sample, and a color or other detectable signal is produced that corresponds to the amount or existence of analyte. The signal is “read” through one of the side walls of compartment 26 .
As used herein, the term “sample” refers to any solid, fluid or gaseous material, which contains at least a portion that can be tested for an analyte. Contemplated solid samples include organic materials, inorganic materials or a mixture of organic materials and inorganic materials. Contemplated organic materials include macromolecules, and assemblies of macromolecules, cells, and tissues. Examples are drugs, viruses, bacterial or eukaryotic cells, and vertebrate tissues. Contemplated inorganic materials include salts, complexes or mixtures thereof, for example, mineral salts and mineral compositions. Liquid samples preferably include water or chemically homogeneous fluids, but may also include mixtures of various liquids with other liquids or components, for example water, petroleum, or coffee. Especially contemplated herein are liquids that comprise complex mixtures of a fluid phase and dissolved or undissolved solids. Examples are bodily fluids, wastewater, beverages and so on. Gaseous samples may include relatively pure gases, but also complex mixtures of relatively pure gases with other gases or vapors. Examples are ambient air and air with various organic contaminants including NO 2 , CO, benzene and so forth.
As used herein, the term “analyte” refers to any component in a sample that is to be analyzed. Analytes are generally at least partially soluble in a solvent, or at least miscible in a fluid. Analytes may be an organic, organometallic, inorganic, or any reasonable combination thereof. Contemplated organic compounds range from complex compounds to very simple compounds. For example, analytes of interest include proteins, growth factors, hormones, transmitters, enzymes, clotting factors, IGF- 1 , bacteria, virus, yeast, acteylcholine, caffeine, benzo(a)pyrene, and dioxin, drugs, calmodulin and Pb-tetraethyl, alkali metal and alkaline earth metal ions such as K + , Na + , Ca 2+ , Mg 2+ , as well as salts.
As used herein, the term “reactant” refers to any composition that can react with a component of a sample, or another reactant, in performing a determination. This includes binding reagents, solid-phases, solvents, wash compositions, signal generators, and so forth. In general, practically any reactant that can be utilized at a lab bench test can also be employed in connection with the containers and devices contemplated herein. Reactants may be contained separately, or in combination, in the various compartments as appropriate for a given test protocol.
One particularly contemplated class of reactants includes test reagents. For example, reactant compartment 22 may contain a fluid that comprises at least one binding pair member. A binding pair member can be any molecule that specifically binds another molecule to form a binding pair, including an antibody or an antigen that specifically binds that antibody. Other contemplated binding pair members include antibody fragments having specific antigen binding capacity, receptors and ligands, sense and anti-sense nucleic acids, metal ions, chelating agents, and aptamers.
In many tests, reagent compartments such as compartment 22 will contain more than one of the reactants for the test being performed, and in the case of assays involving binding, such reactants will often comprise more than one binding pair member. For example, reagent compartment 22 may advantageously contain a first binding pair member and a second binding pair member each having specificity for a different epitope present on an analyte to be detected. In addition, the first binding pair member can be conjugated to a molecule that allows for analyte detection and the second binding pair member can be conjugated to another binding pair member such that an analyte-multiple binding pair member complex can be captured. For example, the fluid within reagent compartment 22 can contain two different antibodies that each bind analyte X present within a sample. The first antibody can be conjugated with an enzyme such that the amount of enzymatic activity can be correlated with the amount of analyte X. The second antibody can be conjugated to biotin such that any complex containing analyte X and the antibodies are captured by streptavidin. It is to be understood that any particular combination of binding pair members can by used to conduct a particular diagnostic test. In another embodiment, a labeled antigen may be used, for example, in competitive assays.
Another contemplated class of reactants includes labels that allow for analyte detection. Once again, as with other aspects of the inventive subject matter, virtually any label that can be employed in a bench test can also be employed in conjunction with the teachings herein. For example, labels can include acridinium esters, isoluminol derivatives, fluorophores, enzymes, and any combination thereof, and enzymes such as alkaline phosphatase, peroxidase, xanthine oxidase, and glucose oxidase can be coupled to a binding pair member to detect the presence of an analyte.
Another contemplated class of reactants includes solid-phase materials, including polypropylene, polyester, polystyrene, polyurethane, nylon, styrene, glass fiber, and thermoplastic. Such solid-phases can be employed in substantially the same manner as employed in ordinary lab procedures. In some classes of tests, for example, a solid-phase may be employed to bind a diagnostically useful compound such as streptavidin. Of special interest are various beads or other particles, and especially paramagnetic particles, which may advantageously be coated with a binding member to bind a target substance. The paramagnetic particles can then be moved under the influence of a magnetic force to separate the bound target substance from the remainder of a sample. A particularly useful application of paramagnetic particles involves the separation of plasma from whole blood. In an exemplary process, whole blood can be combined with a first antibody that has a high specificity for a red blood surface antigen, and subsequently combined with paramagnetic beads to which a second antibody is bound. The second antibody binds to the first antibody, and the red blood cells can be gently pulled away from the remaining plasma under the influence of a magnetic field.
It is specifically contemplated that a solid phase may be moved from one compartment to another. Beads may be moved in that manner, as can a “puck” that alters fluid flows within or between compartments.
Reactants may also comprise a solvent or other simple fluid. The fluid may be used for many purposes, including maintaining the stability of a reactant, or to fluidize a substance that would otherwise be in a solid state, or for use as a wash. Contemplated fluids for these purposes include preservatives, detergents (e.g. CHAPS, Tween-20, Triton X-100, cholate, and SDS), proteins (e.g. BSA), saline, phosphate-buffered saline, tris-buffered saline, water, and compatible aqueous organic solvents.
Another particularly contemplated class of reactants is a filter material. All of the known filter materials are contemplated, including nitrocellulose, steel wool, and so forth.
A very large number of test protocols can be accomplished in accordance with the teaching principles set forth herein. In addition to the tests referred to herein, multiple tests can be run on a single sample by aliquoting portions of the sample to multiple reaction chambers, and additional compartments can be added to accommodate additional reagents. Agitation, heating and other operations can be accomplished by the appropriate actuators, and time delays of anywhere from a fraction of a second, to one or more minutes can readily be accommodated. Thus, the teachings herein should not be read as limiting the application to any particular assay or protocol, or to any particular container or detector.
EXAMPLE
Diagnostic Assay
With respect to FIG. 1, an operator selects a container 10 adapter for an appropriate test, and inserts a 100 μL sample (calibrator, controls, or patient samples) into entry port 12 . The sample passes under pressure to compartment 13 .
The container 10 is then placed in an analyzer 400 , and employing various actuators the analyzer 400 takes control of the testing protocol. First, passageway 16 is sealed, preferably by a sealing actuator compressing the opposing top and bottom sheets of the container 10 at appropriate places. Compartment 18 is then squeezed to aliquot a specific desired volume of sample, with excess sample passing into compartment 20 . The connection between compartments 18 and 20 is then actuator sealed.
Using another actuator, 100 μL of an antibody solution containing biotinylated monoclonal anti-PSA antibody and polyclonal alkaline phosphatase-labeled antibody is passed from compartment 22 into compartment 14 . After addition of the antibody solution, the sample is incubated for 5 minutes at 37° C.
Using another actuator the sample is passed to compartment 26 , in which was stored 25 μL-100 μL of a homogenous suspension of streptavidin-coated paramagnetic particles. Using one or more actuators, a shaking or vibrating motion is imparted to the sample, and further incubation takes place for an interval, such as 2 minutes at 37° C.
Using other actuators, about 1.0 ml of a wash solution is passed from wash compartment 28 into compartment 26 to wash the sample. Further incubation is allowed to take place, during which the paramagnetic particles sediment. Sedimentation may be enhanced using a magnetic force from a permanent magnet.
Using other actuators, about 50 μL-100 μL of a chemiluminogenic substrate (ImmuGlow) is added to compartment 26 from compartment 30 .
Using other actuators, about 100 μL-300 μL of wash is added to the sample in compartment 26 from compartment 31 , and agitated for several seconds. The wash cycle is repeated three to four times.
Chemiluminescence is measured after a specified interval, for example, 15 seconds following addition of the substrate. Determination of the unknown is computed using a standard-dose-response curve. Depending on the test, additional measurements can be made at intervals, such as a minute or longer.
Thus, specific embodiments and applications of methods and apparatus for performing tests have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
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Methods and apparatus for automated sample analysis are provided in which a plurality actuators are involved in moving a samples from one compartment to another, and appropriate reactants are combined with the sample in one or more of the compartments. The actuators are preferably contained in a device that also has a detector, data reduction capabilities, and a printer. Contemplated signal detectors include a photomultiplier tube, a photodiode, and a charge-coupled device. Steps contemplated to be performed automatically include aliquoting the sample, diluting the sample, contacting at least a portion of the sample with a reagent having a substantially selective binding towards the analyte. Contemplated reactants include sense and antisense nucleic acids, antibodies and antigens, solid-phases such as paramagnetic beads, reagents, other substrates, and wash solutions.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to lifting devices for watercraft, more particularly, to a lift for personal watercraft that is pivotally attached to a mooring piling above the surface of the water which allows the watercraft to be lowered into the water for use and then raised from the water and pivoted onto a dock for mounting, demounting storage and servicing.
[0002] All watercraft owners know it is desirable that watercraft be stored out of the water to prevent defiling by barnacles, algae, and other waterborn plants and animals, as such requires expensive and time-consuming periodic cleaning of the bottom surfaces of the watercraft. Although there are watercraft lifts available to raise and store watercraft out of the water, many such lifts are at least partially submerged in water, which leads to defiling of the lift by aquatic plants and animals and shortens the life of the lift. Also, many prior lifts only lift the watercraft out of the water, but do not store it in an easily accessible position for cleaning, maintenance, and mounting or demounting during use. Furthermore, many such lifts require that the watercraft be elevated out of the water by manual means. However, as personal watercrafts often weigh an excess of 750 pounds, it is difficult to lift them without motorized means.
[0003] Thus, there is a need for a watercraft lift that will address the above problems.
[0004] The relevant prior art includes the following references:
Patent No. (U.S. unless stated otherwise) Inventor Issue/Publication Date 5,749,313 Shackelford, Jr. May 12, 1998 1,695,674 Wilson Dec. 18, 1928 2,808,016 Jarnot Oct. 01, 1957 2,990,803 Henderson Jul. 04, 1961 2,979,014 Yordi Apr. 11, 1961 3,060,885 Nolf Oct. 30, 1962 3,177,839 Nolf Apr. 13, 1965 3,830,452 Seay Aug. 20, 1974 5,014,638 Ilves et al. May 14, 1991 5,301,628 Daskalides Apr. 12, 1994 GB 588,394 Lamb et al. May 21, 1947
[0005] Of the above patents only the Shackelford Jr., patent provides some of the advantages of the present invention. However, the present invention, contrary to the Shackelford, Jr., patent differs as it utilizes two separate brackets rather than a tubular housing, has fewer moving parts and is motorized.
SUMMARY OF THE INVENTION
[0006] The primary object of the present invention is to provide a personal watercraft lift that enables a personal watercraft to be raised and lowered into the water easily and quickly.
[0007] further object of the present invention is to provide a personal watercraft lift that allows personal watercraft to be stored out of the water.
[0008] An even further object of the present invention is to provide a personal watercraft lift that provides easy accessibility to the personal watercraft for mounting and demounting during use and for maintenance purposes.
[0009] Another object of the present invention is to provide a personal watercraft lift that has fewer moving parts than watercraft lifts in the prior art.
[0010] An additional object of the present invention is to provide as a personal watercraft lift that is easy to install and maintain.
[0011] Yet another object of the present invention is to provide such as a personal watercraft lift that is motorized.
[0012] A further object of the present invention is to provide a more secure piling attachment means.
[0013] The present invention fulfills the above and other objects by providing a personal watercraft lift for use with a mooring piling having a mounting bracket for attaching the lift to the mooring piling above the surface of the water to which mounting brackets are attached. Both brackets are connected by a front plate and together serve as a guide means for an elongate lift mast. The lower of the two brackets has a roller on the inner side abutting the mast and the upper bracket has a slide block on the outer side so as to also abut the mast to result in a rolling and sliding movement of the mast between them. To the lower end of the mast is attached a cradle. The cradle is also attached by a cable to a motorized means mounted to the front plate of the bracket which allows the lift to be raised and lowered. The lift may be rotated in a lifting position over the body of water or inward to a storage position out of the water, preferably over a dock. A locking pin on the top bracket may be used to secure the lift underneath the lifting or the storage position. The cradle may contain optional vertical upright guards to keep personal watercraft from hitting the cable or the mast as well as crossbars for preventing the personal watercraft lift from moving laterally when it is positioned on the cradle. Further, a more secure piling attachment of the lift is achieved by attachment bolts being angled through the piling.
[0014] The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conduction with the drawing wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the following detailed description, reference will be made to the attached drawings in which:
[0016] FIG. 1 is a perspective view of the personal watercraft lift of the present invention when attached to a mooring piling as it would appear during use;
[0017] FIG. 2 is a top view of the personal watercraft lift of the present invention during use showing a personal watercraft in broken lines in a lowered lifting position over water and a raised pivoted position over a dock and in a storage position;
[0018] FIG. 3 is a side partial plan view of the personal watercraft lift of the present invention in a raid position;
[0019] FIG. 4 is a front view of the watercraft lift with a cradle in a lowered position;
[0020] FIG. 5 is a top view of a top partial plan view of the top mast guide bracket of the present invention; and
[0021] FIG. 6 is a top partial plan view of the lower mast guide bracket with piling attachment method of the personal watercraft lift of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] For purposes of describing the preferred embodiment, the terminology used in reference to the numbered components in the drawings is as follows:
1. PWC cradle 2. mast 3. mast holding cover 4. motor 5. piling bracket 6. piling 7. pivot pin 8. lift cable 9. cradle support rails 10. cradle PWC support cross rails 11. guard pipes 12. a, b pivot brackets 13. a piling attachment bolts 13. b piling attachment nuts 14. pivot head 15. Ac power cord 16 mast cradle receiver 17 bunk board 18 large pulley 19 belt 20 small pulley 21 dock 22 PWC 23 roller 24 sliding block 25 pivot arrow 26 lower mast guide bracket 27 power unit 28 gear drive 29 pivot pin shaft 30 top mast guide bracket 31 pivot licking pin 32 gear shaft 33 bolt holes 34 top mast guide bracket retaining bolts 35 lower mast guide bracket retaining bolts 36 sliding block retaining pin 37 roller retaining pin 38 PWC lift position 39 PWC storage position 40 cable spool 41 side walls of top bracket 42 side walls of bottom bracket
[0023] Referring now to FIG. 1 , the entire personal watercraft, PWC, lift of the present invention is shown attached to a mooring piling 6 . The PWC lift is attached to the mooring pilings 6 by a piling bracket 5 with bolts and nuts 13 that are long enough to pass through the piling 6 . The piling bracket 5 has two pivot brackets 12 a and 12 b holding a pivot pin 7 to which is mounted a pivot head 14 . In turn, attached to the pivot head 14 are two mast guide brackets, a lower bracket 26 and upper bracket 30 which are connected by a cover 3 . An elongate mast 2 , which is preferably made of a non-corrosive metal such as stainless steel or aluminum, is contained between the guide brackets 26 and 30 and cover 3 .
[0024] A cradle 1 is attached at a lower end of the mast 2 by a cradle receiver 16 . The cradle 1 is designed to hold a PWC on support rails 9 which preferably have cross rails 10 for providing lateral support to a PWC when placed on the cradle 1 . Optional guide pipes 11 made of PVC or other flexible material are mounted on a bunk board 17 attached to proximate an inner end of the cradle 1 to prevent a PWC from hitting the mast 2 or lift cable 8 . The cradle 1 is attached to a winch unit 27 by a lift cable 8 . The power unit 27 is shown attached to a top portion of the cover 3 connecting the mast guide brackets 26 and 30 . The winch unit 2 may be manual or preferably motorized as shown, whereby a motor 4 turns a gear drive 28 to roll up or unroll the lift cable 8 to raise or lower the cradle 1 , respectively. The motor 4 is operatively connected to the gear drive 28 by a large pulley 18 , v-belt 19 and small pulley 20 . The motor 4 would be connected to a power source by an AC power cord 15 .
[0025] FIG. 2 shows a top view of the PWC lift of the present invention with a PWC (in broken lines) in both a lowered lift position 38 and at a raised storage position 39 above a dock 21 . In the lowered lift position 38 , the PWC 22 rests on the cross rails 10 of the cradle support rails 9 of the cradle 1 . The cradle 1 would be lowered to the point where it would be just below the water so the PWC 22 could be driven onto the cross rails 10 , then raised and pivoted into a raised storage position 39 over a dock 21 . In the storage position 39 , a user would have easy access to the PWC 22 for mounting and dismounting during use or for cleaning and maintenance of the PWC.
[0026] As further shown in FIG. 2 , is the mast 2 is abuts a sliding block 24 in the top mast guide bracket 30 and a roller 23 in the lower mast guide bracket 26 (not shown in this FIG. 2 , but see FIG. 6 ). There is one or more top mast guide bracket retaining bolts 34 which further help retain the mast within the top mast bracket 30 . A lock pin 31 can be inserted through a hole in the top pivot bracket 12 a to maintain the lift in the raised or storage positions, 38 and 39 , respectively.
[0027] In FIG. 3 , the PWC lift of the present invention is shown in a side elevation view wherein the cradle 1 is in a raised position with the mast 2 at its highest point in which the cradle receiver 16 abuts the lower mast guide bracket 26 . The raising of the cradle 1 is accomplished by activating the motor 4 by switch or remote means resulting in turning the small pulley 12 , the belt 19 , the large pulley 18 and gear drive 27 which rolls up the lift cable 8 onto a spool 40 . Once the cradle 1 is in the elevated position, the cradle 1 may by pivoted by around a pivot pin 7 held within pivot brackets, 12 a and 12 b , until it is in the desired position.
[0028] FIG. 4 shows the PWC lift of the present invention from a frontal view when in a lowered position. This view shows the components of the PWC lift as previously discussed, including the cradle 1 , formed by cradle support rails 9 , cross rails 10 , with optimal bunk boards 17 , and guide pipes 11 all attached at the bottom of the mast 2 . A lift cable 8 connects the cradle 1 to a cable spool 40 within the power unit 27 . The power unit 27 is attached to the top front of the front cover 3 and the motor 4 is mounted on the top of the front cover 3 . The power unit 27 contains a gear shaft 32 with cable spool 40 . The gear shaft 32 operatively engages the large pulley 18 , connected by v-belt 19 to the small pulley 20 on the motor 4 .
[0029] FIGS. 5 and 6 , illustrate in more detail the components of the top and lower mast guide brackets 30 and 26 , respectively. The top mast guide bracket 30 shown in FIG. 5 contains a sliding block 24 mounted between the side 41 by a retaining pin 36 . Behind the mast 2 are one or more retaining bolts 34 which secure the top bracket 30 around the pivot pin 7 in the pivot head 14 .
[0030] In the lower mast guide bracket 26 shown in FIG. 6 , the mast 2 abuts a roller of 23 mounted on a retaining pin 37 between side walls 42 . A retaining bolt 35 in front of the mast 2 holds the front plate 3 to the side walls 42 . The side walls 42 are secured to the lower bracket 26 by the rolling retaining pin 37 which also secures the lower mast guide bracket 26 .
[0031] Finally, as shown in FIG. 6 , a more secure piling attachment method is used for the mounting bracket 14 . This method consists of placing the mounting bracket attachment bolts 13 a through the piling 6 at an angle crossing each other and securing them with bolts 13 b , rather than straight through the piling as in the prior art. This attachment method provides for a safer and stronger PWC lift.
[0032] It is to be understood that while a preferred embodiment of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and show. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not be considered limited to what is shown and described in the specification and drawings.
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The personal watercraft lift attachable to a mooring piling 6 for raising and lowering a watercraft from the water is disclosed. The lift has a cradle 1 attached to a mast 2 secured between two brackets 26 and 30 . A lift cable 8 attaches the cradle 1 to a power unit 27 with motor 4 . Optional guard pipes 11 on the cradle are provided. The lift pivots approximately 180° to enable easy accessibility to a PWC for mounting, demounting storage and maintenance.
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FIELD OF THE INVENTION
This invention relates to an improved printing process and printed products therefrom. More particularly, this invention relates to improving the printing characteristics of cellulosic materials and providing novel printed products exhibiting improved properties.
BACKGROUND OF THE INVENTION
In the development of the technology of printing, considerable effort has been devoted to methods for improving the characteristics of the substrate to be printed. There are two main factors to consider in the printing of papers by any printing process; these are "runnability" and "print quality". Runnability is defined as the ability to get the sheet through the press and is important because failures in runnability cause expensive downtime on the presses. The following sheet characteristics have been found to affect runnability:
(a) Flatness, freedom from buckles, puckers, wave, and curl;
(b) Trimming;
(c) Dirt;
(d) Moisture Content or pH;
(e) Adequate pick resistance;
(f) Adequate water resistance;
(g) Paper-ink relationship;
(h) Mechanical condition.
Print quality is the effect of the paper on the accurate reproduction of the image form to be printed. The significant paper properties effecting print quality are:
(a) Color;
(b) Brightness;
(c) Opacity;
(d) Smoothness;
(e) Gloss
(f) Refractiveness.
Of particular interest for letterpress printing are:
1. Smoothness
2. Levelness
3. Cushion
4. Ink Receptivity
To some degree, the runnability characteristics for gravure printing are considerably less stringent though the printing characteristics listed above continue to be significant.
Improvement in sheet characteristics allows greater variability in printing processes, in ink formulations, and may result in substantial improvement in image quality, economies in processing, or both. Essentially, in the case where printing is to be accomplished on a cellulosic sheet, a modification of the balance between the oleophilic and hydrophilic functionalities of the cellulose molecule has been found useful. Heretofore, improvements in sheet characteristics have been achieved through the use of additives or coatings in the manufacture of many printing or packaging grades of paper. Typical additives such as rosin, alum and the like or typical coatings such as those comprised of starch, clay, appropriate binders and brighteners, are often employed to assist printability and runnability of the substrate. These techniques are frequently costly and cumbersome and often fall wide of the mark of producing an ideal printing substrate.
For certain grades of substrates, in particular newsprint, present techniques of production and factors of the marketplace militate against the suitability of these techniques for modifying the sheet. Further, with respect to newsprint, efficiencies of operation have favored the use of web offset printing systems whose more stringent runnability requirements are barely met by newsprint as presently produced. Linting and inadequate water resistance can result in sheet breaks causing downtime and other problems of press operation.
Some producers of newsprint have installed twin-wire formers whose purpose is to produce a sheet with uniform wire and felt sides. These machine modifications are costly and involved and yet they may result in a sheet whose runnability, while improved, is far from ideal.
It is an object of the present invention to improve the printing characteristics of cellulosic substrates by a process which is eminently compatible with present manufacturing practices.
Another object of the invention is to provide a printing process of improved runnability and printing quality.
Yet another object of the invention is to provide printed products characterized by improved imaging, reduced strike-through, mottling and ink usage, faster drying and reduced linting.
SUMMARY OF THE INVENTION
These and other objects of the invention are obtained by, prior to printing onto at least one surface of a cellulosic substrate, forming a deposit of siloxane and polymers thereof on and integral with the surface onto which the printing is effected.
The improved articles of manufacture provided by the process of the invention comprise a cellulosic substrate having on and integral with at least one surface thereof a deposit of siloxane and polymers thereof and printing ink applied to the siloxane-containing surface of the cellulosic substrate.
It has been discovered that paper or other cellulosic substrates to be printed when treated so as to deposit on one of its surfaces a siloxane and/or copolymers of siloxane so as to be integral with said surface as by chemical bonding, have closer to ideal characteristics for runnability and printability. The deposition of siloxane and polysiloxanes by reactions with available hydroxyl groups in the cellulose and moisture that may be present converts these sites from hydrophilic to oleophilic centers. This enhances the pick-up of pigment and hence improves imaging. The reduction in surface tension provided by the treatment slows penetration by solvents used in printing inks and thus lessens strikethrough, mottling, reduces ink usage, allows faster drying, while providing slight enhancement of lubricity which reduces linting and downtime associated with linting. Water resistance provided by the treatment reduces breaks attributable to loss of strength as the sheet becomes moist in web offset printing. Inhibition of capillary action provided by the treatment results in clearer imaging.
Moreover, sheet smoothness is unaffected by the treatment and the combination of improvements described above may be said to have as ameliorative an effect as improvement in smoothness. Nonetheless, for many grades of paper, it may still be deemed desirable to coat the cellulosic substrate so as to improve brightness, gloss and smoothness prior to the silane treatment.
DETAILED DESCRIPTION OF THE INVENTION
The deposition of siloxane and polysiloxanes onto the cellulosic substrate can be effected in any manner that forms siloxane and polysiloxane chemically bonded to the surface of the cellulosic substrate. One method comprises treating the cellulosic substrate with siloxanes modified to contain substituents reactive with the hydroxy groups of the cellulosic substrate as, for example, carboxyl, amino, halo and like reactive groups. A preferred method involves treating the cellulosic substrate with vapors of lower alkyl silicon halide, for example, by using the process described in U.S. Pat. No. 3,856,558 and U.S. Pat. No. 4,399,479 both of which are hereby incorporated by reference. This preferred method will be described in more detail below.
According to processes of the aforementioned patents, cellulosic materials having a moisture content of below 10% by weight, preferably below 7% by weight are contacted with the organosilicon halide. Cellulose materials having moisture contents in excess of 7% may be heated to remove surface moisture. Alternatively, such materials may first be frozen in accordance with the teachings of U.S. Pat. No. 4,339,479. A moisture content of up to about 7 weight percent in the cellulosic material is preferred in those instances wherein the cellulosic material is not contacted in its cold or frozen state.
The contact time of the cellulosic material and the organosilicon halide is in all cases sufficient to effect siloxane formation and will vary depending upon the temperature of the cellulosic material and organosilicon halide vapor, the concentration of the organosilicon halide in the contacting atmosphere, the pressure within the reaction zone and the moisture content of the cellulosic material. Contact times ranging from 0.1 second up to 2 seconds have been utilized successfully.
The temperature of the organosilicon halide is sufficiently high to effect reaction between the organosilicon halide and hydroxyl groups of the cellulosic material and any water present to form siloxane and/or polysiloxane within the claimed contact time but not so high as to degrade the cellulose at the contact time employed. Suitable temperatures range from 50° F., to about 200° F.
Generally, when employing higher temperatures, shorter contact times are employed and conversely, when employing relatively low temperatures, longer contact times can be employed. Furthermore, the concentration of the organosilicon halide in the atmosphere through which the cellulosic material is passed can be varied up to the saturation level of the atmosphere for the organosilicon halide and, if employed, a solvent for the organosilicon halide. The concentration of the organosilicon halide can range up to the saturation level of the atmosphere but should not be so low as to require excessive contact times in order to effect the desired reaction and to render the cellulosic material water-repellent. Typically, the concentration of the organosilicon halide ranges from about 2% volume percent up to the saturation level of the atmosphere within the reaction zone.
The reaction zone is normally maintained under a slight negative pressure during the treating operation but the pressure therein can vary widely say from as low as 1 Torr up to about 760 Torr.
When a cellulosic material having a moisture content of below 2 weight percent is employed pursuant to one aspect of the present invention the contact time must be increased and the variables of organosilicon halide vapor temperature, concentration, and the contact chamber pressure are maintained so that the final pH of the cellulosic material rendered water-repellent does not fall below 2.5 and preferably not below 3.5. The range of conditions which will ordinarily be employed will fall in the following ranges:
Temperature of organosilicon halide: 50° F. to 200° F.
Temperature of cellulosic material: frozen to 200° F.
Concentration of organosilicon halide: 2% to saturation
Again, within the ranges set forth conditions are selected and maintained so that the final pH of the cellulosic material does not fall below 2.5.
The suitable organosilicon halides useful in this process are those commonly employed in water repellency treatments for cellulosic materials, such as those described by Patnode in U.S. Pat. No. 2,306,222, Norton, U.S. Pat. No. 2,412,470, and in my earlier U.S. Pat. Nos. 2,782,090, 2,824,778 and 2,961,338 which are incorporated herein by reference. Particularly suitable organosilicon halides are the lower alkyl silicon halides such as methylchlorosilanes, ethylchlorosilanes, butylchlorosilanes and propylchlorosilanes.
Typically, however, the silicon halides will be a mixture of dimethyldichlorosilane, (CH 3 ) 2 SiCl 2 ; methyldichlorosilane, CH 3 SiHCl 2 ' and methyltrichlorosilane, CH 3 SiCl 3 which may contain silicon tetrachloride, SiCl 4 . The cellulosic material may be contacted with the vaporized organosilicon halide alone or together with a vaporized solvent for the organosilicon halide which solvent is inert both to the organosilicon halide and the paper being treated. It has been found that the presence of the solvent during the treatment step results in the formation of a treated cellulosic material having a higher pH as compared with a cellulosic material which is treated with the same organosilicon halide without the solvent under equivalent reaction conditions. Representative suitable solvents include toluene, xylene, hexane, perchloroethylene, fluorinated hydrocarbons, or other non-reactive solvents in which the organosilicon halide may be dissolved. It has been found that as little as 10 mole percent solvent is effective but that larger concentrations of the solvents in the range of about 12 to 100 mole percent based upon the total mole of the organosilicon halide and solvent are preferred. A molar quantity ten times or more that of the organosilicon halide is effective. If desired, higher concentrations of the solvent can be employed. However, the presence of excessive concentrations of solvent effects a reduction of reaction rate and increases the expense of the solvent without a significant beneficial effect.
The organosilicon halide or the mixtures of vapors or organosilicon halide in solvent may be formed by bubbling air through the liquid organosilicon halide or an admixture of the halide and solvent or more simply by dropping the liquid of the desired composition slowly onto a hot plate to generate vapors of the same molar composition as the liquid. Alternatively, an aerosol mixture may be employed as described in my U.S. Pat. No. 2,824,778 which is incorporated herein by reference. When employing a solvent having a significantly different vapor pressure than the organosilicon halide and when effecting vaporization by bubbling air, it is preferred that the solvent and organosilicon halide be maintained as separate liquids in order to better control the composition of the vapors formed in the treating chamber.
The air to be mixed with the organosilicon halide in the treatment step should contain as little water as possible to avoid significant reaction of water in the air with the organosilicon halide which results in the formation of hydrogen halide and reduction of the amount of organosilicon halide that can react with the cellulosic material.
In instances where the moisture content of the cellulosic material to be treated is greater than about 10 weight percent, it may be desirable to subject the cellulosic material to a drying step prior to the treatment with organosilicon halide. The drying step need only be conducted at a temperature and a time sufficient to remove part of the surface moisture from the material while retaining at least about 2 weight percent moisture in the material. Heating to about 250° F. for from about 3 to 5 seconds is sufficient in most cases. The desirability or necessity of this step will depend upon such factors as the prevailing humidity on the day of treatment, the uptake of moisture by the material during manufacture and storage and the conditions of treatment. If desired, the cellulosic material treated with organosilicon halide, either in the presence of or in the absence of a solvent, is further treated, upon removal from the organosilicon halide treating step, to remove hydrogen halide gas formed as by product of the reaction prior to a substantial portion of it becoming dissolved by moisture in the cellulosic material. Generally, the hydrogen halide gas removal can be effected by heating the cellulosic material, by applying suction to the cellulosic material or by passing the treated cellulosic material into contact with a moving stream of air.
The present invention is applicable to a cellulosic substrate such as substrates of paper, wallboard, wood, textiles and the like and includes all printing processes whereby printed matter is printed onto one or all surfaces of such substrates. Included are such printing processes as letterpress, offset lithography, gravure, web offset press and screen printing.
The inks or pigments used to print the printed matter images onto the treated surface of the cellulosic substrate can be any of the well known printing inks or pigments used on printing processes. Illustrative of such printing inks are the solvent-type inks, oleoresinous type inks, heat-set inks, steam set inks, newsprint inks, etc.
As aforementioned, the present invention contemplates coating the cellulosic substrate with conventional coating materials to improve smoothness, brightness, gloss, etc., prior to the silane treatment. Such coating materials are well known to those skilled in the art and include, for example, alum, clay, starch, resinous binders, etc.
The following examples are given to illustrate the invention and are in no way to be considered as limiting same.
EXAMPLE I
A sheet of newsprint having a basis weight of 30 lbs. and a moisture content of 4% by weight is exposed to vapors of methyltrichlorosilanes at room temperature and atmospheric pressure for 0.5 second. The sheet is subsequently heated for 10 seconds in an oven set at 300° F. to remove any residual HCl produced in the reaction. The sheet is then printed by web offset press using inks formulated for newspaper production. The sheet is found to have reduced linting, mottling, and strikethrough and better imaging.
In the preferred embodiment of the invention the paper would be treated continuously in a converting operation or at the point of manufacture, using an apparatus similar to that described in pending U.S. application Ser. No. 445,011 to Edward Robbart, filed Nov. 29, 1982, hereby incorporated by reference.
EXAMPLE II
A roll of groundwood paper having a basis weight of 16 lbs. and a moisture content of 5% by weight is exposed as described in Example I to vapors of methyltrichlorosilanes for 0.1 second and subsequently freed of residual HCl by suction. The roll is then sent through a gravure printing press at customary speeds using customary inks. The sheet prints well with reduction of strike-through so that the lighter basis weight is now comparable to a 24 lb. groundwood sheet.
EXAMPLE III
A roll of clay-coated bleached board having a moisture content of 6% by weight is sent through an apparatus similar to that described in pending U.S. application Ser. No. 445,011 and exposed to a mixture of silane vapors comprising by weight 10% methyldichlorosilanes and 90% methyltrichlorosilanes at room temperature and atmospheric pressure for 0.5 second. The roll is subsequently printed by letterpress. The ink pigment bonds better to the surface resulting in improved receptivity and reduced scuffing. The solvent in the ink is held out resulting in faster drying and greater efficiency of operation.
As the above examples illustrate, the present invention is suitable for a variety of printing techniques and paper grades. The concentration and formulation of the silanes and other conditions of treatment may be varied in accordance with the substrate and the properties desired.
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Modified reactive siloxanes are chemically bonded directly to the surface of a cellulosic substrate to form an oleophilic layer of siloxane on the cellulosic substrate and a conventional ink impregnates the oleophilic siloxane to effect printing thereon.
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BACKGROUND
[0001] Nitric oxide (NO) is used in numerous commercial and industrial applications. As a raw material it is used in the semiconductor industry for surface oxidation processes. As a synthesis gas, NO is used in the preparation of nitric acid, hydroxylamine, nitrosyl chloride, metal nitrosyls, and caprolactam, which is used in the synthesis of nylon. Nitric oxide is also used commercially as a polymerization inhibitor during the preparation of olefins and to modify the properties of various polymers.
[0002] Several processes have been developed for the preparation of nitric oxide. Commercially, NO is produced by the Ostwald process in which ammonia is oxidized at temperatures near 800° C. in the presence of a platinum group catalyst. Nitric oxide can also be produced from the reaction of nitric acid and copper or the reaction of sodium nitrate and sulfuric acid. These methods are not convenient for small scale NO production due to the power requirements for heating the reaction mixtures to several hundred degrees Celsius and the hazards inherent in handling strong acids. Several processes have been proposed for bench-scale production of nitric oxide for on-site use in laboratories, production facilities and medical facilities. Attention is directed to U.S. Pat. Nos. 3,853,790; 3,948,610; 4,272,336; 4,774,069; 4,812,300; 5,396,882; 5,478,549; 5,670,127; 5,683,668; 5,692,495; 5,827,420; 6,103,275; 6,534,029; 6,743,404; 6,758,214; 7,025,869; 7,040,313 and 7,048,951. Each of these methods has disadvantages relative to the photolysis of nitrous oxide (N 2 O). For example, some require toxic starting materials or produce toxic byproducts such as nitrogen dioxide (NO 2 ), while others require high temperatures, high voltages or use of strong acids.
[0003] In the analysis of air and other gases for nitric oxide, it is necessary to calibrate the analytical instrument using a gas standard having a known concentration of NO. The most common method used for NO detection is based on chemiluminescence in the reaction of NO with an excess of ozone. The method, which is widely used for air pollution monitoring, for measurements of NO in automobile exhaust and for measurements of NO in exhaled breath, requires frequent calibration with a standard gas mixture. Nitric oxide measurements based on electrochemical techniques, chemiluminescence with luminol and other methods require calibration using a gas standard as well.
[0004] A well known problem with NO gas standards is that NO is unstable in gas cylinders at low concentrations; when NO standards are prepared at part-per-billion by volume (ppbv) levels there is a strong tendency for the concentration of NO in the cylinder to decline with time even though the NO is diluted into an unreactive gas such as nitrogen. One reason for this is that NO is thermodynamically unstable with respect to disproportionation to form N 2 O and NO 2 according to the equilibrium:
[0000] 3NO=N 2 O+NO 2 (3)
[0000] Although extremely slow in the gas phase, this reaction may be catalyzed on the interior walls of compressed gas cylinders. The walls may be treated in various ways to slow the reaction, but the treatment is not always effective, and one cannot be certain that the concentration of NO in a gas cylinder is what it was when the cylinder was first filled. Furthermore, even trace amounts of oxygen (O 2 ) in the diluent gas can react to oxidize NO to NO 2 according to the well known reaction:
[0000] 2NO+O 2 →2NO 2 (4)
[0000] Also, because of reaction 4, NO compressed gas standards cannot be made with air as the diluent. This is a disadvantage since it is desirable to calibrate an NO instrument using the same diluent gas as the gas being analyzed, which is most commonly air.
[0005] Nitric oxide standards are much more stable at high concentrations of NO; thus, it is common to prepare gas standards at the high ppmv level in an unreactive gas such as N 2 to make a compressed gas standard and then dynamically dilute that standard with N 2 or air prior to entering the analytical instrument being calibrated. Although the dynamic dilution method works well for calibration, flow meters are required, and the flow meters must be accurately calibrated, thus adding to the complexity, expense and uncertainty of the calibration procedure.
[0006] Nitric oxide has several medical applications. Blood vessels use nitric oxide to signal the surrounding smooth muscle to relax, thus dilating the artery and increasing blood flow. This underlies the action of nitroglycerin, amyl nitrate and other nitrate derivatives in the treatment of heart disease; the compounds undergo reactions that release nitric oxide, which in turn dilates the blood vessels around the heart, thereby increasing its blood supply.
[0007] Some disorders or physiological conditions can be mediated by inhalation of nitric oxide. Dilation of pulmonary vessels in the lungs due to inhaled NO causes pulmonary gas exchange to be improved and pulmonary blood flow to be increased. The administration of low concentrations of inhaled nitric oxide can prevent, reverse, or limit the progression of disorders such as acute pulmonary vasoconstriction, adult respiratory distress syndrome, acute pulmonary edema, acute mountain sickness, post cardiac surgery acute pulmonary hypertension, persistent pulmonary hypertension in a newborn, perinatal aspiration syndrome, and asthma. For inhalation therapy, it is important that the NO gas mixture be free of the toxic gas NO 2 which can form inside compressed gas cylinders.
[0008] The present invention provides a simple method for the production of nitric oxide from a non-hazardous, gas-phase precursor. Without the need for high temperatures, strong acids, and aqueous solution, the invention allows NO to be produced from a small apparatus for portable, on-site use. The concentration of NO produced can be accurately controlled, thereby making the NO source highly useful as a calibration device for analytical instruments that measure nitric oxide in gases.
[0009] The foregoing example of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
[0010] One aspect of this invention is a means to produce NO by exposing N 2 O to ultraviolet light.
[0011] Another aspect of the invention is to dilute NO produced by exposure of N 2 O to UV light into air, oxygen or a gas mixture for the purpose of inhalation therapy. For example, the NO/gas mixture could be administered to newborn babies, especially those born prematurely.
[0012] Another aspect of the invention is to dilute NO produced by exposure of N 2 O to UV light with air, nitrogen or another gas for calibration of analytical instruments that measure NO such as nitric oxide monitors used to measure NO in ambient air, automotive exhaust and analyzers that measure NO in exhaled breath.
[0013] Another aspect of this invention is to control the concentration or mixing ratio of NO produced by controlling the UV light intensity, pressure, temperature, N 2 O flow rate and/or diluent gas flow rate, with particular attention given to control of the UV light intensity.
[0014] Another aspect of this invention is to produce concentrations of gases other than NO at controlled levels by using different reagent gas sources.
[0015] Disclosed herein is a method for producing nitric oxide by exposing nitrous oxide (N 2 O) to ultraviolet light in a controlled environment. This method has advantages over other methods of producing NO. For example, only one chemical reagent (N 2 O) is required, and this reagent is relatively non toxic (used at mixing ratios of up to 50% in air as an anesthetic) and commercially available in small cartridges as a consumer product for making whipped cream. The only significant byproducts produced are nitrogen and oxygen, the major components of air. For applications where it is desirable or necessary to remove the unreacted N 2 O, methods for the catalytic decomposition of N 2 O into N 2 and O 2 have been developed. In this regard, reference is made to U.S. Pat. Nos. 5,314,673; 6,347,627; 6,429,168 and 6,743,404. The simplicity of the method described here provides for a compact, low power, portable NO source in which the concentration of NO produced is easily controlled.
[0016] The same apparatus designed for producing calibrated concentrations of NO in a diluent gas by photolysis of N 2 O may, with either no or only minor modifications, be used to produce calibrated concentrations of other gases as well. For example, if N 2 O is replaced with carbon dioxide (CO 2 ), the same apparatus may be used to produce controlled concentrations of carbon monoxide (CO). If N 2 O is replaced with SF 6 , calibrated concentrations of molecular fluorine (F 2 ) in a diluent gas can be produced. In fact, concentrations of many different gases may be produced by proper choice of the reagent gas.
[0017] These and other features and advantages of the disclosed method with the chosen components and the combination thereof, the mode and operation and use, as well become apparent from the following description, reference being made to the accompanying drawings that form a part of this specification wherein like reference characters designate corresponding parts in several views. The embodiments and features thereof are described and illustrated in conjunction with systems, tools and methods which are meant to exemplify and to illustrate, not being limiting in scope.
[0018] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tool and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic diagram of an apparatus used to produce NO by photolyzing N 2 O.
[0020] FIG. 2 is a schematic diagram of an apparatus used to produce a variable concentration of NO in a flowing gas stream.
[0021] FIG. 3 is a chart of data showing the measured concentrations of NO produced using the apparatus of FIG. 1 .
[0022] Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. Also, the terminology used herein is for the purpose of description and not of limitation.
DETAILED DESCRIPTION
[0023] In this method N 2 O is photolyzed in the absence of ambient air to produce electronically excited oxygen atoms, which then react with N 2 O to produce NO as follows:
[0000] N 2 O+ hv →N 2 +O( 1 D 2 ) (1)
[0000] O( 1 D 2 )+N 2 O→N 2 +O 2 (2)
[0000] Net: 2N 2 O→2N 2 +O 2 (3)
[0000] and
[0000] N 2 O+ hv →N 2 +O( 1 D 2 ) (4)
[0000] O( 1 D 2 )+N 2 O→2NO (5)
[0000] Net: 2N 2 O→2NO+N 2 (6)
[0000] Here, O( 1 D 2 ) is an electronically excited state of the oxygen atom. N 2 O has a broad absorption band in the wavelength region 160-260 nm, and the quantum yield for reaction 1 is unity at wavelengths shorter than the thermodynamic limit of 230 nm (NASA, 2006). It is believed that the most efficient wavelengths for the conversion are between 170 to 190 nm, inclusive. In pure N 2 O, O( 1 D 2 ) reacts with N 2 O to form two sets of products, either N 2 +O 2 (reaction 3) or 2NO (reaction 5). The two sets of products are produced with yields of 41% and 59%, at 298 K, respectively based on the measured rate coefficients for reactions 3 and 5 (NASA, 2006).
[0024] Another possible fate of the O( 1 D 2 ) atom produced in reaction 1 is deactivation to the ground state according to the following reaction:
[0000] O( 1 D 2 )+M→O+M (7)
[0000] Here, M is any molecule or atom, principally N 2 O. In reaction 7, a ground state oxygen atom is formed. It has been reported that less than 4% of O( 1 D 2 ) produced in the presence of N 2 O is collisionally deactivated to ground state atoms (Wine and Ravishankara, 1982). To the extent that it is formed, the primary fate of this O atom is recombination to form molecular oxygen:
[0000] O+O+M→O 2 +M (8)
[0000] Again, M is any molecule or atom, principally N 2 O.
[0025] The only byproducts produced in reactions 1-8 are N 2 and O 2 , the principal components of air. Significantly, the reaction system does not directly produce the toxic gas nitrogen dioxide (NO 2 ). Potentially, nitrogen dioxide could be produced in the secondary reaction
[0000] 2NO+O 2 →NO 2 (9)
[0000] where the O 2 is derived from reaction 2 and to a much smaller extent from reaction 8. However, reaction 9 has a small rate coefficient and is second order in NO concentration, with the result that reaction conditions can be chosen where the concentration of NO 2 produced is insignificant. As an example, in inhalation therapy the concentration of NO administered is typically in the range 20-100 part per million (ppmv). In order to produce 100 ppmv NO in air with a 1% dilution of the N 2 O/NO source gas into air, the concentration of NO in the N 2 O source gas would need to be 10,000 ppmv. The corresponding amount of oxygen produced in reaction 2 would be 3,500 ppmv. Using the rate coefficient of 1.9 e −38 cm 6 molec −2 S −2 at 298 K for reaction 9 (NBS, 1977), the half life for reaction of 10,000 ppmv NO in the presence of 3,500 ppmv O 2 is calculated to be 0.7 hours, and for a 10 second residence time in the photolysis chamber the NO 2 concentration produced is 40 ppmv, which after diluted into air is 0.4 ppmv. By comparison, the U.S. Occupational Safety and Health Administration permissible exposure limit (PEL) to NO 2 is 5 ppmv and 8 hour time weighted average (TWA) is 3 ppmv.
[0026] Referring first to FIG. 1 , a reaction chamber 1 contains N 2 O gas or liquid. The reaction chamber 1 has been purged of substantially all of the ambient air by the N 2 O flowing into the chamber prior to the start of the reaction. Light from a UV lamp 3 passes through a window 2 into the test chamber. Reaction chamber 1 optionally has an inlet 4 for admitting the N 2 O gas or liquid and an exit 5 for removing reaction products and unreacted N 2 O gas or liquid. When the lamp is turned on, the NO concentration begins to increase inside the reaction chamber. The rate at which NO is produced increases with the density of N 2 O in the chamber and the UV light intensity. Optionally, lamp 3 may be placed inside reaction chamber 1 , in which case window 2 is not required. It is understood that the reaction chamber itself is not required to produce NO provided that the lamp is surrounded by N 2 O gas or liquid.
[0027] Referring next to FIG. 2 , a schematic diagram is provided of an actual apparatus used to produce and control the concentration of NO in a flowing stream of air. Nitrous oxide gas contained in N 2 O cartridge 6 passes through pressure regulator 7 , through connecting tube 8 , through flow controller 9 , through connecting tube 10 , through flow meter 11 , through connecting tube 12 , and into reaction chamber 13 . Ultraviolet light from UV lamp 14 causes NO to be formed inside chamber 13 . UV light from lamp 14 is monitored by photodiode 15 . In the depicted embodiment, a low pressure mercury lamp, which has a weak emission near 185 nm in addition to its principal emission at 254 nm, is used. The radiation at 185 nm, where the N 2 O absorption cross section is high, is responsible for the production of NO. Other types of UV emitting lamps could be used as well, including a high pressure mercury lamp, xenon arc lamp, hydrogen lamp, deuterium lamp and other known or later developed UV emitting sources. A feedback loop in which the voltage to the UV lamp is pulse width modulated is used to maintain a constant signal at photodiode 15 so that NO is produced at a constant rate.
[0028] Unreacted N 2 O, NO and other reaction products flow out of reaction chamber 13 , into connecting tube 16 , and are mixed with a flow of NO-scrubbed air in tube 25 . The NO/air mixture, having a substantially constant NO concentration, exits tube 25 and may be sampled by a NO measurement device for the purpose of calibration. The NO-scrubbed air is produced by drawing in ambient air by air pump 18 through inlet 17 . The air then passes through connecting tube 19 , through NO scrubber 20 , through connecting tube 21 , through flow controller 22 , through connecting tube 23 , through flow meter 24 and into tube 25 . For a fixed lamp intensity, the mixing ratio of NO exiting tube 25 may be varied by varying the diluent air flow rate using flow controller 22 . Because the absorption of UV light is nearly optically thick (nearly every photon of sufficient energy to cause photolysis is absorbed by N 2 O), the output mixing ratio of NO is nearly insensitive to the flow rate of N 2 O.
[0029] The apparatus of FIG. 2 may be used to produce controlled mixing ratios of other gases in a dilute gas as well. For example, if the N 2 O cartridge of FIG. 2 is replaced by a CO 2 cartridge or other source of CO 2 , carbon monoxide and molecular oxygen may be produced by the following mechanism:
[0000] 2×(CO 2 +hv →CO+O) (10)
[0000] O+O+M→O 2 +M (11)
[0000] Net: 2CO 2 +2 hv→ 2CO+O 2
[0000] Thus, the photolysis reaction can be used to produce a controlled concentration of CO and O 2 . Again, the CO 2 flowing into the reaction chamber 1 purges the reaction chamber of substantially all of the ambient air. Although a low pressure mercury lamp can be used to produce low concentrations of CO according to this mechanism, a preferred lamp would be a hydrogen or deuterium lamp, because the lamp emission spectrum better overlaps that of the CO 2 absorption spectrum.
[0030] Similarly, if the N 2 O source is replaced with a source of sulfur hexafluoride (SF 6 ), then a controlled concentration of SF 4 and F 2 could be produced according to the sequence of reactions:
[0000] SF 6 +hv →SF 5 +F (12)
[0000] SF 5 +F→SF 4 +F 2 (13)
[0000] Net: 2SF 6 →2SF 4 +F 2
[0000] Many other reagents can be photolyzed with ultraviolet light. In many of these, the presence of ambient air will cause the photolysis to produce a gas product or products such as ozone. However, if the photolysis in done in the absence of ambient air, a different, and possibly more desirable gas product will be formed. As would be known by the practitioner of the art, a number of gases could be used to produce either the gas products discussed above, or other reaction products, the key being that the concentration of the gas product is controlled by a combination of lamp intensity, flow rate of gas through the photolysis chamber and flow rate of diluent gas. The apparatus of FIG. 2 can thus be used to produce controlled concentrations of specific gases for many applications including calibration of analytical instruments.
Example 1
[0031] Referring next to FIG. 3 , experimental results are shown for production of NO at different mixing ratios using an apparatus described by the schematic diagram of FIG. 2 . The vertical axis is the mixing ratio of NO in parts-per-billion by volume (ppbv) measured using a 2B Technologies Model 400 Nitric Oxide Monitor™. The horizontal axis is time in minutes. The N 2 O volumetric flow rate is 18 cc/min, the air volumetric flow rate is 940 cc/min, the temperature of the reaction chamber is thermostated at 37° C., and the pressure in the reaction chamber is 848 mbar. The UV lamp used was a low pressure mercury lamp with greater than 95% of the surface of the lamp painted to be opaque. The average intensity of the lamp was varied by pulse width modulation to produce NO concentrations in the range 0-270 ppbv as summarized in Table 1.
[0000]
TABLE 1
Region
% Pulse
Average Measured NO
of
Width
Mixing Ratio ± Standard
FIG. 3
Time Interval
Modulation
Error of the Mean, ppbv
26
0.0-11.2
0.0
0.2 ± 0.9
27
11.8-25.0
3.2
50.7 ± 0.7
28
25.7-39.8
6.4
102.3 ± 0.6
29
41.3-54.7
9.6
156.3 ± 0.8
30
55.8-69.8
12.8
209.1 ± 0.5
31
71.2-85.0
16.0
269.1 ± 0.7
32
86.2-99.8
12.8
209.5 ± 0.6
33
101.0-115.0
9.6
156.7 ± 0.6
34
116.2-129.5
6.4
103.6 ± 0.5
35
131.3-151.5
0.0
−0.1 ± 0.4
Example 2
[0032] In a second example, the apparatus of FIG. 2 was used to generate different concentrations of CO in air by using CO 2 as the reagent gas and varying the UV lamp intensity. In this example, the N 2 O cartridge 6 of FIG. 2 was replaced with a CO, cartridge, and the NO scrubber was replaced with a hopcalite scrubber to remove CO. The low pressure mercury lamp was replaced with an unpainted mercury lamp because the extinction coefficient for absorption of the 185 nm emission line of mercury is approximately 400 times less for CO 2 as compared to N 2 O. Also, the volume of the reaction chamber was increased from 4.1 cm 3 to 118.4 cm 3 . A flow of 72-83 cm 3 /min of CO 2 passed through the reaction chamber 13 and mixed with a flow rate of approximately 1 liter/minute of air. The output of the apparatus was analyzed for CO by use of a Thermo Electron Corporation Model 48i CO Gas Analyzer. The results are given in Table 2, which shows that CO is produced in the apparatus and that the concentration produced can be varied by varying the lamp intensity.
[0000]
TABLE 2
CO 2
Lamp
Measured CO
Flow Rate
Duty
Lamp Intensity
Concentration,
Run
cm 3 /min
Cycle, %
Arbitrary Units
ppbv
1
72
30
4280
209
2
74
30
4280
200
3
74
30
4280
199
4
77
30
4280
210
Average:
74
30
4280
205
1
81
49
6400
285
2
79
49
6400
295
Average:
80
49
6400
290
1
79
78
8230
400
2
87
72
8230
395
Average:
83
75
8230
398
[0033] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations therefore. It is therefore intended that the following appended claims hereinafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations are within their true spirit and scope. Each apparatus embodiment described herein has numerous equivalents.
CITED LITERATURE
[0000]
NASA (2006) Chemical Kinetics and Photochemical Data for Use in Stratospheric Modeling, Evaluation Number 15, JPL Publication 06-2.
Wine, P. H. and A. R. Ravishankara (1982) Chemical Physics 69, 365-373.
NBS (1977) NBS Special Publication 513, Reaction Rate and Photochemical Data for Atmospheric Chemistry, 1977.
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The present invention provides a means of producing nitric oxide (NO) by photolysis of nitrous oxide (N 2 O) at ultraviolet wavelengths. One application is the production of a known concentration of NO in a diluent gas for calibration of analytical instruments that measure nitric oxide in gases such as exhaled breath, ambient air and automobile exhaust. A potentially important medical application is the production of NO for inhalation therapy, an advantage being that very little toxic NO 2 gas is produced. The method is useful for producing NO for industrial applications as well. Advantages of this method of NO production include the use of a single, inexpensive, readily available reagent gas of very low toxicity. Furthermore, the concentration of NO produced can be easily controlled by varying the ultraviolet (UV) lamp intensity and relative gas flow rates. The method may also be applied to the production of controlled concentrations of other gases as well such as CO and F 2 by using reagent gases other than N 2 O.
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