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BACKGROUND OF THE INVENTION
(a) The Field of the Invention
The present invention relates to modacrylic fibers, viz, to fibers constituted by copolymers of acrylonitrile with other comonomers copolymerizable therewith, and wherein acrylonitrile is present in amounts from 50% to 85% inclusive, which possess reduced inflammability and high luster, and to compositions and processes for their manufacture.
The modacrylic fibers to which the invention refers are prepared by copolymerization of acrylonitrile with the other monomers in an organic spinning solvent miscible with water, particularly dimethylformamide (DMF), but possibly other solvents as well, such as dimethylacetamide, dimethylsulphoxide, etc., to form a viscous spinning dope, and subsequent extrusion of the spinning dope into a coagulation bath constituted by water mixed with the spinning solvent.
(b) The Prior Art
It is known to make modacrylic fibers having reduced inflammability by copolimerizing acrylonitrile with vinylidene chloride, and in order to confer to the copolymer the desired dyeing properties, a further comonomer containing at least one sulphonic group is used, the whole according to suitable weight ratios. According to the known ternary copolymerization technique, the sulphonic groups containing comonomer is normally constituted by the sodium salt of allyl- or methallyl- or vinyl- or styrene-sulphonic acid.
It is also known to prepare a copolymer of the said type or more exactly a mixture of copolymers, instead of by direct copolymerization of the three comonomers (acrylonitrile, vinylidene chloride, sulphonated monomer) by a two-phase copolymerization process, comprising e.g. firstly the preparation of a binary acrylonitrile/sulphonated monomer copolymer, then the addition of said binary copolymer to a solution of acrylonitrile and vinylidene monomers in DMF or other solvent, and the copolymerization of the two latter monomers in the presence of the preformed copolymer; the resulting viscous solution being subsequently spun, e.g., in the wet in an aqueous coagulating bath.
In all such process the problem of obtaining a glossy or lustrous fiber arises. To this end it has been proposed (DOS No. 2624081) to add, in a two-phase polymerization process as hereinbefore described, substantial amounts of water (up to 10%--anyway not less than 4-5%) to the spinning dope.
SUMMARY OF THE INVENTION
Now the Applicant has surprisingly found that if in a copolymerization process for the preparation of copolymers and copolymer mixtures, of the type described, an unsaturated monomer containing at least a sulphonic group is used which will be defined as "significantly homopolymerizable"--viz. which homopolymerizes, in the presence of 2.10 -3 mols per liter of AIBN (azobisisobutyronitrile), at a concentration of 2.10 -1 mols per liter in DMF which contains 6 mols per liter of water, at a temperature of 67° C., with a conversion above 30-40% after 11 hours--the water content of the spinning dope can be eliminated or at least substantially reduced, and yet a lustrous fiber is still obtained. Said sulphonated monomers must be sufficiently soluble in the copolymerization mixture and in the solvent to allow carrying out a continuous copolymerization process in organic solvent in homogeneous phase. This constitutes an important progress because the addition of water involves complications in the process and increased costs, and, owing to the coagulating properties of water, it endangers the stability of the solution.
The preferred significantly homopolymerizable monomers are the derivatives (especially the alkali and ammonium salts) of the acids having the general formula: ##STR1## wherein R 1 is a hydrogen atom or a short chain alkyl radical, and R 2 ,R 3 ,R 4 ,R 5 ,R 6 , equal to or different from one another, are each a hydrogen atom or an alkyl, cycloalkyl or aryl radical, e.g. of acrylamido-alkanesulphonic acids, among which derivatives, 2-acrylamido-2-methyl-propane-sodium sulphonate which has a homopolymerization capacity, evaluated as set forth hereinbefore, above 50% compared with 4% in the case, e.g., of sodium allylsulphonate, and other which will be mentioned. Said sulphonated monomers, further, exhibit a very high rate of utilization in the copolymerization, e.g. above 90%. "Rate of utilization" means herein the percentage of monomer which becomes a part of the copolymer molecule.
An object of the present invention is therefore textile fibers having reduced inflammability and high glossiness, constituted by copolymers of acrylonitrile, vinylidene chloride, and a significantly homopolymerizable sulphonic comonomer, containing from 50% to 85% by weight of acrylonitrile units, from 13.5% to 46.5% by weight of vinylidene chloride units, and form 1.5% to 3.5% by weight of sulphonated comonomer units, as well as the process for their preparation. A further object of the invention are the compositions of matter constituted by the spinnable viscous solutions containing the said copolymers or copolymer mixtures and containing less than 4% by weight of water, from which compositions the fiber is obtained, as well as the process for their preparation which comprises the steps of copolymerizing, in a first phase, acrylonitrile with at least one significantly homopolymerizable sulphonic monomer, in a first solution in an organic spinning solvent miscible with water, in particular DMF, adding the solution resulting from said first copolymerization phase, which contains the binary copolymer formed as well as unreacted monomers dissolved in said solvent, to a second solution of acrylonitrile and vinylidene chloride (and possibly other comonomers) in the same solvent and subjecting the resulting mixture to a second copolymerization phase.
The proportions expressed as weight percentages employed in the process are as follows.
For the first copolymerization, the overall percentage of the monomers is comprised between 25% and 35% referred to the total weight of the first solution; and the sulphonated monomer constitutes between 8% and 30% by weight of the sum of the two comonomers.
The second solution has an overall weight concentration of acrylonitrile and vinylidene chloride comprised between 40% and 50% of the total, the acrylonitrile constituting between 35% and 85% of the total of the two monomers. The mixed solution comprises between 5 and 40 parts by weight of the solution resulting from the first copolymerization and between 60 and 95 parts by weight of the second solution.
The second copolymerization phase is started immediately upon termination of the first phase and after completely mixing the solution obtained from the first copolymerization with the second solution, in the appropriate ratios.
Otherwise the polymerization technique is the known one. In particular, the catalysts used are preferably chosen among the azo derivatives, in particular azobisisobutyronitrile; the temperatures are between 50° and 70° C. for the first copolymerization phase and between 40° and 60° C. for the second; the durations are respectively comprised between 8 and 12 hours for the first phase and between 10 and 15 for the second. The exact composition of the final viscous solution which results from the second copolymerization phase and which is then used in the spinning, is not precisely known. It is likely that the solution contains both binary copolymers and ternary copolymers and graft copolymers deriving from the copolymerization of the acrylonitrile and vinylidene chloride monomers in the presence of a preformed binary copolymer. The Applicant does not wish to be limited by any interpretation of the exact structure of the spinning dope, which anyway is not relevant to the ends of the invention.
Obviously a plurality of sulphonic derivatives could be used instead of one, all belonging to the class hereinbefore defined, and what has been said with reference to the sulphonic derivative would apply to the sum of the sulphonic derivatives. Further comonomers, such as acrylic esters or other unsaturated compounds, could be present. The results obtained through the invention, and in particular the surprising progress from the viewpoint both of the characteristics of the fiber and of the utilization rate of the sulphonated comonomer in the copolymerization, with respect to what was already known and obtainable by using the sulphonated comonomers heretofore used for this type of production, and the fact that glossy yarns are obtained from dopes which are free of, or contain small amounts of water, are quite surprising.
Investigations which have been carried out suggest that significantly homopolymerizable monomers form homopolymeric segments in the copolymer chain, which other sulphonic monomers do not. Such segments are believed to facilitate the elimination of the spinning solvent from the coagulated bodies and to confer to the filaments, as a consequence, a more compact and void-free structure. While the Applicant believes that these phenomena do occur and cause or contribute to the surprising results of the invention, he does not wish to be bound to any interpretation of the mechanism by which the invention operates, and it suffices that the results thereof can be experimentally ascertained and have been proved by experience, as will appear from the following examples.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In said examples the various binary and ternary copolymers according to this invention are obtained from polymerization in known type reactors equipped for this purpose, the copolymerization being effected in homogeneous phase in organic solvent; the respective fibers have been obtained as specified hereinafter, using as coagulation baths, mixtures of solvent (DMF) and water and producing a count of 3.3 dtex per filament.
Spinning conditions
(A) Spinneret
A spinneret having 175 orifices with a diameter of 65 micron has been used to obtain the desired 3.3 dtex filament count in the final fibre.
(B) Spinneret Feed
A gear micropump delivering 0.6 cc per revolution is used, its number of revolutions being controlled so as to feed to the spinneret the amount of polymeric solution, drawn from a reservoir maintained at 30°-40° C. required to produce the desired count.
(C) Coagulation
The coagulation is carried out in a trough having a length of about 1 meter, containing a bath maintained at 12°-13° C. and at a constant water content of 60% and DMF content of 40%.
(D) Collection
From the coagulation trough, the yarn is drawn by a roller/pin device at a speed of 10 mt/min.
(E) Washing
The yarn passes from the coagulation through into a series of wash tubs, fed with demineralized water kept at 50° C., in countercurrent, until the DMF content of the yarn, calculated on the dry yarn, is less than 0.5%.
(F) Drawing
From the wash tubs, the yarn is passed through a drawing tub having the same dimension as the coagulation trough, which contains demineralized water kept at 98°-100° C. where the yarn undergoes drawing to a draw ratio of 5.5, from which it is collected at a speed of 55 mt/min by means of another roller/pin device; after drawing, the yarn passes through a finishing tub where lubrificants and antistatics, known for this purpose, are applied thereto.
(G) Drying
After drawing, the yarn enters a ribbon dryer which permits the yarn freely to contract during the drying in air at 130° C., by an amount of about 20%.
The fiber thus obtained is ready to undergo the controls established for this case, viz.:
(a) The cross-section of the filament after coagulation is microphotographed (FIGS. 1-4 of the attached sheet);
(b) The dye yield of the final dry fiber is determined through the amount of dye required to obtain in the fibers according to the various examples, the same shade of color obtained in a preferred fiber, according to the present invention, assumed as the basis of the comparison, when it is dyed with a given amount of dye. As preferred comparison fiber, that of example no. 1 has been chosen, and the shade of color to be obtained in all cases is that which the said fiber assumes when dyed with 2 grams of dye per 100 grams of dry fiber.
The color chosen for this control, is a dark brown hue obtained by using a mixture of the following three dyes in the following proportions:
(1) Yellow Maxilon 3 RL=50%
(2) Red Maxilon GRL=24%
(3) Blue Maxilon GRL=26%.
The shade of color obtained, e.g. in the fiber of example 1, has been obtained by dyeing in the conventional way, until exhaustion of the dye, 5 g of fiber in 200 cc of an aqueous solution containing 0.1 g of the aforesaid dye mixture.
Therefore only the number of grams of dye used up by 100 g of the fiber under examination will be indicated under item (b) of the control data. It is obvious that the higher said number, the more opaque will be the fibre.
(c) The degree of inflammability is determined, as expressed by the LOI (Limiting Oxygen Index) value, which indicates the minimum oxygen content in the air required for igniting the product under the test conditions defined by the ASTM-D-2863-70 method. Products having a LOI equal to or greater than 26 are considered as having reduced inflammability.
(d) The dynamometric characteristics of the fibre are determined in the conventional way.
A number of illustrative and non-limitative examples are described hereinafter.
EXAMPLE NO. 1
In this example the conditions are described relative to the two-phase copolymerization process, viz. the process which involves adding the end polymerization mixture resulting from the preparation of the binary acrylonitrile/sulphonated monomer copolymer, to the mixture of acrylonitrile/vinylidene chloride monomers relative to the second polymerization phase.
The sulphonated monomer is 2-acrylamido-2-methylpropane-sodium sulphonate.
The control data relative to the fiber thus obtained, which represents the most preferred embodiment of the present invention, are also set forth.
In the first phase, a binary acrylonitrile/2-acrylamido-2-methylpropane-sodium sulphonate is produced by copolymerizing at 67° C. for 11 hours, 27.20 parts by weight of acrylonitrile and 4.8 parts by weight of said sulphonated monomer in 2 parts by weight of water and 66 parts by weight of dimethylformamide in the presence of 0.027 parts by weight of azobisisobutyronitrile catalyst and 0.015 parts by weight of malic acid stabilizer. At the end of the polymerization the mixture contains 21% by weight of a copolymer composed by 85% by weight of acrylonitrile and 15% parts by weight of 2-acrylamido-2-methylpropane-sodium sulphonate.
One part by weight of the said mixture is mixed immediately, viz. without distilling the unreacted monomers, with 6.5 parts by weight of a mixture containing 26.55 parts by weight of acrylonitrile, 18.45 parts by weight of vinylidene chloride, 4 parts by weight of water and 51 parts by weight of DMF. The resulting mixture is subjected to polymerization at 52° C. for 13 hours in the presence of 0.22 parts of azobisisobutyronitrile catalyst and 0.1 parts of zinc paratoluenesulphonate color stabilizer.
At the end of the polymerization the mixture contains 19.2% of a polymer which, when analyzed in the normal way, is found to contain 61% by weight of acrylonitrile, 36% by weight of vinylidene chloride and 3% by weight of the sulphonated monomer, while the utilization rate of said sulphonated monomer is 90.62%.
The solution is distilled under a vacuum to eliminate and recover the volatile unreacted monomers and to eliminate the water and a final solution is thus obtained which contains 22.5% of polymer, and which is spun as hereinbefore indicated.
The fiber thus produced has the following control data:
a: see photo No. 1 (FIG. 1)
b=2.0
c=26% of O 2
d:
filament count in dtex=3.3
tenacity in g/dtex=2.6
elongation %=32
loop tenacity in g/dtex=1.3
The control data for this example, compared with those of comparison example no. 4 relative to a fiber which has the same final composition but the polymer of which has been obtained by the usual ternary copolymerization process, prove that this fiber has a much higher luster and a considerably higher dye yield. No practical difference exists as to the degree of inflammability and the dynamometric characteristics.
EXAMPLE NO. 2
In this example the control data are set forth of a fiber which has the same final composition as that of example no. 1, viz. 61% by weight of acrylonitrile, 36% by weight of vinylidene chloride and 3% by weight of sulphonated derivative, but which has been obtained by using an end polymerization mixture of the first phase, through which a binary acrylonitrile/sulphonated derivative is produced, which contains a considerably higher percentage (25%) of 2-acrylamido-2-methylpropane-sodium sulphonate with respect to that of example No. 1.
Said copolymer is obtained by polymerizing at 67° C. for 11 hours, 22.5 parts by weight of acrylonitrile and 7.5 parts by weight of 2-acrylamido-2-methylpropane-sodium sulphonate in 4 parts by weight of water and 66 parts by weight of DMF in the presence of 0.027 parts by weight of azobisisobutyronitrile catalyst and 0.015 parts by weight of malic acid stabilizer.
At the end of the polymerization, the mixture contains 20% of a polymer composed of 75% by weight of acrylonitrile and 25% by weight of sulphonated derivative.
One part by weight of said mixture is immediately mixed with 11 parts by weight of a mixture containing 28.12 parts by weight of acrylonitrile, 16.87 parts by weight of vinylidene chloride, 4 parts by weight of water and 51 parts by weight of DMF.
The resulting mixture is subjected to polymerization at 52° C. for 13 hours in the presence of 0.22 parts by weight of azobisisobutyronitrile catalyst and 0.1 parts by weight of zinc paratoluenesulphonate stabilizer. At the end of the polymerization, the mixture contains in all 19.5% of a polymer which is composed of 61% by weight of acrylonitrile, 36% by weight of vinylidene chloride and 3% by weight of sulphonated derivative, while the utilization rate of the sulphonated derivate is about 93%.
After distillation under a vacuum, to eliminate and recover the volatile unreacted monomers and to eliminate the water, a final solution is obtained which contains 22.5% of polymer and which is spun under the same conditions as in example no. 1.
The fiber thus obtained has the following control data:
a. see photo No. 2 (FIG. 2)
b=2.5 g of dye
c=26% of O 2
d:
filament count in dtex=3.2
tenacity in g/dtex=2.7
elongation %=33.5
loop tenacity in g/dtex=1.2
The control data of this example, compared to example no. 1, show a luster and dye yield which are slightly lower, however are still markedly higher than those of comparison example no. 4, while the utilization rate of the sulphonated monomer is still high, and significantly exceeds 90%.
EXAMPLE NO. 3
In this example the control data are set forth of a fibre produced in the same way as in example No. 2, with the sole exception that the amount of vinylidene chloride has been increased from 36 to 45% so that the inflammability of the fiber obtained corresponds to a LOI index of 30%.
The binary copolymer is obtained by copolymerizing at 67° C. for 11 hours, 27.2 parts by weight of acrylonitrile and 4.8 parts by weight of sulphonated derivative, in 2 parts by weight of water and 66 parts by weight of DMF, in the presence of 0.027 parts by weight of azobisisobutyronitrile catalyst and 0.015 parts by weight of malic acid stabilizer. At the end of the polymerization, the mixture contains 21% by weight of a polymer composed of 85% of acrylonitrile and 15% by weight of 2-acrylamido-2-methylpropane-sodium sulphonate.
One part by weight of said end polymerization mixture is immediately mixed with 6.5 parts by weight of a mixture containing 21.60 parts by weight of vinylidene chloride, 4 parts by weight of water and 51 parts by weight of DMF. The resulting mixture is subjected to copolymerization at 52° C. for 13 hours in the presence of 0.2 parts by weight of azobisisobutyronitrile catalyst and 0.1 parts by weight of zinc paratoluenesulphonate stabilizer. At the end of the polymerization, the mixture contains 19.2% of a polymer which is composed of 52% by weight of acrylonitrile, 45% by weight of vinylidene chloride and 3% by weight of 2-acrylamido-2-methylpropane-sodium sulphonate, while the utilization rate of the sulphonated monomer increases to 9.5%.
The resulting mixture is subjected to distillation under a vacuum to eliminate and recover the volatile unreacted monomers and to eliminate the water and a solution containing 22.5% of solid matter is obtained, which is spun under the same condition as in the preceding examples.
The fiber produced has the following control data:
a: see photo No. 3 (FIG. 3)
b=3.0 g of dye
c=30% of O 2
d:
filament count in dtex=3.2
tenacity in g/dtex=2.0
elongation %=36
loop tenacity in g/dtex=1.0
It is seen from the control data the increase in the vinylidene chloride content only slightly lowers the luster and the dye yield of the fiber, which anyway are still markedly superior to those of comparison example No. 4, while the LOI index permits to consider the fibre as self-extinguishing.
EXAMPLE NO. 4 (comparison example)
In this example, which does not illustrate the invention but serves for comparison, the control dat are set forth of a fiber obtained from a ternary copolymer having the same final composition as the copolymer of example no. 1, viz., 61% by weight of acrylonitrile, 36% by weight of vinylidene chloride and 3% by weight of 2-acrylamido-2-methylpropane-sodium sulphonate, which copolymer however has been produced not by the two-phase polymerization process which is an object of this invention, but by the classic and well known single-phase, ternary copolymerization process.
The ternary polymer is obtained by copolymerizing at 52° C. for 13 hours, 27.81 parts by weight of acrylonitrile, 16.20 parts by weight of vinylidene chloride and 0.99 parts by weight of 2-acrylamido-2-methylpropane-sodium sulphonate in 3 parts by weight of water and 52 parts by weight of DMF, in the presence of 0.22 parts by weight of azobisisobutyronitrile catalyst and 0.1 parts by weight of zinc paratoluenesulphonate stabilizer.
At the end of the polymerization, the solution contains 20.3% by weight of a polymer which is composed of 61% by weight of acrylonitrile, 36% by weight of vinylidene chloride and 3% by weight of sulphonated derivative, while the utilization rate of the sulphonate does not exceed 60%. The spinning solution containing 22.5% of said polymer, obtained after distilling off the unreacted monomers, is spun in the same way as in the preceding examples.
The fiber thus obtained has the following control data:
a: see photo No. 4 (FIG. 4)
b=5.6 g of dye
c=26% of O 2
d:
filament count in dtex=3.3
tenacity in g/dtex=2.4
elongation=31
loop tenacity in g/dtex=1.2
The control data relative to this example evidence a much more opaque or lusterless fiber and much lower dye yields than those of the preceding examples, while the utilization rate of the sulphonated monomer is much lower (60%).
The following examples illustrate the use of significantly homopolymerizable sulphonic monomers, of the class hereinbefore defined, other than 2-acrylamido-2-methyl-propane-sodium sulphonate.
EXAMPLE NO. 5
The operations of example No. 1 are repeated using 2-acrylamido-2-propanesulphonic acid as the sulphonic monomer.
The binary acrylonitrile/sulphonic monomer copolymer is produced by using 27.9 parts by weight of acrylonitrile and 4.1 parts by weight of the sulphonic monomer, all other components, quantities and conditions being the same as in example No. 1. At the end of the first copolymerization phase, the copolymer contains 87% by weight of acrylonitrile and 13% by weight of 2-acrylamido-propane-sulphonic acid.
The second copolymerization phase is carried out as in example No. 1, and at the end thereof, the mixture contains 61.5% by weight of acrylonitrile, 36% by weight of vinylidene chloride, and 2.5% by weight of the sulphonic monomer.
EXAMPLE NO. 6
The operations of example No. 1 are repeated using 2-acrylamido-phenylethanesulphonic acid as the sulphonic monomer.
The binary acrylonitrile/sulphonic monomer copolymer is produced by using 27.0 parts by weight of acrylonitrile and 5.0 parts by weight of the sulphonic monomer, all other components, quantities and conditions being the same as in example No. 1. At the end of the first copolymerization phase, the copolymer contains 83.3% by weight of acrylonitrile and 16.7% by weight of 2-acrylamido-phenyl-ethane-sulphonic acid.
The second copolymerization phase is carried out as in example No. 1, and at the end thereof, the mixture contains 60.7% by weight of acrylonitrile, 36% by weight of vinylidene chloride, and 3.3% by weight of the sulphonic monomer.
The control data both of example No. 5 and of example No. 6 do not significantly differ from those of example No. 1.
A number of illustrative embodiments of the invention have been described, but it is clear that it can be carried into practice by a person skilled in the art with many variations and modifications.
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Textile fibers having reduced inflammability and high luster, constituted copolymers of acrylonitrile, vinylidene chloride and a significantly homopolymerizable sulphonic comonomer are described. Significantly homopolymerizable comonomers are defined as monomers which homopolymerize with a conversion above 30°-40° under standard conditions set forth in the specification. A preferred class of such comonomers are the derivatives of acrylamidoalkanesulphonic acids, e.g. 2-acrylamido-2-methylpropane-sodium sulphonate. The fibers are spun from spinning dopes containing said copolymers in solution in organic solvent miscible with water and less than 4% of water. Said spinning dopes can be obtained by preparing a binary copolymer of acrylonitrile and the sulphonic monomer, in solution in the solvent, mixing the solution with a solution of acrylonitrile and vinylidene monomers in the same solvent, and subjecting the mixture to copolymerization. The copolymers finally obtained contain 50-85% of acrylonitrile, 13.5-46.5% of vinylidene chloride, and 1.5-3.5% of the sulphonic comonomer, the percentages being by weight.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] The present invention relates to a method and an apparatus which is helpful in the cost efficient cooling and heating of swimming pools using ambient air temperature.
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] For many years there has been the problem of heating swimming pools during cool weather and cooling down swimming pools in hot climates during hot weather. The problem of heating swimming pools during cool weather can be addressed by any of a number of different well know methods such as passing the pool water through a pool heater (i.e., gas, propane or electric heat exchanger). This passing of the pool water through the heat exchanger normally occurs during the filtration process. The problems with this well known method of heating pool water are the upfront expense of the pool heater, the space requirements for the heater and perhaps most significantly, the very high energy cost of running the pool heater. An additional method of heating pool water is to use solar heat in the heat exchanger rather than fossil fuels or electricity. Examples of patents using solar heat exchangers are set forth in U.S. Pat. No. 4,261,332 entitled “Solar Heating Systems” and U.S. Pat. No. 4,256,087 entitled “Swimming Pool Heater”. These solar heat exchange systems have, inter alia, the disadvantages of high upfront costs and space requirements.
[0004] There have been fewer prior art inventions relating to cooling a swimming pool which is too warm. Nevertheless, this is a real problem in the summertime in hot climates. Often pools become so warm (above the 90+ degree Fahrenheit) that pool use is not as refreshing as in a cooler pool. U.S. Pat. No. 4,189,791 entitled “Swimming Pool Heating and Cooling System” describes a system using air pumps and temperature controllers to control the temperature of the pool using ambient air pumped into pipes located in the pool which act as a heat exchanger. Once again this invention has, inter alia, the problems high up front costs and space requirements. U.S. Pat. No. 3, 941,154 entitled “Swimming Pool Water Circulation System” describes a water circulation system which contains fountains at the water level which can be pointed into the air in order to cool the water being recirculated into the pool. The disadvantages of such a system are the upfront capital costs and the need to retrofit old pools.
[0005] What is needed is a simple method to cool or heat a pool. The method should be inexpensive to operate and require no retrofitting of the pool so that the upfront costs are minimized. All the prior art methods either are expensive to operate because of energy costs or expensive to install because of equipment needs or both.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is the object of this invention to provide a low cost method and apparatus to help in adjusting the temperature of swimming pools.
[0007] In furtherance of the objects mentioned above, the present invention provides a method of cooling or heating a swimming pool using existing pool equipment and running the circulation system at times of the day which facilitate either heating or cooling of the pool. For example, running the circulation system at night to cool a pool during hot weather or alternatively running the circulation system during the hot part of the day to heat a pool which is too cool.
[0008] This optimized timing of running a pool filter system is simple. To cool the pool, run the filter system during the coolest part of the day (usually late at night). To heat a pool, run the filter system during the hottest part of the day (normally during the afternoon and early evening). Since pool filters must be run some minimum period of time each day in any event, this optimized timing does not have any additional costs. This method works best in pools which have waterfalls (e.g., from the pool spa into the main pool) or in pools which have some other way to have the water fall or run throught the ambient air (e.g., a fountain). The exposure of the pool water to the ambient air rather than being recirculated to the pool under the surface of the water greatly increases the heat exchange between the ambient air and the pool.
[0009] However, many pools do not have waterfalls, or if they do have a waterfall, the exposure of the pool water to the ambient air is not maximized because of the relatively limited time period the recirculated water is exposed to the ambient air during its fall into the pool. Accordingly, in a preferred embodiment of the invention an apparatus is provided which is a movable surface which is designed to let the recirculating pool water run over it while being exposed to the ambient air before running or dropping back into the pool. If the pool has only submerged water return openings, then a conduit can be used to channel the recirculated water onto the top of the movable surface and into the ambient air. By changing the size and shape of the movable surface (e.g., a raft) one can maximize the exposure of the recirculating pool water to the ambient air and accordingly maximize the heat transfer between the air and water. By having the movable surface irregularly shaped (e.g., tortuous paths caused by ripples, indentations, pebble shaped bumps, furrows, etc.) One can maximize the amount of time the recirculating water is on the movable surface and accordingly the heat transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a top view of a movable surface situated under a spa waterfall.
[0011] [0011]FIG. 2 is a side view of a movable surface and a conduit which forces recirculated water out of a submerged return opening onto the top of the movable surface.
DETAILED DESCRIPTION OF THE INVENTION
[0012] [0012]FIG. 1 shows movable surface 11 situated underneath of waterfall 14 . (A waterfall for the purpose of this disclosure is any recirculated water entering pool surface 13 from above pool surface 13 .) In this embodiment, movable surface 11 has a specific gravity less than that of water (i.e., less dense than water) and is accordingly floating on pool surface 13 . In other embodiments of the invention, just a section of movable surface 11 could be floating on pool surface 13 (e.g., a pontoon-like structure). There are many types of pool waterfalls but in the FIG. 1, waterfall 14 is caused by the recirculation of pool water into spa 20 which is at a higher elevation than pool surface 13 and accordingly during recirculation, water being recirculated into spa 20 falls back into pool surface 13 through waterfall 14 (caused by a low point in spa wall 23 ).
[0013] In order to maximize the heat transfer of the pool water falling through waterfall 14 , movable surface 11 has been positioned and substantially fixed in position underneath waterfall 14 (movable surface 11 may move on the surface of the water, but should not float away). Therefore, instead of the recirculated pool water entering the pool immediately after dropping from the spa onto pool surface 13 it continues to be exposed to the ambient air because it falls upon movable surface 11 and is forced to run over its top surface which is exposed to ambient air. In a preferred embodiment of the invention, movable surface 11 has slightly raised side walls 17 which help channel the water from the end of moveable surface 11 situated underneath waterfall 14 to the opposite end of movable surface 11 . This channelling of the water along the entire length of movable surface 11 to the discharge end 18 of movable surface 11 maximizes the time the water is on the movable surface 11 which also maximizes the heat exchange between the water and the ambient air.
[0014] This channelling of the recirculated pool water along the entire length of movable surface 11 could also be accomplished by having movable surface 11 slightly slanted downward away from the end of movable surface 11 under waterfall 14 and toward discharge end 18 . Another method of assuring that water runs over the entire length of movable surface 11 could be accomplished by having channels or indentations on the upper surface of movable surface 11 . Channels 15 near waterfall 14 could be designed to channel the water uniformity across the top of movable surface 11 by having channels 15 in a fan-like shape. The remainder of movable surface 11 could be formed to make a tortuous path (e.g., squiggly lines or a pebble-like contour) which maximizes the amount of time the recirculated pool water stays on movable surface 11 . Alternatively, the upper surface of movable surface 11 could be flat or slightly slanted toward discharge end 18 . Movable surface 11 in a preferred embodiment of the invention would double as a raft when not in use as a heat transfer surface. In cases where movable surface 11 has channels 15 or tortuous path 16 on the heat transfer side of the raft the opposing side could be smooth and usable as a raft by swimmers. This double-sided or dual purpose raft design would assure ultimate utility and ease of use. In this way, one would not even have to take raft out of the pool during use by swimmers since it doubles as a standard raft and can be used as either a normal flotation device for swimmers or as a heat exchanger.
[0015] In order to hold movable surface 11 in place under waterfall 14 it is necessary to have some manner of an attachment means of device. There are hundreds or thousands of different types of attachment devices well known in the art available to assure that movable surface 11 remains under waterfall 14 (e.g., straps, Velcro®, buckles, magnets, hooks, etc.). In addition, numerous movable surfaces 11 could be attached together to maximize surface area for heat transfer. However, in order to use movable surface 11 interchangeably as a raft for swimmers and in order to mimimize retrofitting of the pool wall or pool deck 21 , one preferred embodiment would be to have strap or rope 27 detachably connected to movable surface 11 by means of detachable connection 25 and having the opposite end of rope or strap 27 connected to weight 22 . Detachable connection 25 could be any of a number of different detachable connections such as Velcrot, snaps, buckes and so forth. In light of the water environment, Velco® may be a preferred attachment device. Using weight 22 positioned on pool deck 21 such that strap 27 is taunt against movable surface 11 which allows positioning of movable surface 11 essentially anywhere around the perimeter of a pool without any retrofitting of pool deck 21 or the pool walls. Also weight 22 does not have to be very heavy or bulky since there should not be significant lateral forces on movable surface 11 to displace it from underneath waterfall 14 .
[0016] This preferred attachment method and device has the following two advantages: (1) The attachment device is easily detachable from movable surface 11 so that it can be alternatively used as a raft when not in use as heat transfer surface, and (2) since it relies on weight 22 to hold the movable surface 11 in place, it requires no retrofitting of pool deck 21 or the walls of the pool.
[0017] [0017]FIG. 2 sets forth an embodiment of the invention which is preferred when a swimming pool does not have a waterfall in which to place movable surface 11 underneath. Many pools do not have either waterfalls or spas. The water that is recirculated to the pool after filtering enters the pool through submerged water return openings below pool surface 13 . In pool configurations where water return opening 33 is submerged there is a need for a way to get the recirculated water up above pool surface 13 so that it will be able to run over movable surface 11 . A preferred method to get the recirculated water onto movable surface 11 is to use conduit 31 (as used herein, conduit 31 can be any kind of pipe or channel which changes the direction of the recirculated water exiting water return opening 33 ). One end of conduit 31 could abut against pool wall 21 and cover submerged return opening 33 at the end of return pipe 32 . The recirculated water in return pipe 32 normally exits into the pool below pool surface 13 through return opening 33 . However, because of the presence of conduit 31 and the pressure of the water in return pipe 32 , the return water instead travels up through conduit 31 to exit onto movable surface 11 . Once on movable surface 11 the water is subject to the heat exchange (either cooling or heating) caused by it's contact with the ambient air.
[0018] In a preferred embodiment, conduit 31 can be attached or detached very simply in order to maximize ease of use. This mobility allows the pool to be used safely without a permanent conduit or pipe protruding into it. In an experiment, conduit 31 consisted of two separate rigid 2″ UL-90° Std. Bend PVC Sch. 40 (issue no. X-33658) conduit from Cantex fitted together with a standard 2″ PVC coupling. When fitted together the two conduits formed “S” shaped pipe approximately 40″ long. One end of this “S” shaped pipe (conduit 31 ) was abutted against return opening 33 and the other end protruded above pool surface 13 and rested against an end of movable surface 11 . The recirculating water pressure in the experiment was such that it exerted an outward pressure (away from pool wall 21 ) on conduit 31 which had to be counteracted. Counteracting such outward pressure was done by preventing movable surface 11 from moving away from pool wall 21 . In the experiment, this was done by manually holding the raft (movable surface 11 ) in place. Movable surface 11 was about 18-20 inches from pool wall 21 and return opening 33 was about 16-18 inches below pool surface 13 . Accordingly, the position of “S” pipe (conduit 31 ) was such that the water pressure from return opening 33 did not cause the “S” pipe to disengage from either pool wall 21 or movable surface 11 . In short, conduit 11 was stuck in between pool wall 21 and movable surface 11 without any need for permanently anchoring conduit 31 to either movable surface 11 or pool wall 21 .
[0019] Identical with the attachment means set forth in FIG. 1, movable surface 11 could also be prevented from moving away from pool wall 21 by using detachable strap or rope 27 connected to weight 22 . (Unlike in FIG. 1, however, movable surface 11 would probably not abut against pool wall 21 because of the need to accomodate conduit 31 .) The position of return opening 33 (i.e., depth below pool surface 13 ) could necessitate different configurations and/or lengths for conduit 31 . One especially preferred method of addressing varying positions of return opening 33 and/or pressure of water exiting return opening 33 is to design conduit 31 so that its length may be easily varied. One method of easily varying the length of conduit 31 is to make conduit 31 “telescoping pipe” by means well known in the art. The varying length of conduit 31 also requires varying the length of rope or strap 27 so that the distance from movable surface 11 and pool wall 21 can be varied as well.
[0020] The present invention has been described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made in the described embodiments without departing from the nature and scope of the present invention. Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variatins do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims, enable those skilled int he art to understand and practice the same, the invention claimed is:
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A method for adjusting the temperature of a swimming pool having a filter system and a waterfall, comprising running the filter system at times of the day such that heat transfer with ambient air is optimized by the action of swimming pool water falling through the ambient air, and further comprising positioning and substantially fixing the position of a movable surface below the water fall to help maximize the heat transfer with the ambient air. For pools without waterfalls, it is further disclosed to utilize a conduit from a submerged water return opening to the movable surface which could be a raft.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 61/548,560, filed Oct. 18, 2011. The patent application identified above is incorporated herein by reference in its entirety to provide continuity of disclosure.
FIELD OF THE INVENTION
This invention relates to portable shelters such as sun shades, umbrellas, canopies and the like and more particularly relates to an easily transportable sun shade which can be quickly set up to provide users with protection from the sun.
BACKGROUND OF THE INVENTION
Portable shelters such as umbrellas, canopies and tents are very popular due to the detrimental effects of the sun. Conventional umbrellas provide only limited protection based on the size and the circular shape of the umbrella. In addition, umbrellas are fragile and have tendency to flip inside out in strong winds. Alternatively, conventional canopies and tents are require multiple individuals to erect and require multiple tie downs or anchors to prevent the canopies from blowing over, thereby making assembly and take down complicated. A further problem with tents is the lack of air flow. Most importantly, the wind works against umbrellas, canopies and tents by blowing over and/or damaging umbrellas, canopies and tents.
Therefore, a need exists for a collapsible sunshade that is easy to transport, easy to assemble, easy to disassemble, provides an adequate area of shade for one or more users and uses the wind to inflate and support the sunshade as opposed to blowing over the sunshade.
The relevant prior art includes the following references:
Patent No.
(U.S. Patent References)
Inventor
Issue/Publication Date
D625508
Thurrott et al.
Oct. 19, 2010
2010/0101614
Wang et al.
Apr. 29, 2010
2008/0236640
Huali et al.
Oct. 2, 2008
7,406,975
Carrier, Jr.
Aug. 5, 2008
7,780,139
Market
Aug. 24, 2010
2006/0016950
Bright et al.
Jan. 26, 2006
7,246,629
You
Jul. 24, 2007
2004/0226591
You
Nov. 18, 2004
6,866,053
You
Mar. 15, 2005
2001/0035201
Kuzmic
Nov. 1, 2001
6,443,172
Brumfield
Sep. 3, 2002
6,446,649
Bigford
Sep. 10, 2002
6,354,554
Hollenbeck
Mar. 12, 2002
6,164,613
Williams
Dec. 26, 2000
5,636,944
Buttimore
Jun. 10, 1997
5,452,877
Riffle et al.
Sep. 26, 1995
5,207,406
Stine et al.
May 4, 1993
5,122,014
Genfan
Jun. 16, 1992
4,924,893
Furey
May 15, 1990
3,785,388
Schafer
Jan. 15, 1974
2,124,842
Zierold et al.
Jul. 26, 1938
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a collapsible sunshade that is easy to carry and transport to and from the beach or other outdoor areas.
An additional object of the present invention is to provide a collapsible sunshade that is easy to assemble.
A further object of the present invention is to provide a collapsible sunshade that is easy to disassemble.
An additional object of the present invention is to provide a collapsible sunshade that uses the wind to help inflate and support the sunshade as opposed to blowing over the sunshade.
The present invention fulfills the above and other objects by providing a collapsible sunshade that uses a simple support structure and anchoring system to simplify the assembly and disassembly of the sunshade. The collapsible sunshade of the present invention has a substantially-rectangular shaped canopy having a front edge, side edges, a rear edge a top surface and a bottom surface. One or more pockets are located proximal to the rear edge of the canopy. The pockets may be filled with sand or other substances such as gravel to anchor the rear edge of the collapsible sunshade to the ground. One or more air vents may also be located proximal to the rear edge to allow wind to pass through, thereby lessening the pressure of the wind on the bottom surface of the canopy. A front sleeve is located along the front edge of the canopy that houses a front crossbeam. The front cross beam is may be one elongated member or multiple elongated members connected together depending on the desired length. One or more front support poles attach to the front crossbeam by passing through one or more apertures located on the front sleeve and the front crossbeam. The one or more front support poles may be telescoping to allow a user to adjust the height of the front crossbeam. The body of the canopy is supported by wind blowing under the front crossbeam and against the bottom surface of the canopy thereby elevating a rear portion of the canopy and causing the canopy to act like a sail. The rear portion of the canopy may also be supported by a rear crossbeam that is housed by a rear sleeve extending between the sides of the canopy. One or more rear support poles attach to the rear crossbeam by passing through one or more apertures located on the rear sleeve and the rear crossbeam. The one or more rear support poles may also be telescoping to allow a user to adjust the height of the rear crossbeam.
An additional advantage of the collapsible sunshade of the present invention is the compact storage of the sunshade. After removing the front support poles and rear support poles, the poles may be placed parallel to the front edge of the canopy, or inside the front crossbeam and rear crossbeam (if the front crossbeam and rear crossbeam are tubular) and then rolled in the canopy. The rolled sunshade may then be held in a rolled position with ties and/or placed in a carrying bag for easy transportation.
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 conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following detailed description, reference will be made to the attached drawings in which:
FIG. 1 is a perspective side view of a collapsible sunshade of the present invention without a rear support structure;
FIG. 2 is a perspective side view of a collapsible sunshade of the present invention with a rear support structure;
FIG. 3 is a perspective side view of a collapsible sunshade of the present invention having a single front support pole;
FIG. 4 is a front view of a front support structure having a multiple front support poles;
FIG. 5 is a front view of a front support structure having a single front support poles;
FIG. 6 is a front view of a rear support structure of the present invention;
FIG. 7 is a bottom view of the canopy illustrated in FIGS. 1 and 2 ;
FIG. 8 is a bottom view of the canopy illustrated in FIG. 3 ; and
FIG. 9 is a side view of an anchor for securing the proximal ends of the one or more front support poles and/or the one or more rear support poles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of describing the preferred embodiment, the terminology used in reference to the numbered components in the drawings is as follows:
1 . collapsible sunshade, generally
2 . rear support structure
3 . canopy
4 . front edge of canopy
5 . side edge of canopy
6 . rear edge of canopy
7 . top surface of canopy
8 . bottom surface of canopy
9 . pocket
10 . air vent
11 . front sleeve
12 . front crossbeam
13 . front support pole
14 . aperture
15 . proximal end of front support pole
16 . distal end of front support pole
17 . locking means
18 . front support structure
19 . rear portion of canopy
20 . rear sleeve
21 . rear crossbeam
22 . rear support pole
23 . anchor
24 . shaded portion
With reference to FIGS. 1 and 2 , perspective side views of a collapsible sunshade 1 of the present invention without a rear support structure 2 and with a rear support structure 2 , respectively, are illustrated. The collapsible sunshade 1 of the present invention comprises a substantially-rectangular shaped canopy 3 having a front edge 4 , side edges 5 , a rear edge 6 , a top surface 7 and a bottom surface 8 . One or more pockets 9 are located proximal to the rear edge 6 of the canopy 3 . The pockets 9 may be filled with sand or other substances such as gravel to anchor the rear edge 6 of the collapsible sunshade 1 to the ground. One or more air vents 10 may also be located proximal to the rear edge 6 to allow wind to pass through, thereby lessening the pressure of the wind on the bottom surface 8 of the canopy 3 . A front sleeve 11 is located along the front edge 4 of the canopy 3 and houses a front crossbeam 12 . One or more front support poles 13 attach to the front crossbeam 12 by passing through one or more apertures 14 located on the front sleeve 11 and the front crossbeam 12 . The one or more front support poles 13 may be telescoping to allow a user to adjust the height of the front crossbeam 12 . In addition, each front support pole 13 comprises a proximal end 15 that is inserted directly into the ground or into the ground using an anchor 23 (as illustrated in FIG. 10 ) and a distal end 16 that passes through the one or more apertures 14 located on the front sleeve 11 and the front crossbeam 12 . A locking means 17 such as a clamp, threaded connection, threaded cap, threaded nut and so forth may attach to the distal ends 16 of the front support poles 13 to prevent the distal ends 16 from disconnecting from the front crossbeam 12 . The front crossbeam 12 and one or more front support poles 13 comprise the front support structure 18 , as further illustrated in FIGS. 4 and 5 . For additional support, a rear portion 19 of the canopy may have a rear sleeve 20 extending between the side edges 5 of the canopy 3 that houses a rear crossbeam 21 . One or more rear support poles 22 attach to the rear crossbeam 21 by passing through one or more apertures 14 located on the rear sleeve 20 and the rear crossbeam 21 . The one or more rear support poles 22 may also be telescoping to allow a user to adjust the height of the rear crossbeam 21 . The rear crossbeam 21 and one or more rear support poles 22 comprise a rear support structure 2 , as further illustrated in FIG. 6 . When erected, the collapsible canopy 1 provides a shaded portion 24 for the user.
With reference to FIG. 3 , a perspective side view of a collapsible sunshade 1 of the present invention having a single front support pole 13 is illustrated. The number of front support poles 13 necessary for supporting the front crossbeam 12 is dependent on the size of the collapsible sun shade 1 . As illustrated here, the collapsible sunshade 1 is sized for a single user. Therefore, only one front support pole 13 positioned centrally on the front cross beam 12 is necessary to support the front cross beam 12 . When erected, the collapsible canopy 1 provides a shaded portion 24 for the user.
With reference to FIGS. 4 and 5 , a front view of a front support structure 18 having a multiple front support poles 13 and a front support structure 18 having a single front support pole 13 , respectively, are illustrated. One or more front support poles 13 attach to the front crossbeam 12 by passing through one or more apertures 14 located on the front crossbeam 12 . The one or more front support poles 13 may be telescoping to allow a user to adjust the height of the front crossbeam 12 . In addition, each front support pole 13 comprises a proximal end 15 that is inserted directly into the ground or into the ground using an anchor (as illustrated in FIG. 10 ) and a distal end 16 that passes through the one or more apertures 14 located on the front crossbeam 12 . A locking means 17 such as a clamp, threaded connection, threaded cap, threaded nut and so forth may attach to the distal ends 16 of the front support poles 13 to prevent the distal ends 16 from disconnecting from the front crossbeam 12 . The number of front support poles 13 necessary for supporting the front crossbeam 12 is dependent on the size of the collapsible sun shade 1 . For example, the front support structure 18 illustrated in FIG. 4 would be used with a larger collapsible sunshade for use by multiple individuals, as illustrated in FIGS. 1 and 2 , and the front support structure 18 illustrated in FIG. 5 would be used with a smaller collapsible sunshade for use by a single individual, as illustrated in FIG. 3 .
With reference to FIG. 6 , a front view of a rear support structure 2 of the present invention is illustrated. For additional support, a rear portion 19 of the canopy may have a rear sleeve 20 extending between the side edges 5 of the canopy 3 , as illustrated in FIGS. 1 and 2 , that houses a rear crossbeam 21 . One or more rear support poles 22 attach to the rear crossbeam 21 by passing through one or more apertures 14 located on the rear sleeve 20 and the rear crossbeam 21 .
With reference to FIG. 7 , a bottom view of the canopy 3 illustrated in FIGS. 1 and 2 is illustrated. The substantially-rectangular shaped canopy 3 having a front edge 4 , side edges 5 , a rear edge 6 a top surface 7 and a bottom surface 8 . One or more pockets 9 are located proximal to the rear edge 6 of the canopy 3 . One or more air vents 10 may also be located proximal to the rear edge 6 to allow wind to pass through, thereby lessening the pressure of the wind on the bottom surface 8 of the canopy 3 . A front sleeve 11 is located along the front edge 4 of the canopy 3 with one or more apertures 14 located thereon. A rear sleeve 20 extends between the side edges 5 of the canopy 3 with one or more apertures 14 located thereon.
With reference to FIG. 8 , a bottom view of the canopy 3 illustrated in FIG. 3 is illustrated. The substantially-rectangular shaped canopy 3 comprises a front edge 4 , side edges 5 , a rear edge 6 , a top surface 7 and a bottom surface 8 . One or more pockets 9 are located proximal to the rear edge 6 of the canopy 3 . One or more air vents 10 may also be located proximal to the rear edge 6 to allow wind to pass through, thereby lessening the pressure of the wind on the bottom surface 8 of the canopy 3 . A front sleeve 11 is located along the front edge 4 of the canopy 3 with an aperture 14 located centrally thereon. A rear sleeve 20 extends between the side edges 5 of the canopy 3 with one or more apertures 14 located thereon.
With reference to FIG. 9 , a side view of an anchor 23 for securing the proximal ends of the one or more front support poles 13 and/or the one or more rear support poles 22 is illustrated. The anchor 23 screws into the ground and provides a base to hold the proximal ends of the one or more front support poles 13 and/or the one or more rear support poles 22 .
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 shown. 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 to be considered limited to what is shown and described in the specification and drawings.
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A collapsible sunshade ( 1 ) that uses a simple support structure and anchoring system to simplify the carrying, assembly and disassembly of the sunshade. The collapsible sunshade of has a substantially-rectangular shaped canopy ( 3 ) with one or more pockets ( 9 ) located near a rear edge ( 6 ) of the canopy. The pockets may be filled with sand to anchor the rear edge of the collapsible sunshade to the ground. One or more air vents ( 10 ) may also be located proximal to the rear edge to allow wind to pass through, thereby lessening the pressure of the wind on a bottom surface ( 8 ) of the canopy. A front support structure ( 18 ) and optional rear support structure ( 2 ) in combination with wind supports the body of the canopy, which acts like a sail in the wind.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/642,467, filed Aug. 14, 2003, the entire disclosure of which is hereby incorporated by reference herein as if being set forth in its entirety.
FIELD OF THE INVENTION
[0002] The instant invention relates to the field of convertible units for use with babies and very young children; in particular to units which may be easily converted to a play yard, bassinet, changing table, or child's bed-side sleeping enclosure, hereinafter referred to for convenience as a “co-sleeper”, that attaches securely to the parents' bed.
BACKGROUND OF THE INVENTION
[0003] Play yards and playpens for babies and young children are well known and many variations have been marketed over the years. Low portable cribs have also been used as playpens. For reasons of economy and space conservation it has been practical to find additional uses for playpens, such as bassinets and changing tables if such additional uses can be accomplished by means of easy alterations or adjustments that are reversible.
[0004] In U.S. Pat. No. 2,548,769, Burgin teaches a crib that can be lowered for use as a playpen. Shamie, in U.S. Pat. No. 5,339,470 teaches a portable playpen that can be converted to a changing or dressing table. In U.S. Pat. No. 5,553,336, Mariol adds an upper level to a playpen to provide a bassinet. The short legs of the upper level are inserted into openings in the top of the vertical supports of the playpen. Saldana, U.S. Pat. No. 2,691,176, teaches a unit designed for home and travel that may be used as a support for a playpen, bassinet or baby chair. U.S. Pat. No. 5,581,827 to Fong et al. discloses a foldable playpen unit.
[0005] Recently there has been a resurgence in the practice of having babies sleep adjacent the parents' bed. Such bed-side cribs are taught in U.S. Pat. No. 5,172,435 to Griffin et al.; U.S. Pat. No. 5,293,655 to Van Winkle et al. and to Tharalson et al. as U.S. Pat. No. 5,148,561.
[0006] It is an objective of the present invention to provide a single unit that, with quick and easy adjustments, can be adapted for several different purposes, including a playpen, a bassinet, a changing table and a co-sleeper.
[0007] It is another objective of the present invention to provide a unit that can be converted to a co-sleeper that is an improvement over the prior art, that rests on four legs, with or without attached wheels, will not lift, tip or buck and that is secured to the parents' bed with a safety strap so it cannot slide away from the bed.
[0008] It is a further objective to provide a co-sleeper that is adaptable to both U.S. and European bed heights, including means of securing the co-sleeper to beds of both heights. Means should be provided to permit the co-sleeper mattress to be positioned at heights within the co-sleeper suitable for positioning adjacently to both U.S. and European bed surfaces. Likewise, means for adjusting the mattress cover to minimize any excess fabric when switching between U.S. and European mattress height adjustments should be provided.
[0009] Another objective of the present invention is to allow conversion to a co-sleeper while still maintaining the stability of the unit by the repositioning of the front horizontal rail. Such repositioning should provide for both U.S. and European bed heights.
[0010] It is yet a further objective of the present invention that the co-sleeper be adjacent the parents' bed but at a level below the level of the parents' bed. Another objective of the present invention is to provide means to adjust the height of the co-sleeper to conform to the different bed heights. A still further objective of the present invention is to provide a secure washable enclosure for an infant of small child.
[0011] Another objective of the present invention is to provide a playpen in which an infant or small child can be tended to by a care-giver that is physically handicapped. A further objective of the present invention is to provide a unit that folds easily for storage and transport.
[0012] It is still a further objective of the invention to provide a playpen with a floor which can withstand repeated jumping and rough play by an infant or small child without sagging or the risk of breakage. The floor should be constructed of a mesh material to prevent accidental suffocation of an infant or small child who might find his or her way underneath the co-sleeper mattress.
[0013] It is yet a further objective to provide an easily convertible playpen that includes strong, secure hinging mechanisms for the playpen support members. Such mechanisms should lock the members securely in place and yet be simple and easy to release when required. These mechanisms should be padded and enclosed so that movable metallic parts are not accessible to an infant or small child's fingers.
[0014] It is still a further objective of the invention to provide for simple adjustments to the height of the front wall of the co-sleeper while preventing injury to any small fingers that may be inserted into the openings in the adjustment mechanism.
[0015] It is another objective to minimize any loose fabric associated with the co-sleeper mattress that could conceivably cause asphyxiation of an infant or small child.
[0016] Other features and advantages of the invention will be seen from the following description and drawings.
SUMMARY OF THE INVENTION
[0017] The present invention is a portable combination bedside co-sleeper convertibly adapted for use as a bassinet, changing table and playpen. The co-sleeper, includes an enclosure that has an open top, a floor, a mattress support panel, a front wall, and at least one surrounding wall connected to the front wall. The floor has a top surface, a bottom surface and surrounding side edges and is attached to the front wall and the surrounding wall at the surrounding side edges. The mattress support panel has an upper surface, a lower surface, an outer perimeter and is removably attached to the front wall and the surrounding wall at the outer perimeter and is spaced upwardly from the floor. A mattress pad is provided. The mattress pad has an upper surface, a lower surface and is sized and shaped to fit slidably between the front wall and the surrounding wall.
[0018] Means are provided for reversibly lowering a height of at least a portion of the front wall, from a first position at the top to at least one second position below the top. A securing strap assembly is provided for securing the co-sleeper to a parental bed. When the front wall is raised to the first position, the co-sleeper is usable as a bassinet; and when the front wall is then lowered to one of its second positions, the co-sleeper is usable as a changing table. When the securing strap assembly is properly positioned and the co-sleeper is secured to the parental bed it will serve as a co-sleeper.
[0019] In a variant of the invention, the floor further includes a series of first reinforcing straps. The first reinforcing straps are located upon the bottom surface of the floor. At least two of the first reinforcing straps are attached to the enclosure.
[0020] In another variant, the floor further includes at least two fastening portions extending outwardly from the first reinforcing straps and attaching to the enclosure and at least two securing portions. The securing portions attach the fastening portions to a lower edge of the front wall and to a lower edge of the surrounding wall.
[0021] In still another variant, the floor further includes means for removably securing the lower surface of the mattress pad to the top surface of the floor.
[0022] In yet another variant of the invention, the mattress support panel is formed of mesh material.
[0023] In still another variant, the mattress support panel further includes a series of reinforcing panels. The reinforcing panels are attached to the upper surface of the mattress support panel. A series of second reinforcing straps is provided. The second reinforcing straps are attached to the lower surface of the mattress support panel.
[0024] In another variant, spacing of the mattress support panel upwardly from the floor is adjustable between a first, lower position to at least one second higher position, thereby permitting the mattress pad to be maintained at at least two different heights relative to an upper mattress surface of the parental bed.
[0025] In still another variant, the mattress support panel is removably attached to the front wall and the surrounding wall at the outer perimeter using a first zipper.
[0026] In yet another variant, means are provided for securing an openable end of the first zipper.
[0027] In yet a further variant of the invention, the means for securing an openable end of the first zipper includes a first reversibly separable securing tab. The first securing tab attaches to a zipper pull of the first zipper. A zipper pull cover is provided. The zipper pull cover has a side edge, a top surface, a bottom surface and a first reversibly separable pad attached to the bottom surface. The zipper pull cover is attached at the side edge to an inner surface of either the front wall or the surrounding wall adjacent the openable end of the first zipper. A second reversibly separable attachment pad is attached to the upper surface of the mattress support panel adjacent the openable end of the first zipper. When the first zipper is in a closed position, the first reversibly separable pad of the zipper pull cover will attach to the first securing tab and the second reversibly separable attachment pad, thereby preventing easy opening of the first zipper.
[0028] In still a further variant, a flexible covering for an upper portion of the first zipper is provided to prevent injury to an infant or small child.
[0029] In another variant, the mattress support panel includes a surrounding edge panel. The surrounding edge panel extends upwardly from the outer perimeter for a first predetermined distance and has an upper edge. A second zipper is provided. The second zipper removably attaches the surrounding edge panel to the front wall and the surrounding wall at the upper edge. When the second zipper attaches the upper edge to the front wall and the surrounding wall the mattress support panel will be located at the first lower position. When the first zipper also attaches the outer perimeter to the front wall and the surrounding wall the mattress support panel will be disposed at one of the second higher positions.
[0030] In still another variant, means are provided for securing an openable end of the second zipper.
[0031] In yet another variant, the means for securing an openable end of the second zipper includes a second reversibly separable securing tab. The second securing tab attaches to a zipper pull of the second zipper. The zipper pull cover is attached at the side edge to an inner surface of either the front wall or the surrounding wall adjacent the openable ends of the first zipper and the second zipper. A third reversibly separable attachment pad attaches adjacent the upper edge of the surrounding edge panel adjacent the openable end of the second zipper. When the second zipper is in a closed position, the first reversibly separable pad of the zipper pull cover will attach to the second securing tab and the third reversibly separable attachment pad, thereby preventing easy opening of the second zipper.
[0032] In a further variant, the flexible covering is provided for an upper portion of the second zipper to prevent injury to an infant or small child.
[0033] In still a further variant of the invention, the mattress support panel includes means for removably securing the lower surface of the mattress pad to the upper surface of the mattress support panel.
[0034] In another variant, the mattress pad includes means for removably securing the lower surface of the mattress pad to either the upper surface of the mattress support panel or the top surface of the floor.
[0035] In yet another variant, the mattress pad includes a washable cover. The washable cover is sized and shaped to fit over the mattress pad. Means are provided for removably securing the washable cover to the lower surface of the mattress pad. The washable cover has means for being removably secured to the upper surface of the mattress support panel or the floor.
[0036] In yet a further variant, the mattress pad includes at least three portions. Each of the portions has a rigid bottom section and a padded top section. The portions are hingedly attached to each other. Means are provided for removably attaching outer edges of the mattress pad together. The mattress pad serves as an enclosure for the co-sleeper when folded for transport and storage.
[0037] In still a further variant, the mattress pad includes a slat-receiving pocket and a stiffening slat. The slat receiving pocket extends across the bottom sections of the at least three portions and is sized and shaped to receive the stiffening slat for further supporting the mattress pad.
[0038] In another variant of the invention, at least a portion of the surrounding wall is formed of mesh material.
[0039] In still another variant, the surrounding wall includes a reclosable opening. The opening provides access to a space between the floor and the mattress support panel.
[0040] In yet another variant, the co-sleeper includes height adjusting means for changing a height of the co-sleeper such that the upper surface of the mattress support panel is located at a level below an upper surface of a mattress of the parental bed.
[0041] In yet a further variant, the height adjusting means comprises extensions that attach to lower edges of the enclosure.
[0042] In still a further variant, the co-sleeper includes removable wheels. The wheels attach to either the lower edges of the enclosure or the extensions.
[0043] In another variant, the co-sleeper includes at least one pair of alignment means through which the securing strap assembly is directed for maintaining the securing strap assembly in horizontal orientation and preventing lifting or bucking of the co-sleeper when secured to the parental bed. The co-sleeper also includes at least one pair of securing strap attachment means for fastening the securing strap assembly to the co-sleeper.
[0044] In still another variant, the securing strap assembly includes a strap member that has a first end and a second end. A resistance plate member is provided that has at least two slots vertically aligned and centrally located at which the strap member is attached such that the first end and the second end are equidistant from the plate member. Attachment cooperation means are located at the first end and the second end of the strap member for reversible connection to one of the pairs of securing strap attachment means. Adjusting means are provided for adjusting a length of the strap member and tightening it after connecting the attachment cooperation means to one of the pairs of securing strap attachment means. The strap member is properly positioned when located under a mattress and above a surface on which the mattress rests on the parental bed and held in place by the resistance plate member located vertically at a side of the parental bed opposite placement of the co-sleeper and the strap member is tightened so the co-sleeper is held fast to the parental bed.
[0045] In still a further variant of the invention, the front wall is comprised of flexible material and means for supporting the flexible material.
[0046] In yet a further variant, the co-sleeper includes means for constraining a portion of the flexible material when the front wall is lowered from the first position at the top to one of the second positions below the top.
[0047] In another variant, the means for constraining a portion of the flexible material includes a first strap portion. The first strap portion has a first end and a second end and is attached at the first end to an inner surface of the front wall at a level below the at least one second position. A receiving connector is provided. The receiving connector is attached to the first strap portion at the second end. A second strap portion is provided. The second strap portion has a first end and a second end and is attached at the first end to an outer surface of the front wall at a level below the at least one second position. An attaching connector is provided. The attaching connector has a slot. The slot is sized and shaped to fit slidably over the second strap portion. The second strap portion is looped through the slot of the attaching connector and removably attached to itself with a slidable adjusting buckle. When the front wall is in one of the second positions and the attaching connector is disposed in the receiving connector, the slidable adjusting buckle is moved to tighten the first and second strap portions so as to constrain the portion of the flexible material.
[0048] In still another variant, the co-sleeper includes an inside pocket. The inside pocket has a reversibly closable top opening and is located on the inner surface of the front wall with the first end of the first strap portion attached to the front wall within the inside pocket. An outside pocket is provided. The outside pocket has a reversibly closable top opening and is located upon the outer surface of the front wall with the first end of the second strap portion attached to the front wall within the outside pocket. When the first and second strap portions with attached receiving and attaching connectors are not needed to constrain the portion of the flexible material, the strap portions are stored within the inside and outside pockets, respectively.
[0049] In yet another variant, a portion of the front wall is formed of mesh material.
[0050] In a further variant, the means for reversibly lowering the height of at least a portion of the front wall includes a first set of reversibly separable fasteners located adjacent a top edge of the front wall adjacent a first side edge of the front wall. A second set of reversibly separable fasteners is located adjacent a top edge of the front wall adjacent a second side edge of the front wall. When the front wall is lowered from the first, upper position to one of the second lower positions, the reversibly separable fasteners are opened to permit the front wall to be lowered while securing any excessive flexible material when the front wall is in the first upper position.
[0051] In yet a further variant, at least one upper mattress control slit is provided. The upper mattress control slit penetrates the mattress support panel. At least one upper releasable attachment means is provided. The upper releasable attachment means is located on the lower surface of the mattress support panel adjacent the mattress control slit. At least one attachment strip is provided. The attachment strip is attached to the lower surface of the mattress pad, is sized and shaped to fit slidably through the mattress control slit and has means for attaching to the releasable attachment means. When the mattress pad is located on the mattress support panel, the attachment strip is located through the upper mattress control slit and attached to the upper releasable attachment means, the mattress pad will be removably secured to the mattress support panel.
[0052] In still a further variant, at least one lower mattress control slit is provided. The lower mattress control slit penetrates the floor. At least one lower releasable attachment means is provided. The lower releasable attachment means is located on the bottom surface of the floor adjacent the lower mattress control slit. At least one attachment strip is provided. The attachment strip is attached to the lower surface of the mattress pad, is sized and shaped to fit slidably through the lower mattress control slit and has means for attaching to the lower releasable attachment means. When the mattress pad is located on the floor, the attachment strip is located through the lower mattress control slit and attached to the lower releasable attachment means, the mattress pad will be removably secured to the floor.
[0053] In another variant of the invention, the portable combination bedside co-sleeper includes a rigid enclosure that has an open top, a floor, a front wall, a back wall, a first side wall, a second side wall and a mattress support panel. The floor has a top surface, a bottom surface and surrounding side edges and is attached to the front wall, back wall, first side wall and second side wall at the surrounding side edges. The mattress support panel has an upper surface, a lower surface, an outer perimeter and is removably attached to the front wall, back wall, first side wall and second side wall at the outer perimeter and is spaced upwardly from the floor. A mattress pad is provided. The mattress pad has an upper surface, a lower surface and is sized and shaped to fit slidably between the front wall, back wall, first side wall and second side wall.
[0054] A rigid frame is provided. The frame is formed at the top by front and rear upper parallel horizontal rails, first and second upper side horizontal rails, two upper front corner members and two upper rear corner members in cooperation therewith. The frame is formed adjacent the floor by front and rear lower parallel horizontal rails and first side and second side lower parallel horizontal rails in cooperation therewith, a pair of front vertical rails and a pair of rear vertical rails in further cooperation with the two upper front corner members and the two upper rear corner members and the four lower corner leg members. The rigid frame supports the floor, the front wall, the back wall, the first side wall and the second side wall. Each upper front corner member is constructed of two reversibly separable complementary sections. The first of the sections is fixedly attached to an end of the front upper horizontal rail and the second of the sections is fixedly attached to an upper end of one of the front vertical rails. The upper front corner members support the upper front horizontal rail in a first position.
[0055] Receiving means are fixedly attached to each front vertical rail for receiving the first section of an upper front corner member and reversibly maintaining the upper front horizontal rail in at least one lower second position, thereby lowering the front wall and maintaining structural rigidity of the co-sleeper when the upper front horizontal rail is in one of the second positions. A securing strap assembly is provided for securing the co-sleeper to a parental bed. When the upper front horizontal rail and the front wall are in the raised first position, the co-sleeper is usable as a bassinet; and when the upper front horizontal rail and the front wall are then lowered to one of the second positions, the co-sleeper is usable as a changing table. Further, when the securing strap assembly is properly positioned and the co-sleeper is secured to the parental bed it will serve as a co-sleeper.
[0056] In still another variant, first and second padded covers are provided. Each of the padded covers is sized and shaped to fit over one of the two upper front corner members. Means are provided for attaching the first and second padded covers to the first and second side walls. When the upper front horizontal rail is in the second position and the first and second padded covers are installed over the upper front corner members, openings in the corner members will be covered and thus protected from entry by fingers of infants or small children.
[0057] In yet another variant, the front and rear upper parallel horizontal rails and first and second upper side horizontal rails are padded.
[0058] In a further variant, the floor includes a series of first reinforcing straps. The first reinforcing straps are located on the bottom surface of the floor. At least two of the first reinforcing straps are attached to the rigid frame.
[0059] In still a further variant, the floor includes at least two fastening portions extending outwardly from the first reinforcing straps and attaching to the rigid frame. At least two securing portions are provided. The securing portions attach the fastening portions to lower edges of the front wall, the back wall, the first side wall and the second side wall.
[0060] In yet a further variant, the floor includes means for removably securing the lower surface of the mattress pad to the top surface of the floor.
[0061] In another variant of the invention, the mattress support panel is formed of mesh material.
[0062] In still another variant, the mattress support panel includes a series of reinforcing panels. The reinforcing panels are attached to the upper surface of the mattress support panel. A series of second reinforcing straps is provided. The second reinforcing straps are attached to the lower surface of the mattress support panel.
[0063] In a further variant, spacing of the mattress support panel upwardly from the floor is adjustable between a first, lower position to at least one second higher position. This permits the mattress pad to be maintained at at least two different heights relative to an upper mattress surface of the parental bed.
[0064] In still a further variant, the mattress support panel is removably attached to the front wall, back wall, first side wall and second side wall at the outer perimeter using a first zipper.
[0065] In yet a further variant, means are provided for securing an openable end of the first zipper.
[0066] In another variant, the means for securing an openable end of the first zipper includes a first reversibly separable securing tab. The first securing tab is attached to a zipper pull of the first zipper. A zipper pull cover is provided. The zipper pull cover has a side edge, a top surface, a bottom surface and a first reversibly separable pad attached to the bottom surface. The zipper pull cover is attached at the side edge to an inner surface of either of the front wall, back wall, first side wall and second side wall adjacent the openable end of the first zipper. A second reversibly separable attachment pad is provided. The second attachment pad is attached to the upper surface of the mattress support panel adjacent the openable end of the first zipper. When the first zipper is in a closed position, the first reversibly separable pad of the zipper pull cover will attach to the first securing tab and the second reversibly separable attachment pad, thereby preventing easy opening of the first zipper.
[0067] In still another variant, a flexible covering is provided for an upper portion of the first zipper to prevent injury to an infant or small child.
[0068] In yet another variant, the mattress support panel includes a surrounding edge panel. The surrounding edge panel extends upwardly from the outer perimeter for a first predetermined distance and has an upper edge. A second zipper is provided. The second zipper removably attaches the surrounding edge panel either to the front wall, the back wall, the first side wall and the second side wall at the upper edge. When the second zipper attaches the upper edge to the front wall, the back wall, the first side wall and the second side wall the mattress support panel will be located on the first lower position. When the first zipper also attaches the outer perimeter to the front wall, the back wall, the first side wall and the second side wall the mattress support panel will be located on the second higher position.
[0069] In a further variant, means are provided for securing an openable end of the second zipper.
[0070] In still a further variant, the means for securing an openable end of the second zipper includes a second reversibly separable securing tab. The second securing tab attaches to a zipper pull of the second zipper. A zipper pull cover is provided. The zipper pull cover has a side edge, a top surface, a bottom surface and a first reversibly separable pad attached to the bottom surface. The zipper pull cover is attached at the side edge to an inner surface of either of the front wall, back wall, first side wall and second side wall adjacent the openable end of the second zipper. A third reversibly separable attachment pad is provided. The third attachment pad is attached adjacent the upper edge of the surrounding edge panel adjacent the openable end of the second zipper. When the second zipper is in a closed position, the first reversibly separable pad of the zipper pull cover will attach to the second securing tab and the third reversibly separable attachment pad, thereby preventing easy opening of the second zipper.
[0071] In yet a further variant of the invention, a flexible covering is provided for an upper portion of the second zipper to prevent injury to an infant or small child.
[0072] In another variant, the mattress support panel includes means for removably securing the lower surface of the mattress pad to the upper surface of the mattress support panel.
[0073] In still another variant, the mattress pad includes means for removably securing the lower surface of the mattress pad to either the upper surface of the mattress support panel or the top surface of the floor.
[0074] In yet another variant, the mattress pad includes a washable cover. The washable cover is sized and shaped to fit over the mattress pad. Means are provided for removably securing the washable cover to the lower surface of the mattress pad. The washable cover has means for being removably secured to the lower surface of the mattress pad and means for being removably secured to the upper surface of the mattress support panel.
[0075] In a further variant, at least a portion of either of the back wall, the first side wall and the second side wall is formed of mesh material.
[0076] In still a further variant, the back wall includes a reclosable opening. The reclosable opening provides access to a space between the floor and the mattress support panel.
[0077] In yet a further variant, the co-sleeper includes height-adjusting means for changing a height of the co-sleeper such that the upper surface of the mattress support panel is located on at a level below an upper surface of a mattress of the parental bed.
[0078] In yet another variant, the height adjusting means includes extensions that attach to the four lower corner leg members.
[0079] In still another variant, removable wheels are provided. The wheels attach to either of four lower corner leg members and the extensions.
[0080] In a further variant, the co-sleeper includes at least one pair of alignment means through which the securing strap assembly is directed for maintaining the securing strap assembly in horizontal orientation and preventing lifting or bucking of the co-sleeper when secured to the parental bed. The co-sleeper also includes at least one pair of securing strap attachment means for fastening the securing strap assembly to the co-sleeper.
[0081] In still a further variant, the securing strap assembly includes a strap member that has a first end and a second end. A resistance plate member is provided that has at least two slots vertically aligned and centrally located on at which the strap member is attached such that the first end and the second end are equidistant from the plate member. Attachment cooperation means are provided that are located at the first end and the second end of the strap member for reversible connection to one of the pairs of securing strap attachment means. Adjusting means are provided for adjusting a length of the strap member and tightening it after connecting the attachment cooperation means to one of the pairs of security strap attachment means. The strap member is properly positioned when located under a mattress and above a surface on which the mattress rests on the parental bed. The strap member is held in place by the resistance plate member located vertically at a side of the parental bed opposite placement of the co-sleeper. The strap member is tightened so the co-sleeper is held fast to the parental bed.
[0082] In another variant of the invention, the front wall is comprised of flexible material and means for supporting the flexible material.
[0083] In still another variant, means are provided for constraining a portion of the flexible material when the front wall is lowered from the first position at the top to one of the second positions below the top.
[0084] In yet another variant, the means for constraining a portion of the flexible material includes a first strap portion. The first strap portion has a first end and a second end and is attached at the first end to an inner surface of the front wall at a level below the at least one second position. A receiving connector is provided. The receiving connector is attached to the first strap portion at the second end. A second strap portion is provided. The second strap portion has a first end and a second end and is attached at the first end to an outer surface of the front wall at a level below the at least one second position. An attaching connector is provided. The attaching connector has a slot. The slot is sized and shaped to fit slidably over the second strap portion. The second strap portion is looped through the slot of the attaching connector and removably attached to itself with a slidable adjusting buckle. When the front wall is in one of the second positions and the attaching connector is located in the receiving connector, the slidable adjusting buckle may be moved to tighten the first and second strap portions so as to constrain the portion of the flexible material.
[0085] In still another variant, an inside pocket is provided. The inside pocket has a reversibly closable top opening and is located on the inner surface of the front wall with the first end of the first strap portion attached to the front wall within the inside pocket. An outside pocket is provided. The outside pocket has a reversibly closable top opening and is located on the outer surface of the front wall with the first end of the second strap portion attached to the front wall within the outside pocket. When the first and second strap portions with attached receiving and attaching connectors are not needed to constrain the portion of the flexible material, the strap portions are stored within the inside and outside pockets, respectively.
[0086] In yet another variant, a portion of the front wall is formed of mesh material.
[0087] In a further variant, the rigid frame includes means for pivotally mounting the front and rear upper horizontal rails to the upper front corner members and upper rear corner members, respectively. Frame locking devices positioned at center points of the front and rear upper horizontal rail are pivotally mounted to the rails permitting the upper rails to pivot downwardly from the open top of the enclosure. Means are provided for pivotally mounting the first and second upper side horizontal rails to the upper front and rear corner members. Frame locking devices positioned at center points of the first and second upper side horizontal rails are pivotally mounted to the rails permitting each of the rails to pivot downwardly from the open top of the enclosure.
[0088] Means are provided for pivotally mounting the first side and second side lower horizontal rails to the lower corner leg members. Frame pivoting devices positioned at center points of the first side and second side lower horizontal rails are pivotally mounted to the rails permitting each of the rails to pivot upwardly. Means are provided for pivotally mounting the front and rear lower horizontal rails to the lower front and rear corner leg members, respectively. Frame pivoting devices positioned at center points of the front and rear lower horizontal rails are pivotally mounted to the rails permitting each of the rails to pivot upwardly. The frame may be quickly folded into a compact package for transport and storage by releasing the locking devices positioned on the front and rear upper horizontal rails and first and second upper side horizontal rails, depressing the upper horizontal rails downwardly while pulling upwardly on the frame pivoting devices on the lower horizontal rails, thereby causing the upper and horizontal rails to bend downwardly, the lower horizontal rails to bend upwardly and the vertical rails to move inwardly.
[0089] In still a further variant, the mattress pad includes at least three portions. Each of the portions has a rigid bottom section and a padded top section. The portions are hingedly attached to each other. Means are provided for removably attaching outer edges of the mattress pad together. The mattress pad serves as an enclosure for the co-sleeper when folded for transport and storage.
[0090] In yet a further variant, the mattress pad further comprises a slat-receiving pocket and a stiffening slat. The slat receiving pocket extends across the bottom sections of the at least three portions and is sized and shaped to receive the stiffening slat for further supporting the mattress pad.
[0091] In another variant of the invention, the means for reversibly lowering the height of at least a portion of the front wall includes a first set of reversibly separable fasteners located adjacent a top edge of the front wall adjacent a first side edge of the front wall. A second set of reversibly separable fasteners is located adjacent the top edge of the front wall adjacent a second side edge of the front wall. When the front wall is lowered from the first, upper position to one of the second lower positions, the reversibly separable fasteners are opened to permit the front wall to be lowered while securing any excessive flexible material when the front wall is in the first upper position.
[0092] In yet another variant, the first and second sections of the upper front corner members and the receiving means fixedly attached to each front vertical rail for receiving the first section of the upper front corner members and reversibly maintaining the upper front horizontal rail in at least one lower second position include a T-shaped protrusion extending from a point adjacent a lower end of the first section of the upper front corner members toward an upper end of the first section terminating in a stop. A securing extension located on the first section adjacent and below the T-shaped protrusion is provided. The securing extension is bendable away from the T-shaped protrusion and includes a retaining ledge. A first mating T-shaped slot is provided. The T-shaped slot extends from a point adjacent an upper end of the second section of the upper front corner member and terminates above a lower end of the upper front corner members.
[0093] A second mating T-shaped slot extends from a point adjacent an upper end of the receiving means toward a lower end of the receiving means and terminates above a lower end of the receiving means. At least two locating features are provided. The locating features are positioned on the second section and the receiving means adjacent and below the first and second T-shaped slots. The locating features are sized, shaped and located to be removably engaged by the retaining ledge of the securing extension so that the first section of the upper front corner member may be secured to either the second section or the receiving means.
[0094] In still another variant, the rigid frame is formed of hollow tubing. The front, rear, first side and second side upper horizontal rails each have a first portion and a second portion. Each portion has an inboard end and an outboard end, and the frame locking devices positioned at center points of the upper horizontal rails include a connecting frame. The frame is pivotally mounted to the inboard ends of each of the first and second portions of the upper horizontal rails. The connecting frame includes a pair of locking holes. A pair of spring-loaded buttons is mounted within the upper horizontal rails. The buttons are sized, shaped and located to engage the locking holes in the connecting frame when the first and second portions of the upper horizontal rails are collinear. Means are provided for pushing both buttons inwardly so as to clear the locking holes in the connecting frame simultaneously, thereby permitting the upper horizontal rails to be pivoted downwardly.
[0095] In a further variant, the rigid frame is formed of hollow tubing. The front, rear, first side and second side lower horizontal rails each have a first portion and a second portion. Each portion has an inboard end and an outboard end. The frame pivoting devices positioned at center points of the lower horizontal rails include a spring housing. The spring housing is pivotally mounted upon a pair of mounting pins to the inboard ends of each of the first and second portions of the lower horizontal rails. The spring housing includes first and second pairs of arcurate alignment slots and first and second pairs of positioning detents. First and second alignment pins are provided. The alignment pins are mounted parallel to the mounting pins and spaced outwardly from the inboard ends of the first and second portions of the lower horizontal rails. The alignment pins are sized, shaped and located to fit slidably within the arcurate alignment slots. Each of the pairs of positioning detents is spaced apart by a distance slightly less than a diameter of one of the lower horizontal rails. When the first and second portions of the lower horizontal rails are collinear, the rails will be within the spring housing and when the rails are pivoted with respect to one another to fold the co-sleeper, the detents will be urged against the rails by a spring resistance of the housing, causing the housing to spread apart, such resistance serving to maintain collinear alignment of the lower horizontal rails when the co-sleeper is erected.
[0096] In a further variant, the first section of the front upper corner member is a male section and the second section is a female section. The second section has an opening sufficiently small so as to prevent entry of fingers of small children or infants.
[0097] In a final variant of the invention, the receiving means is a female section for association with a male section. The receiving means has an opening sufficiently small so as to prevent the entry of fingers of small children or infants.
BRIEF DESCRIPTION OF THE FIGURES
[0098] Understanding of the present invention will be facilitated by consideration of the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings, in which like numerals refer to like parts:
[0099] FIG. 1 is a perspective view of the preferred embodiment of the invention in a first position at the top;
[0100] FIG. 1A is a perspective view of the rigid frame of the preferred embodiment of the invention illustrating the two reversibly separable complimentary sections of the two upper front corner members, the receiving means, the frame locking devices and the frame pivoting devices;
[0101] FIG. 2 is a perspective view of the preferred embodiment of the invention in the second position below the top illustrating the height adjustment means, the removable wheels and the means for constraining a portion of the flexible material;
[0102] FIG. 2A is a partial cutaway perspective of the FIG. 1 embodiment illustrating the second strap portion attached to the front wall;
[0103] FIG. 3 is a cross-sectional side view of the enclosure illustrating the portion of the surrounding wall formed of mesh material and the reclosable opening;
[0104] FIG. 4 is a perspective view of the co-sleeper attached to the parents' bed by means of the safety strap assembly;
[0105] FIG. 5 is a perspective view of the co-sleeper illustrating the padded covers and means for attaching the padded covers to the side walls;
[0106] FIG. 6 is a perspective view of the enclosure illustrating the floor and top;
[0107] FIG. 7 is a perspective view of the enclosure illustrating the mattress support panel at the first lower position;
[0108] FIG. 8 is a cross-sectional detail of FIG. 7 taken along the line 8 - 8 ;
[0109] FIG. 9 is a perspective view of the enclosure illustrating the mattress support panel at the at least one second higher position;
[0110] FIG. 10 is a cross-sectional detail of FIG. 9 taken along the line 10 - 10 ;
[0111] FIG. 11 is a perspective view of the mattress pad with washable cover;
[0112] FIG. 11A is a perspective view of the means for removably securing the washable cover to the mattress pad and the means for removably securing the mattress pad to the mattress support panel;
[0113] FIG. 12 is a perspective detail view of the mattress support panel removably attached to the enclosure and the means for securing an openable end of the first zipper;
[0114] FIG. 12A is a perspective detail view of the means for securing an openable end of the first zipper, the first reversibly separable securing tab, the zipper pull cover of the first zipper, the second reversibly separable attachment pad, the surrounding edge panel, the flexible covering for an upper portion of the first zipper, the openable end of the second zipper, the second reversibly separable securing tab, the zipper pull cover of the second zipper and the third reversibly separable attachment pad;
[0115] FIG. 12B is a perspective detail view of the means for securing an openable end of the second zipper, the second reversibly separable securing tab, the zipper pull of the second zipper, the zipper pull cover and the third reversibly separable attachment pad;
[0116] FIG. 13 is a perspective view of the frame locking device;
[0117] FIG. 14 is a perspective view of the frame pivoting device;
[0118] FIG. 15 is a perspective view of the floor illustrating the lower mattress control slit, the lower releasable attachment means and the attachment strip;
[0119] FIG. 16 is a perspective view of the upper surface of the mattress support panel;
[0120] FIG. 16A is a perspective view of the lower surface of the mattress support panel;
[0121] FIG. 17 is a perspective view of the mattress pad illustrating the slat-receiving pocket and the stiffening slat;
[0122] FIG. 18 is a perspective view of the bottom surface of the floor and the enclosure;
[0123] FIG. 19 is a perspective view of the height adjusting means and removable wheels attached to the lower edges of the enclosure;
[0124] FIG. 20 is a perspective detail view of the means for reversibly lowering the height of at least a portion of the front wall;
[0125] FIG. 21 is a perspective detail view of the means for reversibly lowering the height of at least a portion of the front wall illustrating the T-shaped protrusion and the securing extension of the first section of the upper front corner member;
[0126] FIG. 22 is a perspective view of the FIG. 1 embodiment in partially collapsed condition;
[0127] FIG. 23 is a perspective view of the FIG. 1 embodiment in further collapsed condition; and
[0128] FIG. 24 is a perspective view of the FIG. 1 embodiment secured within the segmented rigid floor member as a compact package for transportation and storage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0129] As illustrated in FIGS. 1, 2 , 4 , 6 , 11 , 15 , 16 and 16 A, the present invention is a portable combination bedside co-sleeper 10 convertibly adapted for use as a bassinet, changing table and playpen. The co-sleeper 10 , includes an enclosure 15 that has an open top 20 , a floor 25 , a mattress support panel 30 , a front wall 35 , and at least one surrounding wall 40 connected to the front wall 35 . The floor 25 has a top surface 45 , a bottom surface 50 and surrounding side edges 55 and is attached to the front wall 35 and the surrounding wall 40 at the surrounding side edges 55 . The mattress support panel 30 has an upper surface 60 , a lower surface 65 , an outer perimeter 70 and is removably attached to the front wall 35 and the surrounding wall 40 at the outer perimeter 70 and is spaced upwardly from the floor 25 . A mattress pad 75 is provided. The mattress pad 75 has an upper surface 80 , a lower surface 85 and is sized and shaped to fit slidably between the front wall 35 and the surrounding wall 40 .
[0130] Means 90 are provided for, reversibly lowering a height 95 of at least a portion 100 of the front wall 35 , from a first position 105 at the top 20 to at least one second position 110 below the top 20 . A securing strap assembly 115 is provided for securing the co-sleeper 10 to a parental bed 120 . When the front wall 35 is raised to the first position 105 , the co-sleeper 10 is usable as a bassinet; and when the front wall 35 is then lowered to one of its second positions 110 , the co-sleeper 10 is usable as a changing table. When the securing strap assembly 115 is properly positioned and the co-sleeper 10 is secured to the parental bed 120 it will serve as a co-sleeper 10 .
[0131] In a variant of the invention, as shown in FIG. 18 , the floor 25 further includes a series of first reinforcing straps 125 . The first reinforcing straps 125 are located upon the bottom surface 50 of the floor 25 . At least two of the first reinforcing straps 125 are attached to the enclosure 15 .
[0132] In another variant, as shown in FIGS. 3 and 18 , the floor 25 further includes at least two fastening portions 130 extending outwardly from the first reinforcing straps 125 and attaching to the enclosure 15 and at least two securing portions 135 . The securing portions 135 attach the fastening portions 130 to a lower edge 140 of the front wall 35 and to a lower edge 145 of the surrounding wall 40 .
[0133] In still another variant, as shown in FIG. 6 , the floor 25 further includes means 150 for removably securing the lower surface 85 of the mattress pad 75 to the top surface 45 of the floor 25 .
[0134] In yet another variant of the invention, as shown in FIG. 16 , the mattress support panel 30 is formed of mesh material 155 .
[0135] In still another variant, as shown in FIGS. 16 and 16 A, the mattress support panel 30 further includes a series of reinforcing panels 160 . The reinforcing panels 160 are attached to the upper surface 60 of the mattress support panel 30 . A series of second reinforcing straps 165 is provided. The second reinforcing straps 165 are attached to the lower surface 65 of the mattress support panel 30 .
[0136] In another variant, as shown in FIGS. 7 and 9 , spacing of the mattress support panel 30 upwardly from the floor 25 is adjustable between a first, lower position 170 to at least one second higher position 175 , thereby permitting the mattress pad 75 to be maintained at at least two different heights relative to an upper mattress surface 177 of the parental bed 120 .
[0137] In still another variant, as shown in FIG. 12 , the mattress support panel 30 is removably attached to the front wall 35 and the surrounding wall 40 at the outer perimeter 70 using a first zipper 180 .
[0138] In yet another variant, as shown in FIGS. 12 and 12 A, means 185 are provided for securing an openable end 190 of the first zipper 180 .
[0139] In yet a further variant of the invention, as shown in FIGS. 12 and 12 A, the means 185 for securing an openable end 190 of the first zipper 180 includes a first reversibly separable securing tab 195 . The first securing tab 195 attaches to a zipper pull 200 of the first zipper 180 . A zipper pull cover 205 is provided. The zipper pull cover 205 has a side edge 210 , a top surface 215 , a bottom surface 220 and a first reversibly separable pad 225 attached to the bottom surface 220 . The zipper pull cover 205 is attached at the side edge 210 to an inner surface 230 of either the front wall 35 or the surrounding wall 40 adjacent the openable end 190 of the first zipper 180 . A second reversibly separable attachment pad 235 is attached to the upper surface 60 of the mattress support panel 30 adjacent the openable end 190 of the first zipper 180 . When the first zipper 180 is in a closed position 240 , the first reversibly separable pad 225 of the zipper pull cover 205 will attach to the first securing tab 195 and the second reversibly separable attachment pad 235 , thereby preventing easy opening of the first zipper 180 .
[0140] In still a further variant, as shown in FIG. 12A , a flexible covering 243 for an upper portion 245 of the first zipper 180 is provided to prevent injury to an infant or small child (not shown).
[0141] In another variant, as shown in FIGS. 12A and 12B , the mattress support panel 30 includes a surrounding edge panel 250 . The surrounding edge panel 250 extends upwardly from the outer perimeter 70 for a first predetermined distance 255 and has an upper edge 260 . A second zipper 265 is provided. The second zipper 265 removably attaches the surrounding edge panel 250 to the front wall 35 and the surrounding wall 40 at the upper edge 260 . When the second zipper 265 attaches the upper edge 260 to the front wall 35 and the surrounding wall 40 the mattress support panel 30 will be located at the first lower position 170 . When the first zipper 180 also attaches the outer perimeter 70 to the front wall 35 and the surrounding wall 40 the mattress support panel 30 will be located at one of the second higher positions 175 .
[0142] In still another variant, as shown in FIG. 12A , means 270 are provided for securing an openable end 275 of the second zipper 265 .
[0143] In yet another variant, as shown in FIGS. 8, 10 , 12 A and 12 B, the means 270 for securing an openable end 275 of the second zipper 265 includes a second reversibly separable securing tab 280 . The second securing tab 280 attaches to a zipper pull 285 of the second zipper 265 . The zipper pull cover 205 is attached at the side edge 210 to an inner surface 230 of either the front wall 35 or the surrounding wall 40 adjacent the openable ends 190 , 275 of the first zipper 180 and the second zipper 265 . A third reversibly separable attachment pad 290 attaches adjacent the upper edge 260 of the surrounding edge panel 250 adjacent the openable end 275 of the second zipper 265 . When the second zipper 265 is in a closed position 295 , the first reversibly separable pad 225 of the zipper pull cover 205 will attach to the second securing tab 280 and the third reversibly separable attachment pad 290 , thereby preventing easy opening of the second zipper 265 .
[0144] In a further variant, as shown in FIG. 12A , the flexible covering 243 is provided for an upper portion 305 of the second zipper 265 to prevent injury to an infant or small child (not shown).
[0145] In still a further variant of the invention, as shown in FIG. 16 , the mattress support panel 30 includes means 310 for removably securing the lower surface 85 of the mattress pad 75 to the upper surface 60 of the mattress support panel 30 .
[0146] In another variant, as shown in FIG. 11A , the mattress pad 75 includes means 315 for removably securing the lower surface 85 of the mattress pad 75 to either the upper surface 60 of the mattress support panel 30 or the top surface 45 of the floor 25 .
[0147] In yet another variant, as shown in FIGS. 11 and 11 A, the mattress pad 75 includes a washable cover 320 . The washable cover 320 is sized and shaped to fit over the mattress pad 75 . Means 325 are provided for removably securing the washable cover 320 to the lower surface 85 of the mattress pad 75 . The washable cover 320 has means 330 for being removably secured to the upper surface 60 of the mattress support panel 30 or the floor 25 .
[0148] In yet a further variant, as shown in FIGS. 11 and 24 , the mattress pad 75 includes at least three portions 333 . Each of the portions 333 has a rigid bottom section 335 and a padded top section 340 . The portions 333 are hingedly attached to each other. Means 345 are provided for removably attaching outer edges 350 of the mattress pad 75 together. The mattress pad 75 serves as an enclosure 355 for the co-sleeper 10 when folded for transport and storage.
[0149] In still a further variant, as shown in FIG. 17 , the mattress pad 75 includes a slat-receiving pocket 360 and a stiffening slat 365 . The slat receiving pocket 360 extends across the bottom sections 335 of the at least three portions 333 and is sized and shaped to receive the stiffening slat 365 for further supporting the mattress pad 75 .
[0150] In another variant of the invention, as shown in FIG. 3 , at least a portion 370 of the surrounding wall 40 is formed of mesh material 375 .
[0151] In still another variant, as shown in FIG. 3 , the surrounding wall 40 includes a reclosable opening 380 . The opening 380 provides access to a space 385 between the floor 25 and the mattress support panel 30 .
[0152] In yet another variant, as shown in FIGS. 2 and 19 , the co-sleeper 10 includes height adjusting means 390 for changing a height 395 of the co-sleeper 10 such that the upper surface 60 of the mattress support panel 30 is located at a level 400 below an upper surface 405 of a mattress 410 of the parental bed 120 .
[0153] In yet a further variant, a shown in FIGS. 2, 3 and 19 , the height adjusting means 390 comprises extensions 415 that attach to lower edges 420 of the enclosure 15 .
[0154] In still a further variant, as shown in FIGS. 2, 3 and 19 , the co-sleeper 10 includes removable wheels 425 . The wheels 425 attach to either the lower edges 420 of the enclosure 15 or the extensions 415 .
[0155] In another variant, as shown in FIG. 4 , the co-sleeper 10 includes at least one pair of alignment means 430 through which the securing strap assembly 115 is directed for maintaining the securing strap assembly 115 in horizontal orientation and preventing lifting or bucking of the co-sleeper 10 when secured to the parental bed 120 . The co-sleeper 10 also includes at least one pair of securing strap attachment means 435 for fastening the securing strap assembly 115 to the co-sleeper 10 .
[0156] In still another variant, as shown in FIG. 4 , the securing strap assembly 115 includes a strap member 440 that has a first end 445 and a second end 450 . A resistance plate member 455 is provided that has at least two slots 460 vertically aligned and centrally located at which the strap member 440 is attached such that the first end 445 and the second end 450 are equidistant from the plate member 455 . Attachment cooperation means 465 are located at the first end 445 and the second end 450 of the strap member 440 for reversible connection to one of the pairs of securing strap attachment means 435 . Adjusting means 470 are provided for adjusting a length 475 of the strap member 440 and tightening it after connecting the attachment cooperation means 465 to one of the pairs of securing strap attachment means 435 . The strap member 440 is properly positioned when located under a mattress 410 and above a surface 485 on which the mattress 410 rests on the parental bed 120 and held in place by the resistance plate member 455 located vertically at a side 490 of the parental bed 120 opposite placement of the co-sleeper 10 and the strap member 440 is tightened so the co-sleeper 10 is held fast to the parental bed 120 .
[0157] In still a further variant of the invention, as shown in FIG. 2 , the front wall 35 is comprised of flexible material 495 and means 500 for supporting the flexible material 495 .
[0158] In yet a further variant, as shown in FIGS. 1 and 2 , the co-sleeper 10 includes means 505 for constraining a portion 510 of the flexible material 495 when the front wall 35 is lowered from the first position 105 at the top 20 to one of the second positions 110 below the top 20 .
[0159] In another variant, as shown in FIGS. 2A and 6 , the means 505 for constraining a portion 510 of the flexible material 495 includes a first strap portion 515 . The first strap portion 515 has a first end 520 and a second end 525 and is attached at the first end 520 to an inner surface 530 of the front wall 35 at a level 532 below the at least one second position 110 . A receiving connector 535 is provided. The receiving connector 535 is attached to the first strap portion 515 at the second end 525 . A second strap portion 540 is provided. The second strap portion 540 has a first end 545 and a second end 547 and is attached at the first end 545 to an outer surface 550 of the front wall 35 at a level 555 below the at least one second position 110 . An attaching connector 560 is provided. The attaching connector 560 has a slot 565 . The slot 565 is sized and shaped to fit slidably over the second strap portion 540 . The second strap portion 540 is looped through the slot 565 of the attaching connector 560 and removably attached to itself 540 with a slidable adjusting buckle 570 . When the front wall 35 is in one of the second positions 110 and the attaching connector 560 is located in the receiving connector 535 , the slidable adjusting buckle 570 is moved to tighten the first 515 and second 540 strap portions so as to constrain the portion 510 of the flexible material 495 .
[0160] In still another variant, as shown in FIGS. 2A and 6 , the co-sleeper 10 includes an inside pocket 575 . The inside pocket 575 has a reversibly closable top opening 580 and is located on the inner surface 530 of the front wall 35 with the first end 520 of the first strap portion 515 attached to the front wall 35 within the inside pocket 575 . An outside pocket 585 is provided. The outside pocket 585 has a reversibly closable top opening 590 and is located upon the outer surface 550 of the front wall 35 with the first end 545 of the second strap portion 540 attached to the front wall 35 within the outside pocket 585 . When the first 515 and second 540 strap portions with attached receiving 535 and attaching 560 connectors are not needed to constrain the portion 510 of the flexible material 495 , the strap portions 515 , 540 are stored within the inside 575 and outside 585 pockets, respectively.
[0161] In yet another variant, as shown in FIG. 1 , a portion 595 of the front wall 35 is formed of mesh material 600 .
[0162] In a further variant, as shown in FIGS. 1, 2 , 20 and 21 , the means 90 for reversibly lowering the height 95 of at least a portion 100 of the front wall 35 includes a first set of reversibly separable fasteners 605 located adjacent a top edge 610 of the front wall 35 adjacent a first side edge 615 of the front wall 35 . A second set of reversibly separable fasteners 620 is located adjacent the top edge 610 of the front wall 35 adjacent a second side edge 625 of the front wall 35 . When the front wall 35 is lowered from the first, upper position 105 to one of the second lower positions 110 , the reversibly separable fasteners 605 , 620 are opened to permit the front wall 35 to be lowered while securing any excessive flexible material 630 when the front wall 35 is in the first upper position 105 .
[0163] In yet a further variant, as shown in FIGS. 11A and 16 , at least one upper mattress control slit 635 is provided. The upper mattress control slit 635 penetrates the mattress support panel 30 . At least one upper releasable attachment means 640 is provided. The upper releasable attachment means 640 is located on the lower surface 65 of the mattress support panel 30 adjacent the mattress control slit 635 . At least one attachment strip 645 is provided. The attachment strip 645 is attached to the lower surface 85 of the mattress pad 75 , is sized and shaped to fit slidably through the mattress control slit 635 and has means 650 for attaching to the releasable attachment means 640 . When the mattress pad 75 is located on the mattress support panel 30 , the attachment strip 645 is located through the upper mattress control slit 635 and attached to the upper releasable attachment means 640 , the mattress pad 75 will be removably secured to the mattress support panel 30 .
[0164] In still a further variant, as shown in FIGS. 11A and 15 , at least one lower mattress control slit 652 is provided. The lower mattress control slit 652 penetrates the floor 25 . At least one lower releasable attachment means 655 is provided. The lower releasable attachment means 655 is located on the bottom surface 50 of the floor 25 adjacent the lower mattress control slit 652 . At least one attachment strip 645 is provided. The attachment strip 645 is attached to the lower surface 85 of the mattress pad 75 , is sized and shaped to fit slidably through the lower mattress control slit 652 and has means for attaching to the lower releasable attachment means 655 . When the mattress pad 75 is located on the floor 25 , the attachment strip 645 is located through the lower mattress control slit 652 and attached to the lower releasable attachment means 655 , the mattress pad 75 will be removably secured to the floor 25 .
[0165] In another variant of the invention, as shown in FIGS. 1, 1A , 4 , 11 , 15 , 16 , 20 and 21 , the portable combination bedside co-sleeper 10 includes a rigid enclosure 660 that has an open top 665 , a floor 670 , a front wall 675 , a back wall 680 , a first side wall 685 , a second side wall 690 and a mattress support panel 30 . The floor 670 has a top surface 700 , a bottom surface 705 and surrounding side edges 710 and is attached to the front wall 675 , back wall 680 , first side wall 685 and second side wall 690 at the surrounding side edges 710 . The mattress support panel 30 has an upper surface 60 , a lower surface 65 , an outer perimeter 70 and is removably attached to the front wall 675 , back wall 680 , first side wall 685 and second side wall 690 at the outer perimeter 70 and is spaced upwardly from the floor 670 . A mattress pad 75 is provided. The mattress pad 75 has an upper surface 80 , a lower surface 85 and is sized and shaped to fit slidably between the front wall 675 , back wall 680 , first side wall 685 and second side wall 690 .
[0166] A rigid frame 730 is provided. The frame 730 is formed at the top 665 by front 735 and rear 740 upper parallel horizontal rails, first 745 and second 750 upper side horizontal rails, two upper front corner members 755 , 760 and two upper rear corner members 765 , 770 in cooperation therewith. The frame 730 is formed adjacent the floor 670 by front 775 and rear 780 lower parallel horizontal rails and first side 785 and second side 790 lower parallel horizontal rails in cooperation therewith, a pair of front vertical rails 795 , 800 and a pair of rear vertical rails 805 , 810 in further cooperation with the two upper front corner members 755 , 760 and the two upper rear corner members 765 , 770 and the four lower corner leg members 815 , 816 , 817 , 818 . The rigid frame 730 supports the floor 670 , the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 . Each upper front corner member 755 , 760 is constructed of two reversibly separable complementary sections 820 , 825 . The first of the sections 820 is fixedly attached to an end 830 of the front upper horizontal rail 735 and the second of the sections 825 is fixedly attached to an upper end 835 of one of the front vertical rails 795 , 800 . The upper front corner members 755 , 760 support the upper front horizontal rail 735 in a first position 840 .
[0167] Receiving means 845 are fixedly attached to each front vertical rail 795 , 800 for receiving the first section 820 of an upper front corner member 755 , 760 and reversibly maintaining the upper front horizontal rail 735 in at least one lower second position 850 , thereby lowering the front wall 675 and maintaining structural rigidity of the co-sleeper 10 when the upper front horizontal rail 735 is in one of the second positions 850 . A securing strap assembly 115 is provided for securing the co-sleeper 10 to a parental bed 120 . When the upper front horizontal rail 735 and the front wall 675 are in the raised first position 840 , the co-sleeper 10 is usable as a bassinet; and when the upper front horizontal rail 735 and the front wall 675 are then lowered to one of the second positions 850 , the co-sleeper 10 is usable as a changing table. Further, when the securing strap assembly 115 is properly positioned and the co-sleeper 10 is secured to the parental bed 120 it will serve as a co-sleeper 10 .
[0168] In still another variant, as shown in FIGS. 2, 5 and 20 , first 855 and second 860 padded covers are provided. Each of the padded covers 855 , 860 is sized and shaped to fit over one of the two upper front corner members 755 , 760 . Means 865 are provided for attaching the first 855 and second 860 padded covers to the first 685 and second 690 side walls. When the upper front horizontal rail 735 is in the second position 850 and the first 855 and second 860 padded covers are installed over the upper front corner members 755 , 760 , openings 867 , 868 in the corner members 755 , 760 will be covered and thus protected from entry by fingers of infants or small children (not shown).
[0169] In yet another variant, as shown in FIG. 22 , the front 735 and rear 740 upper parallel horizontal rails and first 745 and second 750 upper side horizontal rails are padded.
[0170] In a further variant, as shown in FIG. 18 , the floor 670 includes a series of first reinforcing straps 125 . The first reinforcing straps 125 are located on the bottom surface 705 of the floor 670 . At least two of the first reinforcing straps 125 are attached to the rigid frame 730 .
[0171] In still a further variant, as shown in FIGS. 3 and 18 , the floor 670 includes at least two fastening portions 130 extending outwardly from the first reinforcing straps 125 and attaching to the rigid frame 730 . At least two securing portions 135 are provided. The securing portions 135 attach the fastening portions 130 to lower edges 869 of the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 .
[0172] In yet a further variant, as shown in FIG. 15 , the floor 670 includes means 150 for removably securing the lower surface 85 of the mattress pad 75 to the top surface 700 of the floor 670 .
[0173] In another variant of the invention, as shown in FIG. 15 , the mattress support panel 30 is formed of mesh material 155 .
[0174] In still another variant, as shown in FIGS. 16 and 16 A, the mattress support panel 30 includes a series of reinforcing panels 160 . The reinforcing panels 160 are attached to the upper surface 60 of the mattress support panel 30 . A series of second reinforcing straps 165 is provided. The second reinforcing straps 165 are attached to the lower surface 65 of the mattress support panel 30 .
[0175] In a further variant, as shown in FIGS. 7, 9 , 12 and 12 A, spacing of the mattress support panel 30 upwardly from the floor 670 is adjustable between a first, lower position 170 to at least one second higher position 175 . This permits the mattress pad 75 to be maintained at at least two different heights relative to an upper mattress surface 177 of the parental bed 120 .
[0176] In still a further variant, as shown in FIG. 12 , the mattress support panel 30 is removably attached to the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 at the outer perimeter 70 using a first zipper 180 .
[0177] In yet a further variant, as shown in FIG. 12A , means 185 are provided for securing an openable end 190 of the first zipper 180 .
[0178] In another variant, as shown in FIGS. 12 and 12 A, the means 185 for securing an openable end 190 of the first zipper 180 includes a first reversibly separable securing tab 195 . The first securing tab 195 is attached to a zipper pull 200 of the first zipper 180 . A zipper pull cover 205 is provided. The zipper pull cover 205 has a side edge 210 , a top surface 215 , a bottom surface 220 and a first reversibly separable pad 225 attached to the bottom surface 220 . The zipper pull cover 205 is attached at the side edge 210 to an inner surface 230 of either of the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 adjacent the openable end 190 of the first zipper 180 . A second reversibly separable attachment pad 235 is provided. The second attachment pad 235 is attached to the upper surface 60 of the mattress support panel 30 adjacent the openable end 190 of the first zipper 180 . When the first zipper 180 is in a closed position 240 , the first reversibly separable pad 225 of the zipper pull cover 205 will attach to the first securing tab 195 and the second reversibly separable attachment pad 235 , thereby preventing easy opening of the first zipper 180 .
[0179] In still another variant, as shown in FIG. 12A , a flexible covering 243 is provided for an upper portion 245 of the first zipper 180 to prevent injury to an infant or small child (not shown).
[0180] In yet another variant, as shown in FIGS. 7, 8 , 9 , 10 and 12 A, the mattress support panel 30 includes a surrounding edge panel 250 . The surrounding edge panel 250 extends upwardly from the outer perimeter 725 for a first predetermined distance 255 and has an upper edge 260 . A second zipper 265 is provided. The second zipper 265 removably attaches the surrounding edge panel 250 either to the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 at the upper edge 260 . When the second zipper 265 attaches the upper edge 260 to the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 the mattress support panel 695 will be located on the first lower position 170 . When the first zipper 180 also attaches the outer perimeter 725 to the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 the mattress support panel 695 will be located on the second higher position 175 .
[0181] In a further variant, as shown in FIGS. 12A and 12B , means 270 are provided for securing an openable end 275 of the second zipper 265 .
[0182] In still a further variant, the means 270 for securing an openable end 275 of the second zipper 265 includes a second reversibly separable securing tab 280 . The second securing tab 280 attaches to a zipper pull 285 of the second zipper 265 . A zipper pull cover 205 is provided. The zipper pull cover 205 has a side edge 210 , a top surface 215 , a bottom surface 220 and a first reversibly separable pad 225 attached to the bottom surface 220 . The zipper pull cover 205 is attached at the side edge 210 to an inner surface 230 of either of the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 adjacent the openable end 275 of the second zipper 265 . A third reversibly separable attachment pad 290 is provided. The third attachment pad 290 is attached adjacent the upper edge 260 of the surrounding edge panel 250 adjacent the openable end 275 of the second zipper 265 . When the second zipper 265 is in a closed position 295 , the first reversibly separable pad 225 of the zipper pull cover 205 will attach to the second securing tab 280 and the third reversibly separable attachment pad 290 , thereby preventing easy opening of the second zipper 265 .
[0183] In yet a further variant of the invention, a flexible covering 243 is provided for an upper portion 305 of the second zipper 265 to prevent injury to an infant or small child (not shown).
[0184] In another variant, as shown in FIG. 16 , the mattress support panel 30 includes means 310 for removably securing the lower surface 85 of the mattress pad 75 to the upper surface 60 of the mattress support panel 30 .
[0185] In still another variant, as shown in FIG. 1A , the mattress pad 75 includes means 315 for removably securing the lower surface 85 of the mattress pad 75 to either the upper surface 60 of the mattress support panel 30 or the top surface 700 of the floor 670 .
[0186] In yet another variant, as shown in FIGS. 11 and 11 A, the mattress pad 75 includes a washable cover 320 . The washable cover 320 is sized and shaped to fit over the mattress pad 75 . Means 325 are provided for removably securing the washable cover 320 to the lower surface 85 of the mattress pad 75 . The washable cover 320 has means 325 for being removably secured to the lower surface 85 of the mattress pad 75 and means 330 for being removably secured to the upper surface 60 of the mattress support panel 30 .
[0187] In a further variant, as shown in FIG. 3 , at least a portion of either of the front wall 675 , the back wall 680 , the first side wall 685 and the second side wall 690 is formed of mesh material 375 .
[0188] In still a further variant, as shown in FIG. 3 , the back wall 680 includes a reclosable opening 380 . The reclosable opening 380 provides access to a space 385 between the floor 670 and the mattress support panel 30 .
[0189] In yet a further variant, as shown in FIGS. 2 and 19 , the co-sleeper 10 includes height-adjusting means 390 for changing a height 395 of the co-sleeper 10 such that the upper surface 60 of the mattress support panel 30 is located on at a level 400 below an upper surface 405 of a mattress 410 of the parental bed 120 .
[0190] In yet another variant, as shown in FIGS. 2, 3 and 19 , the height adjusting means 390 includes extensions 415 that attach to the four lower corner leg members 815 , 816 , 817 , 818 .
[0191] In still another variant, as shown in FIGS. 2, 3 and 19 , removable wheels 425 are provided. The wheels 425 attach to either of four lower corner leg members 815 , 816 , 817 , 818 and the extensions 415 .
[0192] In a further variant, as shown in FIG. 4 , the co-sleeper 10 includes at least one pair of alignment means 430 through which the securing strap assembly 115 is directed for maintaining the securing strap assembly 115 in horizontal orientation and preventing lifting or bucking of the co-sleeper 10 when secured to the parental bed 120 . The co-sleeper 10 also includes at least one pair of securing strap attachment means 435 for fastening the securing strap assembly 115 to the co-sleeper 10 .
[0193] In still a further variant, as shown in FIG. 4 , the securing strap assembly 115 includes a strap member 440 that has a first end 445 and a second end 450 . A resistance plate member 455 is provided that has at least two slots 460 vertically aligned and centrally located on at which the strap member 440 is attached such that the first end 445 and the second end 450 are equidistant from the plate member 455 . Attachment cooperation means 465 are provided that are located at the first end 445 and the second end 450 of the strap member 440 for reversible connection to one of the pairs of securing strap attachment means 435 . Adjusting means 470 are provided for adjusting a length 475 of the strap member 440 and tightening it after connecting the attachment cooperation means 465 to one of the pairs of security strap attachment means 435 . The strap member 440 is properly positioned when located under a mattress 410 and above a surface 485 on which the mattress 410 rests on the parental bed 120 . The strap member 440 is held in place by the resistance plate member 455 located vertically at a side 490 of the parental bed 120 opposite placement of the co-sleeper 10 . The strap member 440 is tightened so the co-sleeper 10 is held fast to the parental bed 120 .
[0194] In another variant of the invention, as shown in FIG. 2 , the front wall 675 is comprised of flexible material 495 and means 500 for supporting the flexible material 495 .
[0195] In still another variant, as shown in FIGS. 1 and 2 , means 505 are provided for constraining a portion 510 of the flexible material 495 when the front wall 675 is lowered from the first position 105 at the top 665 to one of the second positions 110 below the top 665 .
[0196] In yet another variant, as shown in FIGS. 2A and 6 , the means 505 for constraining a portion 510 of the flexible material 495 includes a first strap portion 515 . The first strap portion 515 has a first end 520 and a second end 525 and is attached at the first end 520 to an inner surface 530 of the front wall 675 at a level 532 below the at least one second position 110 . A receiving connector 535 is provided. The receiving connector 535 is attached to the first strap portion 515 at the second end 525 . A second strap portion 540 is provided. The second strap portion 540 has a first end 545 and a second end 547 and is attached at the first end 545 to an outer surface 550 of the front wall 675 at a level 555 below the at least one second position 110 . An attaching connector 560 is provided. The attaching connector 560 has a slot 565 . The slot 565 is sized and shaped to fit slidably over the second strap portion 540 . The second strap portion 540 is looped through the slot 565 of the attaching connector 560 and removably attached to itself 540 with a slidable adjusting buckle 570 . When the front wall 675 is in one of the second positions 110 and the attaching connector 560 is located in the receiving connector 535 , the slidable adjusting buckle 570 may be moved to tighten the first 515 and second 540 strap portions so as to constrain the portion 510 of the flexible material 495 .
[0197] In still another variant, as shown in FIGS. 2A and 6 , an inside pocket 575 is provided. The inside pocket 575 has a reversibly closable top opening 580 and is located on the inner surface 530 of the front wall 675 with the first end 520 of the first strap portion 515 attached to the front wall 675 within the inside pocket 575 . An outside pocket 585 is provided. The outside pocket 585 has a reversibly closable top opening 590 and is located on the outer surface 550 of the front wall 675 with the first end 545 of the second strap portion 540 attached to the front wall 675 within the outside pocket 585 . When the first 515 and second 540 strap portions with attached receiving 535 and attaching 560 connectors are not needed to constrain the portion 510 of the flexible material 495 , the strap portions 515 , 540 are stored within the inside 575 and outside 585 pockets, respectively.
[0198] In yet another variant, as shown in FIG. 1 , a portion 595 of the front wall 675 is formed of mesh material 600 .
[0199] In a further variant, as shown in FIGS. 1A, 13 , 14 , 22 , 23 and 24 , the rigid frame 730 includes means 870 for pivotally mounting the front 735 and rear 740 upper horizontal rails to the upper front corner members 755 , 760 and upper rear corner members 765 , 770 , respectively. Frame locking devices 875 positioned at center points 880 of the front 735 and rear 740 upper horizontal rails are pivotally mounted to the rails 735 , 740 permitting the upper rails 735 , 740 to pivot downwardly from the open top 665 of the enclosure 660 . Means 885 are provided for pivotally mounting the first 745 and second 750 upper side horizontal rails to the upper front 755 , 760 and rear 765 , 770 corner members. Frame locking devices 875 positioned at center points 890 of the first 745 and second 750 upper side horizontal rails are pivotally mounted to the rails 745 , 750 permitting each of the rails 745 , 750 to pivot downwardly from the open top 665 of the enclosure 660 .
[0200] Means 895 are provided for pivotally mounting the first side 785 and second side 790 lower horizontal rails to the lower corner leg members 815 , 816 , 817 , 818 . Frame pivoting devices 900 positioned at center points 905 of the first side 785 and second side 790 lower horizontal rails are pivotally mounted to the rails 785 , 790 permitting each of the rails 785 , 790 to pivot upwardly. Means 910 are provided for pivotally mounting the front 775 and rear 780 lower horizontal rails to the lower corner leg members 815 , 816 , 817 , 818 , respectively. Frame pivoting devices 900 positioned at center points 915 of the front 775 and rear 780 lower horizontal rails are pivotally mounted to the rails 775 , 780 permitting each of the rails 775 , 780 to pivot upwardly. The frame 730 may be quickly folded into a compact package 920 for transport and storage by releasing the locking devices 875 positioned on the front 735 and rear 740 upper horizontal rails and first 745 and second 750 upper side horizontal rails, depressing the upper horizontal rails 735 , 740 , 745 , 750 downwardly while pulling upwardly on the frame pivoting devices 900 on the lower horizontal rails 775 , 780 , 785 , 790 , thereby causing the upper 735 , 740 , 745 , 750 horizontal rails to bend downwardly, the lower horizontal rails 775 , 780 , 785 , 790 to bend upwardly and the vertical rails 795 , 800 , 805 , 810 to move inwardly.
[0201] In still a further variant, as shown in FIGS. 11 and 24 , the mattress pad 75 includes at least three portions 333 . Each of the portions 333 has a rigid bottom section 335 and a padded top section 340 . The portions 333 are hingedly attached to each other. Means 345 are provided for removably attaching outer edges 350 of the mattress pad 75 together. The mattress pad 75 serves as an enclosure 355 for the co-sleeper 10 when folded for transport and storage.
[0202] In yet a further variant, as shown in FIG. 17 , the mattress pad 75 further comprises a slat-receiving pocket 360 and a stiffening slat 365 . The slat receiving pocket 360 extends across the bottom sections 335 of the at least three portions 333 and is sized and shaped to receive the stiffening slat 365 for further supporting the mattress pad 75 .
[0203] In another variant of the invention, as shown in FIGS. 2, 20 and 21 , the means 90 for reversibly lowering the height 95 of at least a portion 100 of the front wall 675 includes a first set of reversibly separable fasteners 605 located adjacent a top edge 610 of the front wall 675 adjacent a first side edge 615 of the front wall 675 . A second set of reversibly separable fasteners 620 is located adjacent the top edge 610 of the front wall 675 adjacent a second side edge 625 of the front wall 675 . When the front wall 675 is lowered from the first, upper position 105 to one of the second lower positions 110 , the reversibly separable fasteners 605 , 620 are opened to permit the front wall 675 to be lowered while securing any excessive flexible material 630 when the front wall 675 is in the first upper position 105 .
[0204] In yet another variant, as shown in FIGS. 1, 20 and 21 , the first 820 and second 825 sections of the upper front corner members 755 , 760 and the receiving means 845 fixedly attached to each front vertical rail 795 , 780 for receiving the first section 820 of the upper front corner members 755 , 760 and reversibly maintaining the upper front horizontal rail 735 in at least one lower second position 850 include a T-shaped protrusion 925 extending from a point 930 adjacent a lower end 935 of the first section 820 of the upper front corner members 755 , 760 toward an upper end 937 of the first section 820 terminating in a stop 940 . A securing extension 945 located on the first section 820 adjacent and below the T-shaped protrusion 925 is provided. The securing extension 945 is bendable away from the T-shaped protrusion 925 and includes a retaining ledge 950 . A first mating T-shaped slot 955 is provided. The T-shaped slot 955 extends from a point 960 adjacent an upper end 965 of the second section 825 of the upper front corner member 755 , 760 and terminates above a lower end 970 of the upper front corner members 755 , 760 .
[0205] A second mating T-shaped slot 972 extends from a point 975 adjacent an upper end 980 of the receiving means 845 toward a lower end 985 of the receiving means 845 and terminates above a lower end 985 of the receiving means 845 . At least two locating features 990 , 995 are provided. The locating features 990 , 995 are positioned on the second section 825 and the receiving means 845 adjacent and below the first 955 and second 972 T-shaped slots. The locating features 990 , 995 are sized, shaped and located to be removably engaged by the retaining ledge 950 of the securing extension 945 so that the first section 820 of the upper front corner member 755 , 760 may be secured to either the second section 825 or the receiving means 845 .
[0206] In still another variant; as shown in FIG. 13 , the rigid frame 730 is formed of hollow tubing 1000 . The front 735 , rear 740 , first side 745 and second side 750 upper horizontal rails each have a first portion 1005 and a second portion 1010 . Each portion 1005 , 1010 has an inboard end 1015 and an outboard end 1020 , and the frame locking devices 875 positioned at center points 880 , 890 of the upper horizontal rails 735 , 740 , 745 , 750 include a connecting frame 1025 . The frame 1025 is pivotally mounted to the inboard ends 1015 of each of the first 1005 and second 1010 portions of the upper horizontal rails 735 , 740 , 745 , 750 . The connecting frame 1025 includes a pair of locking holes 1030 , 1031 . A pair of spring-loaded buttons 1035 , 1036 are mounted within the upper horizontal rails 735 , 740 , 745 , 750 . The buttons 1035 , 1036 are sized, shaped and located to engage the locking holes 1030 , 1031 in the connecting frame 1025 when the first 1005 and second 1010 portions of the upper horizontal rails 735 , 740 , 745 , 750 are collinear. Means 1040 are provided for pushing both buttons 1035 , 1036 inwardly so as to clear the locking holes 1030 , 1031 in the connecting frame 1025 simultaneously, thereby permitting the upper horizontal rails 735 , 740 , 745 , 750 to be pivoted downwardly.
[0207] In a further variant, as shown in FIG. 14 , the rigid frame 730 is formed of hollow tubing 1000 . The front 775 , rear 780 , first side 785 and second side 790 lower horizontal rails each have a first 1045 portion and a second portion 1050 . Each portion 1045 , 1050 has an inboard end 1055 and an outboard end 1060 . The frame pivoting devices 900 positioned at center points 905 , 915 of the lower horizontal rails 775 , 780 , 785 , 790 include a spring housing 1065 . The spring housing 1065 is pivotally mounted upon a pair of mounting pins 1070 , 1071 to the inboard ends 1055 of each of the first 1045 and second 1050 portions of the lower horizontal rails 775 , 780 , 785 , 790 . The spring housing 1065 includes first 1075 and second 1080 pairs of arcurate alignment slots and first 1090 and second 1095 pairs of positioning detents. First 1100 and second 1105 alignment pins are provided. The alignment pins 1100 , 1105 are mounted parallel to the mounting pins 1070 , 1071 and spaced outwardly from the inboard ends 1055 of the first 1045 and second 1050 portions of the lower horizontal rails 775 , 780 , 785 , 790 . The alignment pins 1100 , 1105 are sized, shaped and located to fit slidably within the arcurate alignment slots 1075 , 1080 . Each of the pairs 1090 , 1095 of positioning detents is spaced apart by a distance 1085 slightly less than a diameter 1110 of one of the lower horizontal rails 775 , 780 , 785 , 790 . When the first 1045 and second 1050 portions of the lower horizontal rails 775 , 780 , 785 , 790 are collinear, the rails 775 , 780 , 785 , 790 will be within the spring housing 1065 and when the rails 775 , 780 , 785 , 790 are pivoted with respect to one another to fold the co-sleeper 10 , the detents 1090 , 1095 will be urged against the rails 775 , 780 , 785 , 790 by a spring resistance of the housing 1065 , causing the housing 1065 to spread apart, such resistance serving to maintain collinear alignment of the lower horizontal rails 775 , 780 , 785 , 790 when the co-sleeper 10 is erected.
[0208] In a further variant, as shown in as shown in FIGS. 20 and 21 , the first section 820 of the front upper corner member 755 , 760 is a male section 1115 and the second section 825 is a female section 1120 . The second section 825 has an opening 1125 sufficiently small so as to prevent entry of fingers of small children or infants (not shown).
[0209] In a final variant of the invention, as shown in FIGS. 20 and 21 , the receiving means 845 is a female section 1130 for association with a male section 1131 . The receiving means 845 has an opening 1135 sufficiently small so as to prevent the entry of fingers of small children or infants (not shown).
[0210] While one embodiment of the present invention has been illustrated and described in detail, it is to be understood that this invention is not limited thereto and may be otherwise practiced within the scope of the following claims.
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A first playpen enclosure that converts easily to a bassinet, changing table or bed-side crib or “co-sleeper” that attaches securely to the parents' bed. A second enclosure support system maintains a padded enclosure and rigid floor panel at one or more predetermined levels below the top of the playpen to form the bassinet and co-sleeper. The second enclosure has a back, two sides, a bottom and a front flap that converts into a front wall for use in the bassinet mode and overhangs the front horizontal rail for use in the co-sleeper mode. The upper front corners are segmented into a movable section and a fixed section to facilitate lowering the front horizontal rail to at least one lower second position to accommodate various parental bed heights. Extensions of the fixed section are affixed to the front vertical rails and accept the movable sections in several positions to secure the rail in the second positions. The support means, padded enclosure and rigid floor panel complete the changing table with the edges of the front flap secured to the edges of the side walls. The playpen is placed adjacent the parents' bed with the front flap extended over the bed for use as a co-sleeper. Means are provided to secure loose flap material to the front of the co-sleeper. For co-sleeper use, reinforcing straps secure the unit to the parents' bed and prevent movement. The unit is easily folded with its components into a compact carrying case for transport or storage.
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This application is a continuation of application Ser. No. 033,856; filed Apr. 6, 1987, which is a continuation of Ser. No. 874,886 filed June 16, 1986, which is a continuation of Ser. No. 472,915 filed Mar. 7, 1983 all now abandoned.
BACKGROUND OF INVENTION
This invention relates to a coal liquefaction process, and more particularly, it relates to the hydrogenation of undissolved coal hydrogenation and and subsequent liquefaction thereof to provide useful hydrocarbon liquid and gas fuel products wherein solid coal particulates are hydrogenated in a coal/oil slurry of a hydrocarbon liquid solvent in the presence of a particles hydrogenation catalyst.
Conventional processes for coal liquefaction and hydrogenation include a preheating or thermal dissolution step for the coal-oil slurry feed prior to the catalyst reaction step, as generally disclosed in U.S. Pat. No. 3,519,555; 3,700,584; 3,791,957 and 4,111,788. Other coal hydrogenation processes use fine recycled catalysts at plug flow conditions and low solvent/coal ratios such as U.S. Pat. Nos. 4,090,943 and 4,102,775. In these processes, the coal-oil slurry is preheated to near the reactant temperature before feeding it into the catalytic reaction zone.
In these conventional coal hydrogenation processes which utilize the coal-slurry preheating step, the hydrogen donor potential or hydrogen concentration of the coal-derived slurrying oil therein is limited by its mobility and the hydrogen is usually consumed during the coal preheating and dissolution steps. These processes are also lacking in that the coal is not sufficiently hydrogenated to fully liquefy or convert coal to useful hydrocarbon liquids and gas fuel products as provided herein.
The conventional methods of coal liquefaction attempt to liquefy coal while having donatable hydrogen available in the solvent liquid to "seal off" free radicals which crack from the coal. Catalytic processes provide a greater quantity of hydrogen for this purpose by hydrogenating the solvent. In significant contrasts, the process of the present invention relies on substantial hydrogenation of the particulate coal in the first stage, particle but the predominant transfer of the donatable hydrogen to the coal particle takes place before the liquefaction thereof. Once the coal liquefies, the excess hydrogen in the products induces almost immediate reformation reactions which in turn result in stable, light compounds. In hydrocarbon the conventional liquefaction processes, more heavy residual products are made since the polymerization reactions, i.e., condensation, are competitive with the hydrogen transfer from solvent reformation reactions which occur much slower.
In a process developed by Qader and described in U.S. Pat. No. 4,331,530, a process for the hydrogenation of coal and subsequent treatment of hydrogenated coal to produce fuels and chemicals is provided. In this process, there is not any solvent used and the hydrogen provided in the process involves the hydrogen transfer from the gas phase to solid phase. In an attempt to hydrogenate the coal, the coal has been pulverized into very fine particles. This procedure of hydrogenating a dry coal, provides great difficulty in the hydrogenation thereof in order to liquefy or convert such coal to useful fuel products. Thus; the present coal hydrogenation and liquefaction process is needed in order to fully and more completely convert the hydrogenated coal of various types to useful low boiling hydrocarbons liquids and fuel products such as gasoline, diesel fuel oil, and naphtha.
SUMMARY OF INVENTION
The present invention provides a process for the two stage hydrogenation of particulate coal and the subsequent liquefaction thereof to provide useful hydrocarbon liquid and fuel products. The process comprises:
(a) mixing solid coal particles with a hydrocarbon liquid solvent in a solvent/coal weight ratio at least sufficient to provide a flowable coal/oil slurry of the solid coal particles;
(b) passing the coal/oil slurry and hydrogen upwardly through a first reaction zone containing a hydrocarbon liquid in a catalytic bed of particulate hydrogenation catalyst maintained at a temperature ranging from about 400° to about 700° F. and a hydrogen partial pressure of 100 to 2000 psig for a period of time sufficient to substantially hydrogenate the solid coal particles and liquid solvent in the coal/oil slurry;
(c) withdrawing the coal/oil slurry having the hydrogenated coal particles from the first reaction zone and passing the coal/oil slurry to a second reaction zone containing a catalytic bed of particulate hydrogenation catalyst which is maintained at a higher temperature between about 700° and about 850° F., and a hydrogen partial pressure of 0 to 2000 psig to convert the hydrogenated coal particles to gas and liquid fractions;
(d) passing the liquid fractions from the second reaction zone to a gas liquid, solid separation zone from which a liquid stream containing a reduced solids concentration is recycled to provide a hydrogenated coal-derived solvent liquid for the coal/oil slurry; and
(e) recovering from the separation zone hydrocarbon liquid distillate and gaseous hydrocarbon products.
In the process, the nominal residence time of the materials in the first reaction zone ranges from about 5 to about 90 minutes and the residence time in the second reaction zone ranges from about 1 to about 90 minutes.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention can best be understood by reference to the FIG. 1 drawing which is a schematic diagram of the present continuous two stage process of the hydrogenation/liquefaction of coal, wherein the hydrogenation reactor, liquefaction/conversion reactor, separation-purification systems and recycle conduits are shown.
FIG. 2 is a chart showing a comparison of yield distributions of solubles for the process of the present invention.
FIG. 3 is a graph showing the effect of hydrogen pressure on percent coal conversion.
FIGS. 4 and 5 are charts showing the comparative conversion results for the present conversion process compared to other processes for bituminous and low rank coals.
FIG. 6 is a chart showing comparative performance of the present process compared to other known processes for subbituminous coal mixed with heavy petroleum resid solvent.
DESCRIPTION OF INVENTION
The present process of hydrogenating coal particles and subsequently liquefying such hydrogenated particles to provide useful products involves the operation of two close-coupled catalytic bed reactors, i.e., first and second reaction zones. In the first reaction zone, the conditions are designed to promote the hydrogenation of the coal particles and to effect most of the heteroatom removal to by-products such as hydrogen sulfide, ammonia and water. In the second reaction zone, the conditions are maintained sufficient for the conversion/liquefaction of the hydrogenated coal to hydrocarbon convert it readily to liquid products while removing still more of the heteroatoms, e.g., hydrogen sulfide, ammonia and water.
According to the present invention, coal is hydrogenated prior to liquefaction in a system capable of providing usable hydrogen to sites within the solid coal matrix directly and also through the hydrogenated solvent oil. The process according to the present invention involves a well mixed catalytic first stage reaction zone in which a slurry of coal and hydrocarbon solvent is present with any suitable hydrogenation catalyst under increased temperature and hydrogen pressure. A suitable catalyst would be a cobalt/molybdenum catalyst on a substrate of alumina. According to the present invention, there is no limitation as to the hydrogenation catalyst used in the process. That is, any catalyst may be used providing it will promote the hydrogenation of solid coal particles. Also, the catalysts would be heterogenous and can be supported on any porous substrate, e.g., alumina or silica or mixtures thereof. The catalysts used in the beds of the first and second reaction zones may be a particulate catalyst having a substrate containing an active metal or metal compound selected from the group consisting of: Co/Mo; Ni/Mo; LiW or Sn promoted Co/Mo; NiS; CoS; MoS; FeS; FeS 2 ; LiH; and MgH 2 . Also, the catalyst used in the first and second reaction zones may be a noble metal such as platinum. More specifically, the catalyst may be a substrate material containing an active metal or metal compound selected from the group consisting of: metals of Group VIII of the Periodic Table, and their salts; tin; zinc; copper; chromium; and antimony. The catalyst may be the same in both the first and second reaction zones but this is not necessarily the preferred mode of operation.
The coal that is fed into this process and catalytically hydrogenated before it is liquefied may be any bituminous coal, such as Illinois No. 6 or Kentucky No. 11, or a subbituminous coal such as Wyodak. The feed material may also be lignite, or peat. In each case, the type of coal or coal/oil feedstock used will dictate the conditions required in the first and second reaction zones.
In the process, hydrogen is provided initially to the catalytic reaction to start up the process but during the course of the continuous two stage operation, hydrogen is recovered from the process and recycled to be fed into the first reaction zone to hydrogenate the feedstock, i.e., coal particles and hydrocarbon slurrying oil. During the process, a sufficient amount of hydrogen is provided in order to fully hydrogenate the coal feed so that it may be liquefied or converted easily at the higher temperature within the second reaction zone. Under normal conditions, the amount of hydrogen consumed or utilized in the first reaction zone, based on the weight of dry coal fed therein is between about 2.0 and about 4.0 W %. This amount of hydrogen may vary as based on the type of coal feed that is utilized in the present process.
The coal-derived solvent used to make up the coal/oil slurry may be any suitable coal-derived hydrocarbon liquid material wherein a substantial portion thereof has a normal boiling point ranging from about 400° F. to about 1100° F. Of this coal-derived liquid material i.e., solvent, at least about 50% has a normal boiling point above about 975° F.
According to the present invention, it has been found that a suitable hydrocarbon liquid solvent utilized in the coal/oil slurry may be selected from the group consisting of petroleum-derived residual oil, shale oil, tar sands, bitumen and an oil derived from coal other than that processed within the present process. The solvent oil is catalytically hydrogenated internally in the first reaction zone and migrates into the pore structure of the solid coal particles. Where the solvent gives up hydrogen to the coal particle matrix. The hydrogenated solvent molecules do this repeatedly until an equilibrium hydrogen content is achieved in the coal particles and coal/oil slurry.
In the first reaction zone, the coal is fed with hydrogen and through the first reaction zone into the catalytic bed, where the catalytic bed is maintained at a temperature ranging from about 400° to about 700° F. and a hydrogen partial pressure of 100 to 2000 psig with the total pressure being between about 100 and 4000 psig, and preferably ranging between about 1000 and about 3000 psig. The residence time of the materials in the first reaction zone ranges from about 5 to about 90 minutes, which is sufficient to hydrogenate the solid coal particles and the hydrocarbon solvent liquid in the coal/oil slurry.
After the coal solid particles have been hydrogenated in the first reaction zone, the coal/oil slurry is introduced into the second reaction zone where liquefaction of the coal occurs at higher temperature. The conditions in the second reaction zone are near to but less severe than the conditions for the conventional liquefaction of coal. Since the coal structures are weakened by the hydrogenation of the matrix, less thermal energy will be required to liquefy the coal in the second reaction zone since an excess of hydrogen exists in the solid phase of the coal; as well, a lower hydrogen partial pressure will still provide sufficient gas phase hydrogen to terminate free radicals of liquefaction products. The end result is to produce lighter or lower boiling hydrocarbon liquid products (i.e., distillate oil and naphtha) with less severe reaction conditions being required relative to the conventional coal liquefaction process. The temperature of the second reaction zone ranges from about 700° to about 850° F. and the hydrogen partial pressure ranges from about 0 to about 2000 psig with the total pressure being between about 500 and about 4000 psig and preferably ranging between about 1500 and about 2500 psig. The residence time of the materials in second reaction zone ranges from about 1 to about 90 minutes.
Although the second reaction zone is preferably a catalytic reaction zone, it may instead be a non-catalytic back mixed thermal reaction zone.
The coal particles fed to the present process have a particle size ranging from about 20 mesh to about 400 mesh (U.S. Sieve Series), and preferably from about 70 mesh to about 100 mesh (U.S. Sieve Series).
The products of the two stage hydrogenation and conversion process generally are distillate liquid hydrocarbon products such as naphtha, gasoline and diesel fuel and insoluble materials and ash are removed from the process.
According to the present invention, the product yields as provided by the prehydrogenation of the coal before it is liquefied results in the advantages of:
(a) the need for less severe conditions in the conversion/liquefaction reaction zones; and
(b) an increase in the yield or production of the products, i.e., hydrocarbon liquid distillate and products.
According to the present invention and as indicated and discussed below in the Examples, by use of the present invention, an increase in product yields will average from between at least about 5 and about 24% over that resulting from a conventional coal liquefaction process or single stage catalytic hydrogenation process. The yields from the present process of hydrocarbon liquid material such as cyclohexane solubles ranges from about 60 to about 90 W% of the coal feed.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the FIG. 1 drawing, a continuous two-stage coal liquefaction process is schematically shown. As shown, a coal feed or feedstock is provided at 10. The coal being, e.g., an Illinois No. 6 coal or other bituminous coal, is ground to a particle size of about 70 mesh (U.S. Sieve Series) and smaller and dried to remove surface moisture and passed to a slurry mix tank 12. Here the particulate coal is blended with a process derived oil or an oil derived from coal in other than the process herein. The process derived oil or solvent is blended in at weight ratio of solvent to coal which is at least sufficient to provide a pumpable slurry mixture, and usually has a weight ratio range of solvent to coal ranging from about 8/1 to about 1.5/1.
The coal/oil slurry, i.e., blend from slurry mixing tank 12, is pressurized by pump 14, heated in feed preheater 26 and pumped through conduit 15 to blend along with make-up hydrogen through conduit 17 directly to an ebullated bed reactor 20 containing hydrogenated coal-derived liquid, the hydrogen and a bed 22 of particulate hydrogenation catalyst. The coal/oil slurry is passed with hydrogen through flow distributor grid plate 21 and upwardly through the catalyst ebullated bed 22 at sufficient velocity to expand the bed. The catalyst 22, which suitably may comprise particles such as 0.030-0.130 inch diameter extrudates of nickel/molybdate or cobalt/molybdate on alumina or a similar support material, is expanded by at least about 20% and not over about 100% of its settled height by the upflowing fluids, and is kept in constant random motion during reaction by the upward velocity of the coal/oil slurry and hydrogen gas.
The coal/oil slurry is passed upwardly through reactor 20 and in contact with the catalyst at average nominal residence times ranging from about 5.0 to about 90 minutes, and preferably from about 10 to about 30 minutes. The reaction conditions maintained within the first reaction zone 20 are a temperature of 400° to 700°; preferably 550° to about 650° F., and a 100-2000 psig hydrogen partial pressure, or a total pressure of between about 100 and 4000 psig, preferably ranging from about 1000 to about 3000 psig. The reactor liquid is recycled through a downcomer conduit 24 and recycle pump 25 and then passed upwardly through the distributor plate 21 to maintain sufficient upward liquid velocity to expand the catalyst bed and maintain the catalyst at random motion in the liquid to assure intimate contact with complete reactions to substantially hydrogenate the coal particles both directly and through the hydrocarbon solvent liquid therein.
From the first stage reactor 20 effluent stream 29 containing, the hydrogenated coal particles in the coal/oil slurry is passed into the bottom of the second stage reactor 30. The hydrogenated coal is then passed through a flow distributor and catalyst support grid plate 31 into an ebullated bed 32 of catalyst, in much the same way as the material flows through first stage reactor 20. The hydrogenated coal/oil slurry is passed upwardly through the reactor 30 in contact with the catalyst at nominal average residence times of about 1.0 to about 90 minutes, and preferably from about 10 to about 30 minutes. The reaction conditions maintained in the second stage reactor 30 are a higher temperature ranging from about 700° to about 850° F., preferably about 800° to about 825° F., and a 0-2000 psig hydrogen partial pressure, or a total pressure of between about 500 and about 4000 psig, preferably ranging from about 1500 to about 2500 psig. The reactor liquid in the second reactor 30 is recycled through downcomer conduit 34 and recycle pump 35 to heat exchanger 36 for heating and controlling the temperature of the reaction liquid of the second reactor 30 within a relatively narrow range. The reactor liquid is then passed upwardly through distributor plate 31 to maintain sufficient mixing and upward liquid velocity to expand the catalyst abullated bed and maintain the catalyst in random motion in the liquid to assure intimate contact and complete reactions therein.
From the second reactor 30 effluent stream 39 containing, the reaction liquid, i.e., liquefied coal and gaseous materials, is usually cooled and passed to hot separator 40. The resulting vapors are passed through conduit 41 and may be processed in a first separation-purification system 60 as desired to obtain recovered low purity hydrogen, which is recycled through conduit 16 to preheater 18 and then into the bottom of reactor 20. Other light gases such as hydrogen sulfide, NH 3 , and CO x are emitted from purification system 60 through conduit 51; and product gases, i.e., low boiling, light hydrocarbon gases are emitted from system 60 through conduit 52.
From the bottom of the hot phase separator 40, a coal-derived slurry liquid is withdrawn through conduit 42. The slurry liquids in conduits 42 are processed in a second separation-purification system 62 to obtain a recycle liquid or slurry containing a reduced solids concentration which is passed through conduit 44 without additional or separate hydrogenation to the slurry mix tank 12. The coal-derived liquid solvent recycled through conduit 44 has a normal boiling point ranging from about 400° F. to about 1100° F., with at least about 50 W% of the solvent material having a normal boiling point above about 975° F. Also, the slurry liquid from conduit 42 is processed in the second system 62 as desired to remove ash and insoluble materials through conduit 45, and to remove product liquids, i.e., distillate hydrocarbon liquids, through conduit 46.
The recovered hydrogen is recycled into the process through conduit 16 to preheater 18, where it is heated prior to being passed through conduit 19 into the bottom of the first reactor 20. This arrangement including make-up hydrogen at 17 as needed provides the hydrogen needed in the continuous process of the present invention.
The present invention and its advantages are further illustrated by the following examples, which are not intended to be limiting for the scope of the invention.
EXAMPLE 1
Present and Single Stage Coal Liquefaction Processes
In order to show the effectiveness of the present process, a comparison was made between the present process and a single stage H-Coal®, coal liquefaction process. The conditions and process yield results of the two processes are provided below in Table 1. In both cases, Illinois No. 6 coal from Burning Star mine and known to be relatively difficult to liquefy, was processed and liquefied.
TABLE 1______________________________________Comparison of Continuous Process ResultsFor Burning StarIllinois No. 6 Coal Present Process H-Coal ®______________________________________Reaction Conditions1st stage temperature, °F. 5501st stage reaction time, min. 301st stage H.sub.2 pressure, psig 20002nd stage temperature, °F. 800 8502nd stage reaction time, min. 30 302nd stage H.sub.2 pressure, psig 2000 2250YIELDS, W % Dry CoalC.sub.1 -C.sub.3 Gas 7.2 9.9C.sub.4 -400° F. Liquid 15.4 19.8400-650° F. Liquid 19.8 18.6650-975° F. Liquid 21.1 10.0975° F.+ Material 11.8 19.5Total C.sub.4 -975° F. Liquid 56.3 48.4Hydrogen Consumption 4.6 5.2Coal Conversion 93.0* 94.0H.sub.2 O, H.sub.2 S, NH.sub.3, etc. 13.0 9.9Ash 11.8 11.5______________________________________ *Not Optimized
As shown in Table 1 above, the present process yields less hydrocarbon gas, more distillate liquid, less 975° F.+ bottoms fractions, more heteroatom gases, and consumes less hydrogen than in the single reaction stage H-Coal process. These results, as shown in Table 1, were obtained at a lower maximum temperature and hydrogen partial pressure for the present process than those employed in the conventional H-Coal process.
The results listed in Tables 1, 2 and 3 are for approximately the same catalyst age. Table 2, below, shows a further comparison between the present process and a single stage H-Coal process operated at the conditions listed in Table 1. These results show that there is less heteroatom sulfur and nitrogen compounds in the products i.e., product fractions from the present process than in the products from the conventional single stage H-Coal process. The advantages of the present process over the single stage H-Coal process, which were operated at the conditions listed above in Table 1, are shown below in Table 3. The higher C 4 -975° F. distillate yields and lower hydrogen consumptions result in a much higher hydrogen efficiency for the present process as compared to the single stage H-Coal process.
TABLE 2______________________________________Comparative Heteroatom Removal For Single Stage Vs. TwoStage Catalytic-Catalytic Process Present H-Coal ® Process______________________________________Sulfur, in Products W %C.sub.4 -400° F. 0.04 0.05400-650° F. 0.05 0.03650-975° F. 0.18 0.05Nitrogen, in Products W %C.sub.4 -400° F. 0.16 0.09400-650° F. 0.55 0.19650-975° F. 0.97 0.60______________________________________
TABLE 3______________________________________Process Efficiency Present H-Coal ® Process______________________________________C.sub.4 -975° F. YieldsAs W % of Dry Coal 47 56Hydrogen EfficiencyExpressed As Ratio of C.sub.4 -975° F. yieldTotal Hydrogen Consumed 9.6 12.2______________________________________
EXAMPLE 2
Present and Two Stage Thermal/Catalytic Liquefaction Processes
In order to further illustrate the effectiveness of the present process, a comparison was made between the present process and a two stage thermal/catalytic liquefaction process. The operating parameters and yields for the present process and the thermal/catalytic two stage process are provided below in Table 4. In both cases, Burning Star, Illinois No. 6 coal was processed and liquefied. The results of Table 4 are for a comparable catalyst age.
TABLE 4______________________________________Comparison of Continuous Process ResultsFor Burning StarIllinois No. 6 Coal Thermal/ Present Catalytic Process Two-Stage______________________________________Reaction Conditions1st stage temperature, °F. 550 8501st stage reaction time, min. 30 301st stage H.sub.2 pressure, psig 2000 22502nd stage temperature, °F. 800 7702nd stage reaction time, min. 30 302nd stage H.sub.2 pressure, psig 2000 2250Yields, W % Dry CoalC.sub.1 -C.sub.3, Gas 7.2 7.2C.sub.4 -400° F. Liquid 15.2 17.4400-975° F. 40.9 34.0975° F.+ 11.8 15.8Total C.sub.4 -975° F. Liquid 56.3 51.4Hydrogen Consumption 4.6 5.1Coal Conversion 93.0* 94.0H.sub.2 O, H.sub.2 S, NH.sub.3, etc. 13.0 12.8Ash 11.8 11.7______________________________________ *Not Optimized
As shown in Table 4, equivalent gas yields and light distillates C 4 -400° F. fractions yields are obtained, but more diesel and heavy distillate vacuum gas oil fractions are obtained from the present process than from the thermal/catalytic process. In addition, total distillate yields are increased and total 975° F.+ bottoms yields are decreased for the present process as compared to the thermal/catalytic process.
A comparison of the heteroatom contents for the various product cuts from the thermal/catalytic and present process are listed below in Table 5. These results show that the present process produces less heteroatom sulfur and nitrogen compounds in the various product cuts or fractions. The process efficiencies for coal liquefaction and hydrogen consumption for the two processes are listed below in Table 6. These results show that higher distillate yields and lower hydrogen consumption results in better process conversion product fractions hydrogen efficiency for the present process than for the thermal/catalytic process.
TABLE 5______________________________________Comparative Heteroatom RemovalForTwo Stage Processes Thermal/ Catalytic Present Two-Stage Process______________________________________Sulfur, in Product Fractions W %C.sub.4 -400° F. 0.16 0.05400-650° F. 0.10 0.03650-975° F. 0.16 0.05Nitrogen, in Product Fractions W %C.sub.4 -400° F. 0.07 0.09400-650° F. 0.25 0.19650-975° F. 0.64 0.60______________________________________
TABLE 6______________________________________Process Efficiency Comparison Thermal/ Catalytic Present Two Stage Process______________________________________C.sub.4 -975° F. yieldAs W % of dry coal 52 56Hydrogen EfficiencyExpressed as ratio of C.sub.4 -975° F.total hydrogen consumed 10.6 12.2______________________________________
EXAMPLE 3
Comparison of Present Process With Existing Coal Liquefaction Processes
In order to show the effectiveness of the present process, a comparison was made of a run of the present process for the liquefaction of coal, with runs of existing coal liquefaction processes: H-Coal®, Chevron Coal Liquefaction (CCLP); Solvent Refined Coal I (SRC I); and SRC II. In all cases, Burning Star, Illinois No. 6 coal was processed and liquefied. The operating conditions for the various runs were similar and comparable to those for the present and H-Coal® processes, listed above in Table I of Example 1. The results and yields for the various processes are provided below in Table 7.
TABLE 7__________________________________________________________________________Yield of Burning Star Illinois No. 6 Coal(All quantities expressed in Wt % AF coal) PresentFraction Process H-Coal ® CCLP* SRC I** SRC II**__________________________________________________________________________NH.sub.3, H.sub.2 S, H.sub.2 O, 12 11 15 10 12CO, CO.sub.2C.sub.1 -C.sub.3 Gases 8 11 7 7 17C.sub.4 -400° F. 19 23 9 NA 11400-650° F. 24 22 26 NA 10650-975° F. 26 12 29 NA 23C.sub.4 -975° F. 69 56 64 12 44950° F.+ 10 21 9 63 26Unconverted Coal 6 6 10 8 4H.sub.2 Consumption 5 5 5 3 3Total 105 105 105 103 103__________________________________________________________________________
As shown above in Table 7, the present process gives higher distillate yields of (C 4 -975° F.) fraction than any reported process. Less 975° F.+ bottoms yield and higher hydrogen efficiency are also observed for the present process. Also, the results for the present process were obtained at lower hydrogen partial pressures than those employed in the single stage H-Coal® process.
EXAMPLE 4
Comparison of Present and H-Coal® Batch Processes
In order to further illustrate the overall effectiveness of the present process catalytic reaction, batch processes runs comparing the present two-stage process and the single stage H-Coal® process were made. The conditions and yields of both batch process runs are provided below in Table 8, which shows that appreciably higher yields of soluble hydrocarbon materials are provided by the present process.
Also, in FIG. 2 below, the effectiveness of the present process is demonstrated for the conversion of Burning Star Illinois No. 6 coal as compared to that of the single-stage H-Coal® process. The processes in both runs A and B use a standard Co/Mo catalyst, whereas in run C a different Co/Mo catalyst, i.e., AMOCAT 1A is used. The results, i.e., yield distributions, are set forth as conversion to solubles in various solvents such as cyclohexane, toluene, and tetrahydrofuran.
The results provided in FIG. 2 show that for a given thermal severity in the 2nd stage reaction, the present process yields higher conversions to various solubles than does the conventional H-Coal® process at the same severity. An increase of about 20% in cyclohexane solubilities is obtained. Increases in toluene solubilities range from about 15 to about 20% and increases in tetrahydrofuran solubles (a measure of total conversion) range about 5 to 10%. Table 8 lists the yields from Illinois No. 6 Burning Star Coal in the batch tests. These results show the superiority of the present process over the H-Coal® process. The total conversions of coal for tetrahydrofuran solubles is 6% higher for the present process, for cyclohexane solubles is 23% higher for the present process, and maximum obtained toluene solubles are 20% higher in the present process than for the H-Coal® process. The total higher percent conversion of coal for the present process, as shown in FIG. 2 are: (1) 6% higher for tetrahydrofuran solubles; (2) 23% higher for cyclohexane solubles; and (3) 20% higher for toluene solubles than for the single stage H-Coal process.
TABLE 8__________________________________________________________________________Maximum Comparative Yields for IllinoisNo. 6 Coal in Batch Tests H-Coal ® Process Present Process__________________________________________________________________________Yields, W % MAFCyclohexane Solubles 67 90Toluene Solubles 73 93Tetrahydrofuran Solubles 90 96Reaction Conditions1st Stage Temperature, °F. -- 5501st Stage Time min. -- 601st Stage Pressure, psi -- 20002nd Stage Temperature, °F. 830 8002nd Stage Time min. 30 602nd Stage Pressure, psi 2000 2000__________________________________________________________________________ ##STR1##
In FIG. 3, below, the effect of pressure on the present process is illustrated. Batch runs were made on Illinois No. 6 coal with cobalt/molybdenum catalyst at hydrogen partial pressure of 500, 1,000, and 2,000 psig. As shown, the yields of solubles at for 500 pounds per square inch pressure in the present two-stage process conducted at 550° F. in the first stage for a 30 minute residence time, and 800° F. and 30 minutes residence time in the second stage, are greater than those obtained for the single stage H-Coal® processing at 500 psig hydrogen partial pressure, 800° F. temperature and 60 minutes residence time. Thus, it follows that the present process can be operated at lower pressures than the conventional single-stage H-Coal® process and still obtain higher yields of desired hydrocarbon liquids. ##STR2##
EXAMPLE 5
Present and H-Coal® Processes For Conversion of Various Coals
In order to show the effectiveness of the present process for processing different coals, runs were made using the present process and the conventional single stage H-Coal® process for both Burning Star, Illinois No. 6 coal and a low volatile coal. The operating conditions for both the present and H-Coal® processes were the same as those listed above in Table I of Example 1. The results of these tests are illustrated below in FIG. 4, and are presented on a conversion to various solubles bases, i.e., conversion to cyclohexane solubles, toluene solubles, and tetrahydrofuran solubles. The cross-hatched bars represent equivalent second stage thermal severities for the various tests. The open bars represent the maximum obtained conversion for the individual processes.
In FIG. 4, no maximum conversion data is illustrated for the low volatile coal since these results represent a single data point. The data in FIG. 4 indicates that the low volatile coal is less reactive under the conventional H-Coal® process than Illinois No. 6 Burning Star coal. On the other hand, the results for the present process show that the low volatile coal is as reactive as the Illinois No. 6 coal, and yields far more solubles than the conventional H-Coal® process yields with this coal. Thus, in the present process, an unreactive low volatile bituminous coal is made as reactive as highly reactive Burning Star, Illinois No. 6 coal. ##STR3##
EXAMPLE 6
Present, H-Coal®, and Thermal/Catalytic Processes
A series of runs were made to show the effectiveness of the present process in the conversion of a high rank, medium volatile bituminous, high ash coal. The present process was compared to a conventional single stage H-Coal® process and to a two-stage thermal/catalytic process in small batch runs for raw and cleaned coals. The operating conditions for the different processes were as follows:
______________________________________ Processes Thermal/Conditions H-Coal ® Catalytic Present______________________________________1st Stage Temperature, °F. 550 5501st Stage Reaction Time, Min. 30 301st Stage Pressure, psi 2000 20002nd Stage Temperature, °F. 850 850 8002nd Stage Reaction Time, Min 30 30 302nd Stage Pressure, psi 2250 2250 2000______________________________________
The results of the various runs are illustrated and set forth below in FIG. 5. The illustrated results of FIG. 5, show that on an ash free basis, the present process yields higher conversions to cyclohexane, toluene and tetrahydrofuran (THF) solubles than does the H-Coal® process or the thermal/catalytic process. For this coal a 17% increase in cyclohexane solubles, a 12% increase in toluene solubles and a 1 to 3% increase in the THF solubles, are observed for the present process over the H-Coal® process. Thus, the present process is effective in converting a high rank, medium volatile bituminous coal to solubles and hydrocarbon liquid products. ##STR4##
EXAMPLE 7
Present, One Stage Thermal, H-Coal®; Thermal/Thermal; and Thermal/Catalytic Processes
A series of runs were made to show the effectiveness of the present process in the conversion of a highly unreactive, Western Canadian sub-bituminous coal. The series of runs compared the effectiveness of the present process with (1) one-stage thermal (2) H-Coal®, (3) two-stage thermal/thermal and (4) two-stage thermal/catalytic processes. In comparing these processes small batch tests were conducted, employing a heavy petroleum resid as a solvent for the coal.
The operating conditions for the different processes were as follows:
__________________________________________________________________________ Processes Thermal/ Thermal/Conditions Thermal H-Coal ® Thermal Catalytic Present__________________________________________________________________________1st Stage Temperature, °F. 550 550 5501st Stage Reaction Time, Min 30 30 301st Stage H.sub.2 Pressure, psig 2000 2000 20002nd Stage Temperature, °F. 850 850 800 800 8002nd Stage Reaction Time, Min 30 30 30 30 302nd Stage H.sub.2 Pressure, psig 2000 2250 2000 2000 2000__________________________________________________________________________
The results of the comparative tests as illustrated below in FIG. 6, are based on a total slurry solubles of solubility on a M.A.F. basis. The results of the present process run show an increase of slurry 11% cyclohexane solubles, 11% toluene solubles and 11% tetrahydrofuran solubles over those produced by the H-Coal® process. Also, the results show that for the present process, 100% tetrahydrofuran solubility is obtained. This indicates that all the coal is convertible to tetrahydrofuran solubles in the present process, but is not convertible in any other test mode shown. Also, a higher conversion to cyclohexane and toluene solubles were obtained for the present process than for any other process mode. ##STR5##
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A process for the hydrogenation of undissolved coal and subsequent liquefaction of the hydrogenated coal particles to provide useful hydrocarbon liquid products including naphtha, gasoline and diesel fuel. These low boiling hydrocarbon liquids are produced by the process comprising: (a) mixing solid coal particles with a coal derived solvent in a solvent/coal ratio ranging from about 8/1 to about 1.5/1 to provide a flowable coal/oil slurry of solid coal particles; (b) passing the coal/oil slurry and hydrogen upwardly through a first reaction zone containing a coal-derived liquid and bed of particulate catalyst maintained at a temperature ranging from about 400° to about 700° F. and a hydrogen partial pressure of 100 to 2000 psig for a time sufficient to hydrogenate the solid coal particles; and (c) withdrawing the coal/oil slurry having the hydrogenated coal particles from the first reaction zone and passing the coal/oil slurry to a second reaction zone containing a catalytic bed which is maintained at a temperature of between about 700° and about 850° F. and a hydrogen partial pressure of 9 to 2000 psig to liquefy and convert the coal to useful hydrocarbon liquid fuel products. The first and second reaction zones may include the same or different catalysts such as Co/Mo on a porous substrate, or the second reaction zone can include a noble metal such as platinum on a porous substrate such as alumina or silica.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to artificial tress, and more particularly, to an electrically illuminated artificial Christmas tree wherein groups of seed lights are connected in parallel across sets of two wires which are respectively connected in series to wires of different sets, to eliminate the need for a transformer and allow the use of an inexpensive selenium rectifier control for establishing a suitable level of voltage operation for the seed lights.
2. Description of the Prior Art
Electrically illuminated artificial holiday trees having integrated circuits are well known. See U.S. Pat. Nos. 4,573,102; 3,970,834; 3,735,117; 3,617,732; 3,603,780; and 2,188,529.
SUMMARY OF THE INVENTION
1. An object of the present invention is to eliminate the need for a transformer as a current source for electrically illuminated artificial trees, in order to reduce the cost thereof.
Another object of the invention is to enable the use of inexpensive devices such as selenium rectifiers to control the voltage applied to the illumination means.
Still another object of invention is to provide an electrically illuminated artificial tree that is easy of assemblage.
Still another object of invention is to provide an electrically illuminated artificial tree that is easy of manufacture.
A further object of the invention is to provide an electrically illuminated artificial Christmas tree that can be conveniently stored from Christmas season to Christmas season, and used again and again.
In accordance with the present invention, an electrically illuminated artificial tree having branches, incorporates among the various branches, sets of circuits having lights arranged in parallel therein, and interconnects the respective wires of the parallel circuits in series with the different parallel circuits. A selenium rectifier in series with the serially connected different wires of the parallel circuits provides the current and enables voltage regulation thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features, and advantages of the invention will be apparent from a consideration of the following description of an illustrative embodiment thereof, when taken together with the accompanying drawings wherein;
FIG. 1 is a diagrammatic front view of an assembled artificial Christmas tree incorporating the invention;
FIG. 2 is a diagrammatic view of a typical limb, and branches, of the artificial Christmas tree, including its physical and electrical connection mechanisms;
FIG. 3 is a frontal view, partially in section, showing a portion of the artificial Christmas tree trunk, including physical and electrical connection mechanisms;
FIG. 4 is a side view of a portion of a limb 12 showing details of its construction;
FIG. 5 is a diagrammatic view of a portion of the electrical circuit and showing principles of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the drawings and particularly FIG. 1 thereof, there is shown an electrically illuminated artificial Christmas tree having a hollow plastic trunk 10 and radially extending, hollow plastic limbs 12 spaced in layers with respect to the tree trunk 10 and circumferentially with respect to each in every layer. Each limb 12 has many hollow plastic branches 14 (FIG. 2) formed integrally therewith and extending laterally outwards and bearing seed lights or lamps 16 via holders 18 suitably molded in the branches 14 and establishing electrical connection of the lights 16 with wires 20 (FIG. 5) in the branches 14 and limbs 12. The seed lights 16 are connected in parallel across the wires 20 so that extinguishment of one does not extinguish the others or result in significant voltage changes within the light circuits.
Limbs 12 are attached physically and electrically to the trunk 10 via wiring terminal plugs 22 (FIG. 2) fitted within the ends of the hollow limbs and adapted to be received within limb receptacles 24 (FIG. 3) formed integral with the trunk 10. A key 26 (FIG. 2) on the end of each limb 12 is received within a slot 28 in the corresponding limb receptacle to anchor the limb 12 in proper angularity. The plug 22 bears two male electrical terminals 30 and 32 intended to be received in a female electrical socket 34 (FIG. 5) to establish in series electrical connections with the wiring in adjacent limbs or layers of limbs via wires 36 in trunk 10 (FIG. 3). Of course, with the smaller limbs near the top, the lights of two or more limbs may be mounted in one parallel circuit.
The lower end of the trunk 10 is shown as inserted in a rectifier control box 38 setting on a stand 40 for providing vertical stability. A 120 volt cord and plug 42 is shown as emanating from the rectifier control box 38.
The trunk 10 may be formed with a separable upper portion 10a constituting the supporting structure for the upper portion of the tree which is generally constructed as the lower portion is except for reduced proportions. The physical and electrical connections between the trunk 10 and the trunk portion 10a may be of the same nature as between a limb 12 and trunk 10 earlier described. Similar physical and electrical connections may be made between the trunk 10 and the rectifier control box 38.
A tree as described above facilitates modular construction and compact packaging by manufacturers for ease of shipment, storage, and consumer marketing. It is easy to install. It is also easy to disassemble and store by the end user between Christmas seasons. But for those who do not wish to disassemble, limbs 12 (FIG. 4) and branches 14 are formed with cuts 44 on their underneath sides to permit upward and inward folding of the limbs and branches about the trunk 10 to form a compact storage arrangement.
It will also be appreciated the limbs 12 and branches 14 need not be hollow, but may be solid with the conductors 20 molded therein. Also that the limbs 12 may be lighter but the conductors heavier to assist in performing the limb beam function. Additionally, such conductors may be tempered to allow the flexure needed for storage folding without producing permanent set or distortion.
A feature of the invention resides in the electrical circuitry. As shown in FIG. 5, sets of forty seed lights 16 are connected in parallel across a set of limb and branch wires 20. One of these wires 20 is connected in series with one of the wires of an adjacent set of parallel wires connecting forty lights in parallel. The other of this second set of parallel wires is connected in series with one of wires of another adjacent set of parallel wires connecting forty lights in parallel. Typically twelve sets of parallel circuits each connecting forty seed lights in parallel would be incorporated in the artificial Christmas tree, with the other wires of the first set of parallel wires and the twelfth set of parallel wires (the exterior set) (set 2 through 11 being considered the interior set) being connected across an inexpensive selenium rectifier 46 (FIG. 5) in the control box 38 (FIG. 1). Such a selenium rectifier 46 may be adjusted to vary the voltage level determining the brightness level of the seed lights 16.
In manufacturing, the improved tree of this invention would be constructed in parts, and the parts packaged in a compact container. The end user will open the package, place the stand 40 on the floor, secure the rectifier control box 38 to the stand, and place the lower end of the trunk 10 in the control box 38, thereby also establishing electrical connection between the trunk wires 36 and the selenium rectifier 46. The various limbs 12 would be attached to the tree by inserting their wiring terminal plugs 22 in the receptacles 24 of the trunk 10, thereby also establishing electrical connections for the lights 16 on the limb's branches 14. Finally, the upper portion of the tree would be put in place physically and electrically by connecting the lower end of the trunk portion 10a with the upper end of the trunk 10. All of the seed lights 16 would now be connected in groups of forty between the wires 20 of various sets of parallel wires, which wires 20 are each connected in series with a wire of a different electrically adjacent set of parallel wires or one of the contacts of the selenium rectifier 46, through the trunk wires 36. If the 120 volt cord and plug 42 are now inserted into an electrical outlet, and the selenium rectifier 46 switched on, the seed lights 16 will light up to brighten the Christmas tree in traditional fashion.
After the Christmas season, the tree may be disassembled for storage by reversing the procedure set forth above. Alternatively only the top portion of the tree may be separated by removing the lower end of the trunk portion 10a from the upper end of the trunk 10, and the main portion of the tree separated from the rectifier control box 38 and the stand 40 by pulling out the lower end of the trunk 16 from the rectifier control box 38. The limbs 12 and branches 14 might then be folded upward and inward to form a compact somewhat cylindrical arrangement which can be conveniently sorted. The cuts 44 in the limbs 12 and 14 facilitate the upward and inward bending of the limbs and branches. Placing the compact cylindrical arrangement in a plastic bag would protect the tree from dust and other problems during the non-Christmas season.
While the invention has been described with reference to a particular embodiment, it should be realized that the description is illustrative, and that the invention can be incorporated in many other embodiments. Various modifications can be made without departing from the spirit of the invention, and it is intended that the scope of the invention only be limited by the appended claims.
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An electrically illuminated artificial Christmas tree, eliminating the need for a transformer while providing all of the advantages of low voltage distribution and isolated light failure, connects groups of seed lights in parallel across sets of two wires which are respectively connected in series to wires of different sets, enabling use of an inexpensive power source for establishing suitable levels of low voltage operation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to pressurizers for beer kegs and in particular to a foot-operated pressurizer for beer kegs.
2. Description of Related Art
Previous beer-keg pressurizers for serving tap beer have been hand operative or pressure-tank operative. Pressure in space above beer in kegs forces the beer out through a pipe that reaches down into the beer.
Hand operation requires one hand to operate a pump and the other to hold a tap that usually is not stationary in beer-party conditions. This prevents filling a glass held with one hand and usually requires two people for filling a beer glass or mug. It obstructs functioning freely with both hands for filling beer glasses, drinking beer and other partying during festive conditions where beer kegs are used most often.
Pressure tanks and frequently motor-operated air pumps are applicable mostly for long-term use at taverns and various types of club houses. They inject carbon dioxide gas into beer kegs for a two-fold purpose of (a) pressurizing the beer keg and (b) creating a thick head of foam on top of beer in drinking containers to impress customers.
A large market exists for one-time or short-term purchase of beer in kegs. A deposit is paid on the kegs, a hand pump with a keg-outlet fitting and frequently a cooler tub. It is a party market where hand-free use is highly desirable and a thick head of foam does not induce customer traffic.
Prior art that is different but related is described in the following patent documents: U.S. Pat. No. 4,094,135, issued to Haensch on Jun. 15, 1978; U.S. Pat. No. 3,563,424, issued to Johnston on Feb. 16, 1971; U.S. Pat. No. 3,498,313, issued to Belich on Mar. 3, 1970; and U.S. Pat. No. 3,464,591, issued to Nicola on Sep. 2, 1969.
SUMMARY OF THE INVENTION
In light of need for a more convenient beer-keg pressurizer, objects of this invention are to provide a foot-operated beer-keg pressurizer which:
Is foot-operative to free both hands for filling beer-drinking containers and engaging in other party activities;
Requires only one person for filling a beer mug or glass from a beer keg with a manual pressurizer;
Has a keg fitting that can be positioned firmly, reliably and conveniently into standardized quick-disconnect outlets of conventional beer kegs;
Is one-foot operative from a standing or sitting position without bodily destabilization;
Can be attached to variously remote kegs and operated from a different position; and
Is inexpensive, long-lasting, convenient to handle and aesthetically pleasing.
This invention accomplishes these and other objectives with a foot-operated beer-keg pressurizer having a floor-based foot pump with which air is pumped through a pressure tube from a variably remote beer keg to a keg faucet that is attachable to conventional beer-keg connectors. A beer tube extended from the keg faucet in the variably remote beer keg has a beer tap that is preferably a squeeze or push-button type. Foot operation of the floor-based foot pump by a user or by a separate person frees both hands of a user for filling beer-drinking containers.
BRIEF DESCRIPTION OF DRAWINGS
This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are described briefly as follows:
FIG. 1 is an elevation view;
FIG. 2 is a partially cutaway expanded fragmentary view of a keg faucet attached to a keg-faucet connector;
FIG. 3 is an alternative embodiment of the FIG. 2 illustration with a valved inlet and outlet into a keg faucet;
FIG. 4 is a front elevation view of cup type of foot pump;
FIG. 5 is a partially cutaway side view of a cup type of foot pump;
FIG. 6 is a partially cutaway side view of a piston type of foot pump;
FIG. 7 is a side elevation view of a bellows type of foot pump with a clean-air conveyance; and
FIG. 8 is a partially cutaway front view of the FIG. 7 illustration.
DESCRIPTION OF PREFERRED EMBODIMENT
Reference is made first to FIGS. 1-2. A floor-based foot pump 1 is sized, shaped and structured to pump air into a beer keg 2 under pressure between a top surface of beer 3 and a bottom surface of a keg-aperture wail 4 containing a closeable keg aperture 5 having a keg-faucet connector 6.
The beer keg 2 is a conventional type used in the beer industry for distributing beer to be dispensed as tap beer from a beer tap 7 on a distal end of a beer tube 8 through which beer is forced to flow as a result of air pressure or other gas pressure in the beer keg 2. Commercial retailers and other long-term dispensers of tap beer, such as taverns, clubs and bars, usually have an electrical pump for pressurizing beer kegs 2. Many also employ carbon dioxide under pressure in a tank for generating gas bubbles that form a thick head of foam on tops of beer in beer glasses and mugs. Some use either the electric pump or the pressure tank separately.
Intermittent users and short-term users of beer kegs 2 comprise a large portion of the market for tap beer. The kegs 2 of beer 3 is sold to the intermittent and short-term users through liquor stores and, where legal, through grocery stores and liquor departments of supermarkets. The same kegs 2 or slightly larger ones with the same keg-faucet connectors 6 are used for intermittent and short-term users and for commercial and long-term users. Instead of an electrical pump and/or a pressure tank, a hand pump on a hand-pump faucet of various types is used by the intermittent and short-term users. Many retailers of tap beer with relatively low sales volume also use the hand-pump faucet.
Some short-term users have their own hand-pump faucets. Usually, however, dispensers of beer in kegs 2 supply them and require a deposit that is much larger than a deposit that is required also for the kegs 2 and other tap-beer paraphernalia.
Replacing cumbersome and inconvenient hand-pump faucets with a keg faucet 9 that provides hands-free use is an objective of this invention. Party-goers, club members, bar customers and others will be able to tap a remote keg 2 of beer 3 at their own table or be served easily by others as desired. Many retailers now using electric pumps and/or pressure tanks can switch to the more convenient keg faucet 9 with the floor-based foot pump 1. It can be made to use either the same keg-faucet connector 6 as for hand-pump faucets, electric pumps and/or pressure tanks or to use a specially designed keg-faucet connector 6 if found economically advantageous. Moreover, it is safer and less expensive than electric pumps and/or pressure tanks.
The beer tap 7 has an outlet valve that is a conventional type represented by a handle with which it is operated on a top portion of the beer tap 7. An outlet aperture at a distal end of the beer tap also is a conventional type that is not shown separately because of its conventional construction.
The keg faucet 9 has a fluid conveyance 10 in fluid communication between a beer inlet 11 and a beer outlet 12. The beer inlet 11 of a keg faucet 9 that is attached to the keg-faucet connector 6 is in fluid communication with an internal volume 13 of the beer keg 2 by way of passage by a keg valve 14 and through a keg tube 15 into the beer 3 where air under pressure from the fluid conveyance 10 can rise to a top of the beer 3 and force the beer 3 out through the beer inlet 11 and the closable keg aperture 5. Air pressure is conveyed to the fluid conveyance 10 through a pressure-tube inlet 16 that is in fluid communication between the floor-based foot pump 1 and the pressure-tube inlet 16 through a pressure tube 17.
A pressure-relief valve 18 can be provided to relieve pressure in the keg 2 when desired to disconnect the keg faucet 9 or to store the keg 2 for an extended period of time without internal pressure. A pressure-relief valve 18 is not essential, however, because pressure can be released by slight loosening of the keg faucet 9 in the keg-faucet connector 6. Some present hand-pump faucets have pressure-relief valves and some do not.
Referring to FIGS. 2-3, the keg-faucet connector 6 has a quick-disconnect boss 19 that is extended from a connector mount 20 and slides first in a thread slot 21 in a quick-disconnect faucet thread 22 when the keg faucet 9 is positioned in the keg-faucet connector 6 and rotated a few degrees. In FIG. 3, the quick-disconnect boss 19 is represented as a crosshatched circle as it enters and passes through the thread slot 21. After passing through the thread slot 21, the quick-disconnect boss 19 is positioned on a designedly horizontal or non-sloping top of the quick-disconnect faucet thread 22 where it is shown extended inwardly from the connector mount 20 in locked-sealing contact of a seal surface of a faucet seal 23 and a seal surface of a connector seal 24.
Positioning and rotation of the keg faucet 9 in the keg-faucet connector 6 is accomplished with the FIG. 2 embodiment by hand-grasping and hand-manipulation of faucet handles 25.
In FIG. 3, an embodiment of the keg faucet 9 has a beer outlet 12 and a pressure-tube inlet 16 in line concentrically. This allows in-line positioning of a beer-outlet valve 26 and a pressure-tube-inlet valve 27 in order to operate the beer-outlet valve 26 by actuation of the pressure-tube-inlet valve 27. The beer-outlet valve 26 can have a valve stem 28 that is preferably reciprocal in the pressure-tube-inlet valve 27. Also, the beer-outlet valve 26 can be attached to the pressure-tube-inlet valve 27 with a beer-outlet-valve spring 29 as shown. Closing actuation of the pressure-tube-inlet valve 27 against opposition to air pressure from the pressure-tube inlet 16 is provided by a pressure-tube spring 30. Concentric travel of the pressure-tube-inlet valve 27 can be assured by travel of a sleeve of the pressure-tube-inlet valve 27 in a valve-guide sleeve 31.
Preferably the beer-outlet-valve spring 29 is shorter and more resistant than the pressure-tube spring 30. This allows the pressure-tube-inlet valve 27 to be actuated quickly and easily to close the beer-outlet valve 26 in addition to opening the pressure-tube-inlet valve 27 in response to air pressure from the pressure-tube inlet 16. Larger diameter of these springs with the same wire diameter causes the desired higher pressure of the beer-outlet-valve spring 29.
Optionally, the valve stem 28 can be attached rigidly to the pressure-tube-inlet valve 27 with slightly less speed and efficiency in preventing air from entering the beer tube 8 when air is being pumped from the floor-based foot pump 1. Entry of beer into the pressure tube 17 when not operating the floor-based foot pump 1 at a lower position than the keg faucet 9 can be arrested by the pressure-tube-inlet valve 27 separately. Optionally also, the beer-outlet valve 26 can be omitted if not desired to prevent entry of air into the beer tube 8 when pressuring the keg 2.
Further optionally, an inlet pipe 32 for air pressure and an outlet pipe 33 for beer 3 can have sufficient strength and rigidity for use as handles for the keg faucet 9.
The keg faucets 9 and the keg-faucet connectors 6 illustrated in FIGS. 2-3 are not drawn to scale. Nor are the keg-faucet connectors 6 shown exactly as manufactured differently by various manufacturers. Instead, the keg-faucet connectors 6 in particular are represented with functional components in working relationship of parts that are variously common to most keg-faucet connectors 6. Conventional keg-faucet connectors 6 generally have some form of a connector mount 20 from which a quick-disconnect boss 19 is extended horizontally. The boss 19 has various shapes and sizes and the connector mount 20 can be a separate ring or a structural portion of a connector housing 34 which houses the keg valve 14, a keg-valve spring 35, the closable keg aperture 5 and various types and sizes of keg tubes 15.
Usually, beer kegs 2 are pressurized with carbon dioxide or air prior to commercial distribution in order to seal the keg valve 14 against a sealing surface of the closable keg aperture 5 prior to a slight pressure that occurs from vaporization of alcohol in the beer. The keg valve 14 is pushed inwardly or down against the keg-valve spring 35 with a valve-relief extension 36 from the faucet seal 23. The valve-relief extension 36 can be a tubular member with serrations or other means for allowing passage of beer 3 through the beer inlet 11 while also pushing the keg valve 14 away from a keg-valve seat at the closable keg aperture 5. It is after dissipation of original pressure in the keg 2 that pressurization of the keg 2 is required to pump beer 3 from the keg 2.
Referring to FIGS. 1 and 6, a floor-based foot pump 1 can be a piston type with a piston 37 operated by a piston shaft 38 attached to a pump pedal 39 that is hinged to pump base 40. Air enters a cylinder 41 through a one-way inlet-valved aperture 42 and exits through a one-way outlet-valved aperture 43. The pressure tube 17 is connected to the one-way outlet-valve aperture 43. A pump spring 44 having contraction resistance is positioned with contraction resistance to downward travel of the pump pedal 39 and with resistance to pressure-outlet travel of the piston 37. The piston 37 and the cylinder 41 can be variously upright and variously attached to the pump pedal 39 and the pump base 40. Optionally also, the pump pedal 39 can be omitted for direct foot operation of the piston shaft 38 that can be variously covered. Further optional, the entire cylinder 41 and piston shaft 38 can be covered with a resilient shroud. The pump spring 44 can be either a leaf type as depicted in FIG. 1 or a coil type as depicted in FIG. 6.
Referring to FIGS. 4-5, the floor-based pump 1 can be a cup type with a rubberlike cup 45 attached to a cup-pump base 46 with an attachment means such as a hose connector 47. The one-way inlet-valved conveyance 42 and one-way outlet-valved conveyance 43 can be extended from the cup-pump base 46 with a working relationship as described in relation to FIGS. 1 and 6.
Referring to FIGS. 7-8, the floor-based foot pump 1 can be a bellows type with a pleated bellows 48 operable between a pump pedal 39 and a pump base 40. As for other types of pumps, the one-way inlet-valved conveyance 42 and one-way outlet-valved conveyance 43 can be extended from the pleated bellows 48 with a working relationship as described in relation to FIGS. 1 and 6.
Optional for all types of floor-based foot pumps 1 can be a clean-air conveyance 49 in fluid communication with the one-way inlet-valved conveyance 42 as depicted in FIGS. 7-8. The clean-air conveyance 49 can contain an air filter 50 as an additional option for particularly dusty conditions such as occur frequently near dance floors where tap beer is served. A clean-air conveyance 49 can have inlet orifices 51 in side walls to prevent dropping of particles into it and can have a pump handle 52 for ease of handling and operation. A nonskid surface 53 can be provided on bottoms of pump bases 40 and on tops of pump pedals 39.
The floor-based foot pump 1 can be operated with either a user's toe or heel portion of their foot. Some users may prefer heel operation in order to maintain balance by toe contact with a floor. Some will use a toe for standing operation and a heel for sitting operation or vice versa.
It is foreseeable that conventional keg-faucet connectors 6 will change from time-to-time. Consequently, this invention is made adaptable to beer-keg connectors or keg-faucet connectors 6 that may be designed with forseeable types of quick-disconnect attachments.
Referring further to FIGS. 1-3, a top pressure relief valve 54 can be positioned in fluid communication with fluid conveyance 10 when inlet pipe 32 and outlet pipe 33 are employed. The inlet pipe 32 and the outlet pipe 33 may be used in lieu of faucet handles 25 in this embodiment.
A new and useful foot-operated beer-keg pressurizer having been described, all such modifications, adaptations, substitutions of equivalents, combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims are included in this invention.
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A foot-operated beer-keg pressurizer has a floor-based foot pump (1) with which air is pumped through a pressure tube (17) from a variably remote beer keg (2) to a keg faucet (9) that is attachable to conventional beer-keg connectors (6). A beer tube (8) extended from the keg faucet in the variably remote beer keg has a beer tap (7) that is preferably a squeeze or push-button type. Foot operation of the floor-based foot pump by a user or by a separate person frees both hands of a user for filling beer-drinking containers.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/782,542, filed Mar. 14, 2013, entitled ENERGY ABSORBING LOCK SYSTEMS AND METHODS, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Exterior doors of homes, office buildings, hotels, apartment buildings, etc. are typically equipped with some means (e.g., a door lock) of securing entry into the building. Interior doors of such buildings may also be equipped with some means of securing the door. Such door lock apparatuses are typically rigid and mechanical and to some extent easily defeated by a sudden and forceful action, such as kicking or shouldering. An average adult male is capable of generating a significant amount of force over an effective area of the door lock while using a violent swift action directed at the door lock. In instances of forced entry through the door, the more direct a strike is directed to the door lock, the more successful a perpetrator is at defeating the door lock, typically.
SUMMARY
[0003] According to certain aspects of the present disclosure, a door lock assembly is adapted to secure a door in a closed configuration within a doorframe. The door lock assembly includes a bolt guide, a bolt, a bolt actuator, and a bolt receiver. The bolt extends between a proximal end and a distal end. The bolt includes a first portion that is adjacent to the proximal end and a second portion that is adjacent to the distal end. The bolt actuator is adapted to move the bolt along the bolt guide between a locked position and an unlocked position. The second portion of the bolt extends beyond the bolt guide when the bolt is moved to the locked position. The bolt receiver is adapted to receive the second portion of the bolt when the bolt is moved to the locked position. The bolt is adapted to deform within the bolt receiver and thereby absorb energy delivered to the door lock assembly by an intrusion load. The energy delivered to the door lock assembly by the intrusion load is predominantly absorbed by deformation of the bolt.
[0004] In certain embodiments, the bolt is a deadbolt. The bolt actuator may be actuated by a key via a keyhole of the door lock assembly. The bolt receiver may include an integral strike plate. The bolt receiver may be a cup shaped bolt receiver and may be adjacent the second portion of the bolt along at least three sides of the second portion of the bolt when the bolt is moved to the locked position. The cup shaped bolt receiver may be adjacent the second portion of the bolt along all exterior sides of the second portion of the bolt when the bolt is moved to the locked position. The bolt receiver may include a first portion that is adapted to receive the second portion of the bolt when the bolt is moved to the locked position and no intrusion load is placed on the door. The bolt receiver may include a second portion adapted to receive at least some of the second portion of the bolt when the bolt is positioned at the locked position and the intrusion load is placed on the door thereby deforming the bolt.
[0005] In certain embodiments, the second portion of the bolt receiver may include a deformation guide that guides the deformation of the bolt when the intrusion load is placed on the door. The deformation guide of the second portion of the bolt receiver may include a taper. The deformation of the bolt may be elastic deformation and/or may be inelastic deformation (i.e., may result in yielding of the bolt). The bolt guide may be mounted to the door and the bolt receiver may be mounted to the doorframe. In other embodiments, the bolt guide may be mounted to the doorframe and the bolt receiver may be mounted to the door.
[0006] In certain embodiments, the bolt may include a spring metal core that is surrounded by an energy absorbing polymer. The bolt may further include a metal end cap at the distal end that is connected to the spring metal core. The bolt guide may include a deformation guide that guides the deformation of the bolt when the intrusion load is placed on the door.
[0007] According to other aspects of the present disclosure, a door lock assembly is adapted to secure a door in a closed configuration within a doorframe. The door lock assembly includes a bolt guide, a bolt, a bolt actuator, and a bolt receiver. The bolt extends between a proximal end and a distal end. The bolt includes a first portion that is adjacent to the proximal end, a second portion that is adjacent to the distal end, and a thickness. The bolt actuator is adapted to move the bolt along the bolt guide between a locked position and an unlocked position. The second portion of the bolt extends beyond the bolt guide when the bolt is moved to the locked position. The bolt receiver is adapted to receive the second portion of the bolt when the bolt is moved to the locked position. The bolt is adapted to deform within the bolt receiver and thereby absorb energy delivered to the door lock assembly by an intrusion load. A maximum deformation of the bolt prior to failure of the door lock assembly from the intrusion load is at least 4% of the thickness of the bolt. In certain embodiments, the maximum deformation of the bolt prior to the failure of the door lock assembly is at least 25% of the thickness of the bolt. In certain embodiments, the maximum deformation of the bolt prior to the failure of the door lock assembly is at least 120% of the thickness of the bolt.
[0008] Still other aspects of the present disclosure are directed to a door lock assembly that is adapted to secure a door in a closed configuration within a doorframe. The door lock assembly includes a bolt guide, a bolt, a bolt actuator, and a bolt receiver. The bolt extends between a proximal end and a distal end. The bolt includes a first portion that is adjacent to the proximal end, a second portion that is adjacent to the distal end. The bolt actuator is adapted to move the bolt along the bolt guide between a locked position and an unlocked position. The second portion of the bolt extends beyond the bolt guide when the bolt is moved to the locked position. The bolt receiver is adapted to receive the second portion of the bolt when the bolt is moved to the locked position. The bolt is adapted to deform within the bolt receiver and thereby absorb energy delivered to the door lock assembly by an intrusion load. A maximum deformation of the bolt prior to failure of the door lock assembly from the intrusion load is at least 40% of a maximum overall deflection of the door lock assembly. In certain embodiments, the maximum deflection of the bolt prior to the failure of the door lock assembly is at least 55% of the maximum overall deflection of the door lock assembly. In certain embodiments, the maximum deflection of the bolt prior to the failure of the door lock assembly is at least 72% of the maximum overall deflection of the door lock assembly.
[0009] Yet other aspects of the present disclosure are directed to a door lock assembly that is adapted to secure a door in a closed configuration within a doorframe. The door lock assembly includes a bolt guide, a deformable bolt, a bolt actuator, and a bolt receiver. The deformable bolt extends between a proximal end and a distal end. The deformable bolt includes a first portion that is adjacent to the proximal end, a second portion that is adjacent to the distal end. The bolt actuator is adapted to move the deformable bolt along the bolt guide between a locked position and an unlocked position. The second portion of the deformable bolt extends beyond the bolt guide when the deformable bolt is moved to the locked position. The bolt receiver is adapted to receive the second portion of the deformable bolt when the deformable bolt is moved to the locked position. The bolt receiver includes a deformation guide that is adapted to guide deformation of the deformable bolt.
[0010] A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a partial exploded perspective view of a door lock system according to the principles of the present disclosure;
[0012] FIG. 2 is a partial reverse perspective view of the door lock system of FIG. 1 ;
[0013] FIG. 3 is a partial exploded elevation view of the door lock system of FIG. 1 ;
[0014] FIG. 4 is a partial exploded cross-sectional plan view of the door lock system of FIG. 1 , as called out at FIG. 3 ;
[0015] FIG. 5 is a partial exploded plan view of the door lock system of FIG. 1 ;
[0016] FIG. 6 is a partial exploded cross-sectional elevation view of the door lock system of FIG. 1 , as called out at FIG. 5 ;
[0017] FIG. 7 is a partial cross-sectional plan view of the door lock system of FIG. 1 , shown in a normally closed configuration;
[0018] FIG. 8 is the partial cross-sectional plan view of FIG. 7 , but with the door lock system shown in a deformed configuration;
[0019] FIG. 9 is a partial cross-sectional plan view of the door lock system of FIG. 1 , shown in the normally closed configuration;
[0020] FIG. 10 is the partial cross-sectional plan view of FIG. 9 , but with the door lock system shown in a deformed bolt-jamming configuration;
[0021] FIG. 11 is a cross-sectional plan view of a portion of the door lock system of FIG. 1 , shown in the normally closed configuration;
[0022] FIG. 12 is a cross-sectional plan view of the door lock system of FIG. 1 , shown in the deformed configuration;
[0023] FIG. 13 is a partial perspective view of another door lock system according to the principles of the present disclosure; and
[0024] FIG. 14 is an elevation view of a strike plate suitable for use with the door lock system of FIG. 14 .
DETAILED DESCRIPTION
[0025] According to the principles of the present disclosure an energy absorbing lock system 100 , and in particular, a system including an energy absorbing bolt 140 (e.g., an energy absorbing deadbolt) is effective at preventing entry through a door 200 by dynamic action that is applied to the door 200 . Such dynamic action may include kicking with a foot, shouldering with a shoulder, and ramming with a police-style battering ram. In contrast, typical conventional bolt-style lock systems and typical conventional latch systems are susceptible to failure from application of such dynamic action, thereby allowing entry through the door.
[0026] In various embodiments, the energy absorbing bolt 140 may be made of various energy absorbing materials and/or deformable materials. The energy absorbing materials and/or the deformable materials may include energy absorbing plastics (e.g., polycarbonate, PVC, etc.), energy absorbing rubbers (neoprene, isoprene, etc.), energy absorbing composites, etc. In one embodiment, the energy absorbing bolt 140 includes 60 durometer PVC. In another embodiment, the energy absorbing bolt 140 includes 50 durometer PVC.
[0027] The typical bolt-style lock systems and the typical latch systems are substantially inflexible and have minimal energy absorption qualities. Energy that is applied to the door by the dynamic action is concentrated upon a connection between a deadbolt and strikeplate in the case of the typical bolt-style lock system and is concentrated upon a connection between a latch and a catch in the case of the typical latch system. The typical latch system and the typical bolt-style lock system may be included on the same door and offer a modest amount of improvement in preventing entry as the dynamic action causes failure of both the typical latch system and the typical bolt-style lock system. The failure of the typical latch system and/or the typical bolt-style lock system may or may not occur from failure of the deadbolt and/or the strikeplate, in the case of the typical bolt-style lock system, and/or failure of the latch and/or the catch, in the case of the typical latch system. The failure of the typical latch system and/or the typical bolt-style lock system may or may not occur from failure of connecting structure (e.g. the door, a connection between the door and the bolt-style lock system, a doorframe, a connection between the doorframe and the bolt-style lock system, a connection between the door and the latch system, a connection between the doorframe and the latch system, etc.). As, the typical latch system and the typical bolt-style lock system are substantially inflexible, the energy delivered by the dynamic action may result in impact of relatively short time duration and relatively high force levels. The high force levels may cause high stresses to develop in the above-mentioned parts and the high stresses may cause the failure.
[0028] In contrast, according to the principles of the present disclosure, the energy absorbing lock system 100 includes the deformable bolt 140 that is substantially flexible. The energy delivered by the dynamic action may result in impact of relatively long time duration and relatively low force levels. The relatively low force levels may result in lower stresses developing in corresponding parts and the lower stresses may be below a failure point. In addition, the deformable bolt 140 absorbs the energy delivered by the dynamic action and may dissipate the energy as heat.
[0029] The energy absorbing lock system 100 is therefore a device designed to absorb and thwart the concentrated energy of an attempted forced entry through the door 200 or a similar access point. When a perpetrator places a sudden force onto the door, the substantially rigid mechanisms of the typical bolt-style lock system and/or the typical latch system designs often fail due to their inability to absorb the energy. The energy absorbing lock system 100 will, in most cases, absorb the energy and return the door 200 to its original position. In cases where there are only substantially rigid mechanisms, repeated blows often weaken (e.g., fatigue, cause crack initiation and crack growth, etc.) the lock/latch assemblies and the door/doorframe until a point of failure is reached. The energy absorbing lock system's 100 absorption qualities continue to function after repeated blows.
[0030] Extensible material is used in the deformable bolt 140 . In certain embodiments, the extensible material is neoprene and/or isoprene. As depicted, the extensible material may be formed into the deformable bolt 140 . A proximal end 142 of the extensible material may be operably connected (e.g., molded) to an actuator 180 (e.g., a conventional metal actuator) of the energy absorbing lock system 100 . A key and/or other rotating input may actuate the deformable bolt 140 between a locked configuration and an unlocked configuration.
[0031] A bolt receiver 220 (i.e., a female portion) is separate from a deformable bolt and actuator assembly 110 . The bolt receiver 220 may be a single piece (e.g., a steel piece, a formed piece, a forged piece, and/or a solid piece, etc.) that includes a deformation guiding portion 230 (see FIGS. 9 and 10 ). The bolt receiver 220 may be secured directly to a doorframe 300 . The bolt receiver 220 may be secured directly to the doorframe 300 at a jamb 310 of the doorframe 300 . The energy from the sudden blow is expended, absorbed, and/or dissipated as the deformable bolt 140 is bent, stretched, and/or compressed. The bending, stretching, and/or compressing of the deformable bolt 140 may be guided, at least in part, by the deformation guiding portion 230 . The bending, stretching, and/or compressing of the deformable bolt 140 may cause a recoiling effect and urge and/or force the door 200 back to its original position.
[0032] A metal insert 160 may be provided in the deformable bolt 140 . The metal insert 160 may be made of spring steel. The metal insert 160 may connect to the actuator 180 . A cap 170 may be provided at a distal end 144 of the deformable bolt 140 . The cap 170 may connect to the metal insert 160 . The metal insert 160 may provide tensile reinforcement to the deformable bolt 140 . The metal insert 160 may provide a tensile connection between the actuator 180 and the cap 170 .
[0033] The energy absorbing lock system 100 will absorb considerably more energy than the conventional deadbolt system, often made of some form of steel. As the conventional deadbolt system includes primarily rigid components, repeated blows typically weaken the lock assemblies, the door, and/or the doorframe until it a point of failure is reached. The energy absorbing lock system 100 functions after repeated blows.
[0034] In certain embodiments, the deformable bolt 140 of the energy absorbing lock system 100 is similar to the form and function of a conventional steel deadbolt found on residential and/or commercial business doors 200 . However, the materials used in the construction may be substantially different. In certain embodiments, the deformable bolt 140 (e.g., the deadbolt) is constructed of a hardened steel spine 160 (e.g., a spring steel spine) of about 0.025 to about 0.070 inch thickness that is secured to a steel end cap 170 that is about 3/16 inch thick. The hardened steel spine 160 is then covered with a neoprene or an isoprene materiel to create a body of the deformable bolt 140 . In other embodiments, the hardened steel spine 160 and/or the steel end cap 170 may be omitted.
[0035] The bolt receiver 220 (i.e., the female structure) may be composed of all steel and fit into an opening 320 of the jamb 310 where a conventional female receiver from a conventional deadbolt system fits into the door frame 300 . However, in certain embodiments, the bolt receiver 220 fully lines the opening 320 thus forming a hollow cavity 226 (e.g. a pocket made of steel). The bolt receiver 220 may include an exterior plate 224 (see FIG. 1 ) with outside dimensions of 2¼ inch×1 inch, which are industry standards in the United States. The exterior plate 224 may have two holes 236 for screws 238 that may be of standard diameter. The female opening 226 may have an industry standard height of ¾inch and may include a typical semi-half oval form 228 on opposing top and bottom ends.
[0036] A difference between the typical face plate and the bolt receiver 220 may be found at a side 222 (see FIG. 10 ) of the female opening 226 that first receives the deformable bolt 140 . It may be wider at this point (e.g., ¾inch) than the standard opening (⅝ inch) at the face plate 224 , but only slightly wider than the distal male end 144 of the steel end cap 170 of the deformable bolt 140 at a distal end 242 of the hollow cavity 226 (i.e., the hollow opening). A purpose of the narrowing of the cavity 226 may be to allow the deformable bolt 140 to seat in an innermost depth 242 of the cavity 226 . When the door 200 is struck with force, the first point to make contact with the bolt receiver 220 (i.e., the female apparatus) may be the end cap 170 of the deformable bolt 140 . As force is placed on the deformable bolt 140 , it will begin absorbing energy and bending and/or otherwise deforming. While bending, a first side 152 (see FIG. 9 ) of the deformable bolt 140 will make contact (e.g., bearing contact) along the offset inner wall 230 of the bolt receiver 220 until it reaches an edge 234 of the faceplate 224 . At this point, the deformable bolt 140 will absorb energy while bending the inner hardened steel spine 160 , all while cushioning the blow as the material (e.g., the neoprene material) compresses and/or otherwise deforms.
[0037] In the event that the perpetrator should continue to repeatedly deliver blows to the door 200 , the deformable bolt 140 may bend, compresses, and/or otherwise deforms in a manner that causes the door 200 to pinch the deformable bolt 140 into the doorframe 300 making thereby jamming the door 200 (see FIGS. 9 and 10 ).
[0038] Turning now to FIGS. 3 , 5 , 7 , and 9 , the energy absorbing bolt 140 will be described in detail. As illustrated at FIG. 5 , the energy absorbing bolt 140 generally defines a thickness t that extends between the first side 152 and a second side 154 . As illustrated at FIG. 3 , the energy absorbing bolt 140 generally defines a height h that extends between a third side 156 and a fourth side 158 . As illustrated at FIG. 2 , the third side 156 and the fourth side 158 may include a curved shape and/or a tapered shape. In certain embodiments, the curved shape matches similar shapes of conventional bolts found on conventional door lock assemblies. In certain embodiments, the height h is generally 0.75 inch, and the thickness t is generally 0.625 inch.
[0039] As mentioned above, the energy absorbing bolt 140 may terminate at a distal end 144 . The cap 170 may define the distal end 144 . In other embodiments, the distal end 144 of the energy absorbing bolt 140 may not include a cap. The general perimeter of the energy absorbing bolt 140 may continue across a thickness of the cap 170 . In particular, the cap 170 may also define the thickness t and the height h. The first side 152 , the second side 154 , the third side 156 , and the fourth side 158 may continue in a smooth and uninterrupted manner across the energy absorbing bolt 140 , including the cap 170 .
[0040] The energy absorbing bolt 140 extends between the proximal end 142 and the distal end 144 . As depicted at FIGS. 7 and 9 , the proximal end 142 of the energy absorbing bolt 140 may be positioned a substantial distance away from the end 202 of the door 200 and may be positioned within the door 200 .
[0041] The energy absorbing bolt 140 includes a first portion 146 , adjacent the proximal end 142 , and a second portion 148 , adjacent the distal end 144 . The proximal end 142 retracts within the bolt guide 190 when the deformable bolt and actuator assembly 110 are in the unlocked position. In particular, the distal end 144 of the energy absorbing bolt 140 may be substantially flush with the end 202 of the door 200 . When the deformable bolt and actuator assembly 110 is moved to the locked configuration, the first portion 146 is slid out of the bolt guide 190 and extends beyond the end 202 of the door 200 .
[0042] Turning now to FIGS. 6 , 9 , and 10 , the bolt receiver 220 will be described in additional detail. In certain embodiments, the bolt receiver 220 is formed of a continuous material and thereby is substantially stronger than a conventional bolt receiver. In certain embodiments, the cavity 226 of the bolt receiver 220 is surrounded on all sides except an opening 227 of the cavity 226 . Thus, the cavity 226 is surrounded by a perimeter of material 225 that generally extends around an axis A defined by the energy absorbing bolt 140 (e.g., as the energy absorbing bolt 140 slides). A bottom 229 of the cavity 226 may be integrally attached to (e.g., one monolithic piece with) the perimeter 225 . The bolt receiver 220 thereby defines a cup-shape structure with a high degree of strength as it is reinforced in every direction by the perimeter 225 and the bottom 229 .
[0043] The bolt receiver 220 may further include the exterior plate 224 (i.e., the strike plate). The exterior plate 224 may serve as a flange around the perimeter 225 and further strengthen and reinforce the bolt receiver 220 . As depicted at FIG. 6 , the bolt receiver 220 may include a set of holes 236 through the exterior plate 224 . As depicted at FIG. 6 , the bottom 229 of the hollow cavity 226 may include another hole 236 . A pair of fasteners 238 (e.g., screws) may attach the exterior plate 224 to the jamb 310 of the door frame 300 . A fastener 240 may secure the bottom 229 of the hollow cavity 226 to the door frame 300 . The fasteners 238 and/or 240 may extend beyond the jamb 310 of the door frame 300 and structurally attach the bolt receiver 220 to a frame of the building. By including the holes 236 and the fasteners 238 , 240 as illustrated, the bolt receiver 220 is mounted with a high degree of structural stability. In particular, the fasteners 238 , 240 are positioned in at least two planes that are separated by a distance. In contrast, a conventional strike plate may only fasten to the jamb of the door frame at a single plane.
[0044] The bolt receiver 220 may include a portion 250 that engages snugly with the energy absorbing bolt 140 . As depicted at FIG. 9 , the portion 250 is included adjacent the bottom 229 and/or the distal end 242 of the bolt receiver 220 . The distal end 144 of the energy absorbing bolt 140 may engage the portion 250 snugly and thereby give a positive feel to the locking of the door 200 when under normal loading conditions. The positive feel when closing and locking may feel much like the locking of a conventional door lock. The snug fitting between the distal end 144 and the portion 250 does not interfere with and may enhance the overall dynamic deformation characteristic of the energy absorbing lock system 100 when the intrusion load L is placed on the door 200 . In certain embodiments, the cap 170 engages with the portion 250 and thereby provides the energy absorbing lock system 100 with a metal-on-metal interface when the deformable bolt and actuator assembly 110 is positioned to and/or from the locking position.
[0045] Turning now to FIGS. 1 and 2 , exploded perspective views illustrate the energy absorbing lock system 100 , as installed on the door 200 and the door frame 300 . As depicted, the deformable bolt and actuator assembly 110 are installed in the door 200 , and the bolt receiver 220 is installed in the door frame 300 . In other embodiments, the deformable lock and actuator assembly 110 may be installed in a door frame, and the bolt receiver 220 may be installed in a door. As depicted, the door 200 is a conventional door found, for example, on residential dwellings, business buildings, school buildings, etc. The door 200 may be made of metal, wood, plastic, composites, etc. In certain embodiments, the door 200 includes a framework inside the door 200 . In such embodiments, the deformable bolt and actuator assembly 110 and/or the energy absorbing bolt 140 may be structurally connected to the framework of the door 200 . In other embodiments, the deformable bolt and actuator assembly 110 and/or the energy absorbing bolt 140 may not be substantially attached to a framework of the door 200 .
[0046] In certain embodiments, the door 200 is hung from the door frame 300 and pivots about hinge axes that are defined by hinges mounted between the door 200 and the door frame 300 . In certain embodiments, as illustrated at FIGS. 9 and 10 , the door 200 is constrained to normally open in only one rotational direction. In other embodiments, the door 200 may swing inwardly and outwardly about a door hinge axis and/or about door hinge axes (e.g., about a French door hinge system).
[0047] As illustrated at FIGS. 9 and 10 , the energy absorbing bolt 140 fits into the bolt receiver 220 and thereby locks the door 200 in a closed position. FIG. 9 illustrates the door 200 in a normal locked position. FIG. 10 illustrates the door 200 in a locked position, but with an intrusion load L applied against the door 200 thereby displacing (e.g., linearly displacing, rotationally displacing, or linearly and rotationally displacing the door 200 ). As illustrated at FIG. 9 , when the door 200 is in the normally locked position, the energy absorbing bolt 140 occupies a first portion 232 of the bolt receiver 220 . As illustrated at FIG. 10 , when the intrusion load L is applied to the door 200 , a portion of the energy absorbing bolt 140 occupies a second portion 233 of the cavity 226 of the bolt receiver 220 . The deformation guiding portion 230 may control the deformation of the energy absorbing bolt 140 and may thereby influence the energy absorption of the energy absorbing bolt 140 . FIG. 8 also shows the energy absorbing bolt 140 occupying the second portion 233 of the cavity 226 of the bolt receiver 220 when the intrusion load L is placed against the door 200 . FIG. 7 also illustrates the door 200 in the normal locked position with the energy absorbing bolt 140 positioned in the first portion 232 of the cavity 226 of the bolt receiver 220 .
[0048] FIG. 8 illustrates the energy absorbing bolt 140 absorbing energy by a bending mode. In certain embodiments, this bending mode may be a first mode that the energy absorbing bolt 140 enters while protecting the door 200 and the door frame 300 from the intrusion load L. Upon the intrusion load L increasing in magnitude, the energy absorbing bolt 140 may enter a compression mode (e.g., a pinching mode). By entering the compression mode or a second mode, the energy absorbing bolt 140 may employ additional energy absorbing means to prevent the door 200 from opening under the intrusion load L. These additional energy absorbing means may be used in isolation or together in various combinations with any other energy absorbing means.
[0049] These energy absorbing means may include the cap 170 contacting the cavity 226 of the bolt receiver 220 thereby placing the metal insert 160 in tension. These energy absorbing means may include a compressing of material of the energy absorbing bolt 140 . In particular, the edge 234 of the cavity 226 of the bolt receiver 220 may initiate substantial compression into the energy absorbing bolt 140 . As illustrated, the edge 234 includes a curved profile (e.g., a radius) that may influence the compression means of absorbing energy by the energy absorbing bolt 140 . In particular, the radius of the edge 234 should be large enough to avoid cutting the material of the energy absorbing bolt 140 . However, the radius of the edge 234 may be sized sufficiently small to penetrate by compression the first side 152 of the energy-absorbing bolt 140 . A bolt guide 190 may guide normal sliding of the energy absorbing bolt 140 when the actuator 180 moves the energy absorbing bolt 140 between the locked position and an unlocked position. The bolt guide 190 may include an edge 192 . The edge 192 may include a curved radius similar to the edge 234 of the cavity 226 of the bolt receiver 220 . The edges 192 and 234 may together bite into the energy absorbing bolt 140 and thereby resist the opening of the door 200 under the intrusion load L.
[0050] The energy absorbing bolt 140 may further include high friction as an additional energy absorbing means to resist the opening of the door 200 under the intrusion load L. The high friction may generally operate between the jamb 310 of the door frame 300 and an end 202 of the door 200 adjacent the deformable bolt and actuator assembly 110 . In certain embodiments, the intrusion load L may be sufficient to bind-up the door 200 , the energy absorbing bolt 140 , and the jamb 310 of the door frame 300 and may thereby cause the door 200 to stick with the energy absorbing bolt 140 jammed between the door 200 and the door frame 300 .
[0051] Turning now to FIGS. 13 and 14 , another energy absorbing lock system 200 , according to the principals of the present disclosure, is illustrated. The energy absorbing lock system 200 may include some or all of the features of the energy absorbing lock system 100 . The energy absorbing lock system 200 further includes a deformation guiding portion 230 ′ at or adjacent an edge 192 ′ of a bolt guide 190 ′. The deformation guiding portion 230 ′ operates in much the same manner as the deformation guiding portion 230 , described above. However, the deformation guiding portion 230 ′ is a part of the bolt guide 190 ′. The deformation guiding portion 230 ′ may be used in conjunction with the deformation guiding portion 230 . By combining two deformation guiding portions 230 , 230 ′, additional energy may be absorbed by the energy absorbing bolt 140 . As depicted, the deformation guiding portion 230 ′ resides on the door 200 and the deformation guiding portion 230 resides on the door frame 300 .
[0052] As depicted, the energy absorbing bolt 140 is made of material that may be extruded along the bolt axis A (see FIG. 6 ). For example, the hardened steel and/or spring steel spine 160 (i.e., the spring spine) includes an extruded shape along the bolt axis A. In other embodiments, the material of the energy absorbing bolt 140 may be extruded in other directions and/or varying directions. For example, the energy absorbing bolt 140 may include a coil spring (e.g., a steel coil spring) that may follow a helical path. The coil spring may include a net shape of the energy absorbing bolt 140 and/or the coil spring may include a coating covering the coil spring. The coil spring may be embedded in other energy absorbing material or other material of the energy absorbing bolt 140 . In other embodiments, a non-coil spring of the energy absorbing bolt 140 may also include a net shape of the energy absorbing bolt 140 (e.g., a pair of leaf springs) and/or the non-coil spring may include a coating of the energy absorbing bolt 140 covering the non-coil spring. The non-coil spring may be embedded in other energy absorbing material or other material of the energy absorbing bolt 140 .
[0053] The energy absorbing bolt 140 may further include the following materials, either alone or in combination with other material or materials.
[0054] Viton Extreme from DuPont
[0055] Tetrafluoroethylene Propylene, FEPM
[0056] Silicone Rubber, VMQ/PVMQ
[0057] Polyurethane Elastomer, AU or EU
[0058] Polysulphide Rubber, TR
[0059] Perfluoroelastomer, FFKM—known as the DuPont product Kalrez
[0060] Hydrogenated Nitrile Rubber, HNBR
[0061] Nitrile Butadiene Rubber, NBR
[0062] Fluorosilicone, FVMQ
[0063] Fluorelastomere, FKM/FPM, also known as Viton Elastomer by DuPont
[0064] Ethylene Propylene Copolymer EPM or EPDM
[0065] Epichlorhydrin (CO)
[0066] Chlorosulphonated Polyethylene (CSM)
[0067] Chloronated Polyethylene (CPE)
[0068] Ethylene Acrylic, AEM
[0069] Alkyl Acrylic copolymer, ACM
[0070] Polychloroprene, CR
[0071] Chlorobutyl Rubber (CIIR)
[0072] Isobutylene-isopropene copolymere (IIR)
[0073] Polybutadiene (BR)
[0074] Stryrene Butadiene (SBR)
[0075] Synthetic cis-polyisoprene (IR)
[0076] Natural Cis-Polyisoprene (NR)
[0077] This application is being filed concurrently with a U.S. non-provisional patent application known by docket number 17012.0002USU1 and entitled ENERGY ABSORBING LATCH SYSTEMS AND METHODS which is incorporated herein by reference in its entirety. The subject matter of the ENERGY ABSORBING LATCH SYSTEMS AND METHODS and the subject matter of the present patent application may be used on the same door 200 and/or door frame 300 .
[0078] Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that the scope of this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.
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A door lock secures a door when closed within a doorframe. The lock includes a bolt guide, a bolt, a bolt actuator, and a bolt receiver. The bolt includes a first portion that is adjacent to a proximal end and a second portion that is adjacent a distal end of the bolt. The actuator moves the bolt along the bolt guide between a locked position and an unlocked position. The second portion extends beyond the guide when in the locked position and is received by the receiver. The bolt deforms within the receiver and thereby predominantly absorbs energy from an intrusion load. A maximum deformation of the bolt prior to failure of the lock from the intrusion load is at least 4%, 25%, or 120% of a thickness of the bolt. A maximum deformation of the bolt prior to failure of the lock may be at least 40%, 55%, or 72% of a maximum overall deflection of the lock. The receiver may include a deformation guide that guides deformation of the bolt.
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RELATIONSHIP TO OTHER APPLICATION
This application claims priority from provisional Application Ser. No. 60/287,320, filed Apr. 30, 2001 and entitled CHAIR.
FIELD OF THE INVENTION
This invention relates to a chair of the type used in offices and the like, and in particular to an improved chair back having limited vertical swinging movement about an axis disposed adjacent the upper edge of the back.
BACKGROUND OF THE INVENTION
Chairs of the type used in offices and the like are often utilized for permitting a seated occupant to carry out work-intensive tasks adjacent a desk or worksurface, including keyboarding and other tasks which require the person to sit generally upright or even lean forwardly so as to partially overlie a worksurface. When used in this manner, the back of the chair generally loses contact with the occupant's back, and thus provides no supportive engagement therewith.
It is an object of this invention to provide an improved office-type chair wherein the back of the chair has limited vertical swinging movement generally about the upper portion thereof so that when a person using the chair leans forwardly, the back of the chair will be urged forwardly, as by a spring, through at least a limited extent and hence the lower portion of the chair back, such as in the lumbar region, will continue to maintain supportive engagement with at least the lower back of the chair occupant.
SUMMARY OF THE INVENTION
This invention is directed to a new and useful chair including a frame having laterally spaced first and second rigid uprights. A back is attached to the frame and includes upper and lower ends. Also attached to the frame adjacent to the lower end of the back is a seat. A pivot assembly couples the first and second uprights to the back for permitting pivoting of the back about a substantially horizontal pivot axis that projects laterally of the back and is positioned in the vicinity of the upper end of the back. The pivot assembly includes a spring arrangement that exerts a force on the back a substantial distance below the pivot axis for biasing the back toward a forward position.
Other objects and purposes of the invention will be apparent to persons familiar with constructions of this type upon reading the following specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a chair according to the present invention shown positioned adjacent a conventional desk.
FIG. 2 is a side view of the chair shown in FIG. 1 .
FIG. 3 is a further perspective view taken generally from the rear of the chair shown in FIG. 1 .
FIG. 4 is a perspective view which illustrates solely the back frame for the chair back of this invention and its connection to the rear inner shell of the chair back.
FIG. 5 is a back elevational view of the construction illustrated in FIG. 4 .
FIG. 6 is a side elevational view of the arrangement shown in FIGS. 4 and 5.
FIG. 7 is a side elevational view showing in cross sectional view the chair arm and its connection to the upright associated with the back frame, and specifically showing in solid lines the chair arm in both its uppermost and lowermost height adjusted positions.
FIG. 8 is a top view of the arrangement shown in FIG. 7 and showing both positions of the chair arm in solid lines.
FIG. 9 is a rear elevational view of the arrangement shown in FIGS. 7-8 and again showing both elevational positions of the chair arm in solid lines.
DETAILED DESCRIPTION
Referring to FIGS. 1-3, there is illustrated a chair 10 according to the present invention. This chair includes a conventional base 11 having legs 12 and a central height-adjustable pedestal 13 projecting upwardly therefrom. The pedestal at its upper end connects to the underside of a generally horizontally enlarged seat arrangement 14 . The seat arrangement 14 , as is generally conventional, includes a generally rigid structural inner shell 15 having a cushion thereover 16 , with the cushion and shell being generally enclosed by a surrounding covering such as a fabric or vinyl covering.
A back frame structure 21 joins to the underside of the seat structure 14 and projects upwardly for supportive engagement with a back arrangement 22 which projects upwardly from the seat arrangement 14 in the vicinity of the rear edge thereof. This back arrangement 22 , in the illustrated embodiment of the invention, has chair arms 61 associated therewith, which chair arms are cantilevered forwardly from the back frame arrangement 21 and are mounted for height adjustment with respect thereto.
The back arrangement 22 includes an inner structural back member or shell 23 typically constructed of wood or rigid plastic, and this inner shell is appropriately covered on a front side thereof with a cushion 24 such as of plastic foam, and the inner shell and foam cushion are appropriately enclosed within an outer covering of fabric, vinyl or the like. The rear of the back arrangement is typically closed by a rear cover or shell 27 which overlies the inner structural shell and is secured thereto. The general construction of the back arrangement 22 , like the seat arrangement, is conventional.
The back frame arrangement 21 as illustrated in FIGS. 4-6 includes a pair of generally upright frame members 31 which are substantially identical except for being mirror images of one another so as to be disposed adjacent the right and left sides of the chair back. Each upright frame member 31 includes a main elongate center part 32 which extends generally vertical and which at a lower end joins to a curved portion 33 which projects forwardly so as to terminate at a lower free end part 34 . The lower free end parts 34 of the upright frame members 31 are rigidly joined by a cross strap or plate 35 , the latter in turn being fixedly secured to the underside of the structural shell 15 associated with the seat arrangement 14 . The upright frame members 31 , at the upper ends thereof, are also provided with curved portions 36 which form an upper leg which projects toward and terminates in a free end 37 disposed adjacent the rear surface 28 of the inner back shell 23 in the vicinity of the upper edge 45 thereof.
The pair of sidewardly-spaced upright frame members 31 , at their upper ends, are rigidly joined by a top cross rod or bar 38 which has the free ends thereof non-rotatably and fixedly joined to the upper free end parts 37 of the side frame members 31 . This cross bar 38 , extending inwardly from the free ends thereof, has generally aligned and substantially horizontally extending rod portions 41 which project inwardly from the side frame members toward the center of the back shell. These horizontal rod members 41 are bent through about 90° angles and joined to a generally U-shaped center rod portion 42 . This center rod portion 42 includes side legs 43 which project generally vertically downwardly adjacent the rear surface of the back shell 23 , and these side legs 43 join through generally right angle bends to a bottom cross rod 44 which extends generally horizontally. The cross bar 38 and its rigid securement between the upper ends of the spaced side frame members 31 , and the bottom strap 35 and its rigid securement between the lower ends of the side frame members 31 , thus define a rigid frame assembly which is of a generally closed endless configuration, and provides a connection to support the back arrangement 22 from the seat arrangement 14 as described hereinafter.
To connect the back arrangement 15 to the frame arrangement, the back shell 23 fixedly mounts thereon, in the vicinity of the upper corners thereof, a pair of sidewardly spaced journals or bearings 46 which are fixed to and project outwardly from the rear surface 28 of the back shell 23 . This pair of spaced journals 46 define aligned openings 47 therein in which are snugly but rotatably accommodated the horizontal rod parts 41 of the cross bar 38 . This connection of the horizontal rod parts within the journals secured to the back shell thus couples the back shell 23 , and hence the back arrangement 22 , to the frame assembly 21 while permitting relative pivoting of the back arrangement 22 about the longitudinally extending horizontal axis 48 defined by the horizontal rod parts 44 .
To control and limit the amount of pivoting movement of the back arrangement 22 relative to the back frame assembly 21 about the pivot axis, the back assembly 22 has a restraining member 51 fixedly secured to and projecting rearwardly from the rear surface of the back shell 23 at an elevation which is spaced downwardly a substantial distance below the horizontal pivot axis 48 . This restraining member 51 in the illustrated arrangement is formed generally as a horizontally elongate strap which is fixedly secured to the back shell 23 , and the strap has a pair of control parts 52 in sidewardly spaced relationship therealong. These control parts 52 are formed generally as U-shaped parts, or yokes, and effectively extend around and provide control over the vertical rod portions 43 . More specifically, each of the control yokes 52 has generally parallel side legs 53 which are spaced apart so as to permit the side rods 43 to move lengthwise of the control yoke until restricted by the closed end 54 of the yoke which is spaced from the rear surface 28 of the seat shell 23 and functions as a stop. These control yokes 51 thus permit the back shell 23 to pivot about the horizontal pivot axis 48 through a limited extent as permitted by the vertical rods 43 abutting the ends of the yokes 52 as a forward limit position, and by the shell 23 swinging rearwardly into a rearwardmost position in which it effectively abuts the U-shaped center rod part 42 . The forward and rearward positions are diagrammatically indicated in FIG. 6 .
The back arrangement 22 is normally maintained in its forwardmost position by the urging of a spring arrangement 56 which, in the illustrated embodiment, comprises two coil-type torsion springs 57 which surround the horizontal center rod part 44 and have one leg 58 thereof anchored to the rod, with the other leg 59 of each torsion type coil spring being in abutting engagement with the rear surface of the back shell 23 . The legs 59 of the torsion springs which project inwardly for contact with the back shell 23 are, in the preferred embodiment, joined together to define a generally U-shaped configuration which bears against the rear surface of the seat shell at a location disposed in the vicinity of the horizontal rod part 44 and hence vertically approximately at the middle of the back shell. The contact of the spring against the seat shell is thus spaced a substantial distance downwardly from the pivot axis 48 and hence, acting through the long lever arm defined between the pivot axis and the spring, urges the seat shell 23 forwardly into the forward position as limited by the vertical rods 43 contacting the stop parts 54 defined at the ends of the control yokes 52 .
When the chair of this invention is not occupied, the spring 56 will normally urge the back arrangement 22 forwardly (counter-clockwise in FIG. 6) about axis 48 into the forwardmost position for the back. When the chair is occupied, however, and the occupant leans against the back in the normal manner, the force imposed on the back 22 by the occupant will overcome the spring force and the back will swing back (clockwise) into its rearwardmost position wherein the back shell 23 abuts the U-shaped rod part 42 and thus defines a generally solid or rigid back assembly.
However, if the occupant leans forwardly and relieves the force against the back 22 , such as when carrying out an intensive task on a table, such as a keyboarding function, then the back of the occupant will partially move away from the back and relieve the load on the back. At the same time, however, the spring 56 acting against the back shell 23 causes the lower portion of the back 22 to pivot forwardly about the top hinge axis 48 , and thus the lower portion of the back 22 will be disposed so as to continue to maintain supportive engagement with at least the lower portion of the occupant's back, particularly in the lumbar area.
Since the torsion springs 57 and their reaction against the rear surface of the back shell 23 occurs at a point which is spaced downwardly a substantial distance below the hinge axis 48 , the springs 57 acting through the large lever arm created by this spacing thus results in creation of a significant mechanical advantage so that a rather significant moment can be applied to the back 22 about the pivot axis 48 , even though the individual torsion springs themselves are small, and thus a significant force urging the lower portion of the back 22 forwardly can be achieved so as to continue to maintain partial supportive contact with the lower region of the occupant's back.
At the same time, however, the overall mechanism including the cross bar 38 as well as the restraining member 51 and springs 57 is small and compact, and can be easily enclosed in a small space defined between the inner structural back shell 23 and the outer rear cover 27 . The uprights 31 , however, and specifically the elongate upright parts 32 are positioned exteriorly of the back arrangement 22 and connect thereto only adjacent the upper corners thereof.
Considering now the construction and operation of the height-adjusting chair arms 61 as associated with the chair of this invention, each height-adjusting chair arm 61 includes an elongate support sleeve 63 which is fixed to and encircles the vertically extending portion 32 of the respective side frame member 31 over a significant extent of the length thereof. This tubular support member 63 has an opening therethrough for snugly receiving therein the elongate straight portion 32 of the side frame member 31 , and the tubular support member 63 is formed in two halves which enable it to be snugly clamped around the side frame member and then secured thereto by screws or similar fasteners which extend through the two halves of the support member as well as the side frame member.
The tubular support member 63 has an exterior configuration which is preferably polygonal and is defined by a plurality of flat sides, which exterior polygonal configuration in the preferred embodiment is generally rectangular and more specifically square.
The exterior front side wall 64 of the support tube 63 has a toothed or racklike configuration formed thereon throughout the vertical extent thereof, whereby adjacent teeth 65 are vertically separated by a notch or recess 66 which extends transversely (i.e. generally horizontally) with the upper side of this notch merging smoothly into a ramplike surface which slopes outwardly and upwardly to define the tooth.
The opposite or rear flat wall 67 of the support tube 63 is generally flat but has a series of transversely (i.e. horizontally) extending notches or recesses 68 formed therein. The series of notches 68 are disposed in vertically spaced relationship along the support tube, with the vertical spacing between adjacent notches 68 generally corresponding to the vertical spacing between adjacent recesses 66 associated with the front wall of the support tube 63 .
The upright back frame members 31 are disposed substantially totally exteriorly of the back arrangement 22 , and the elongate vertical uprights 32 associated with the back frame members 31 are disposed so that they are positioned closely adjacent but spaced slightly rearwardly and slightly outwardly from opposite sides of the back arrangement 22 . Each of the elongate vertical upright portions 32 of the back frame elements 31 , specifically those portions having the support tubes 63 secured therearound, support thereon one of the cantilevered arm assemblies 61 .
Each cantilevered arm assembly 61 includes a generally horizontally elongate arm member 71 which is mounted on and projects forwardly from the respective support tube 63 , with this arm member in turn having a top cap member 72 fixedly mounted thereon, which top cap member typically incorporates some type of resilient cushioning material enclosed within an appropriate exterior cover, such as is conventional, so that further description thereof is believed unnecessary.
The arm member 71 at the rearward end thereof is provided with a sleeve part 73 which has an opening 74 extending vertically therethrough, the cross section of which is noncircular and is sized so as to nonrotatably but vertically axially accommodate therein the respective support tube 63 , as illustrated in FIG. 8 .
The sleeve part 73 defines thereon, on the front side of the interior opening 74 adjacent the lower end thereof, a transversely extending rib 75 which projects rearwardly into the interior of the sleeve part and is sized so as to engage a selective one of the recesses 66 defined between the teeth 65 on the front or rack-bearing side of the support tube 63 .
The rear side of the opening 74 , in the vicinity of the upper end thereof, has a further rib 76 which extends transversely and projects outwardly in a forward direction so as to terminate in a generally flat outer end. This latter projection 76 is adapted to bear against the rear surface 67 of the support tube 63 in the flat regions between the notches 68 . This rear projection 76 is also disposed vertically upwardly a substantial distance above the front projection 75 , as illustrated by FIG. 7 .
The support hub 73 on the arm member 71 also has a small platelike spring 77 which is mounted interiorly thereof and has a cantilevered portion which terminates in a free end part 78 adapted to resiliently engage one of the latching notches 68 formed on the rear wall of the support tube 63 . This spring 77 has the upper end thereof secured over the rear support rib 76 associated with the support hub so that the spring is fixed to and hence carried with the support hub 73 . The spring 77 as it projects downwardly is cantilevered so as to be resiliently urged forwardly for engagement with the rear wall 67 of the support tube 63 .
With the height-adjusting arm arrangement of the present invention, the individual arms can each be vertically adjusted in height from an uppermost position as illustrated in FIGS. 7-9 to the lowermost position illustrated therein. This height adjustment range is preferably between about seven inches, with the arm when at the upper limit as illustrated in FIGS. 7-9 typically being at the uppermost height which is conventionally provided for arms associated with office type chairs. Conversely, however, when the arm is in the lowermost position illustrated in FIGS. 7-9, the arm is now disposed so that it is positioned closely adjacent the outer side edges of the seat arrangement 14 , and elevationally is positioned closely adjacent or just slightly above the upper surface of the seat arrangement, whereby in this latter position the arms are at an elevation whereby they are compactly stored directly adjacent the seat arrangement, and thus the chair in its entirety, except for the back arrangement, can be readily stored in a position under even low tabletops or worksurfaces. Further, even when the chair is occupied, the arms can be disposed in this lowermost position whereby they do not interfere with the occupant's movements if the occupant prefers to have the sides of the chair seat free of obstructions.
The operation of the height-adjusting arms is extremely simple since, if the occupant when sitting in the chair grips the arm 71 adjacent the rear end thereof and lifts upwardly, this causes the arm to rock about the bearing rib 76 , thereby causing the locking rib 75 to be withdrawn from engagement with the rack. The operator can then move the arm vertically, either upwardly or downwardly, since the spring 77 will merely function like a releasable detent and effectively “click” upwardly or downwardly along the support tube 63 and hence define the various locking positions. When the arm reaches the desired elevational position, the operator then allows the arm to tilt back downwardly causing the locking rib 75 to engage the respective recess 66 associated with the rack, thereby relocking the arm in the selected position, substantially in the manner illustrated by FIG. 7 . In this locking position, the weight of the arm tending to swing it downwardly (counter-clockwise in FIG. 7) thus effectively maintains the support hub 73 of the arm in locked engagement with the support tube 63 . No additional complex locking mechanisms are required, and in addition no separate levers or trigger mechanisms are required so as to release the arm for height adjustment purposes.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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A chair having a swingable chair back with a top pivot includes a frame having laterally spaced first and second uprights. A back having upper and lower ends is attached to the frame. Also attached to the frame adjacent the lower end of the back is a seat. A pivot assembly couples the first and second uprights to the back and permits pivoting of the back about a substantially horizontal pivot axis. The pivot axis projects laterally of the back and is positioned in the vicinity of the upper end of the back. A biasing device cooperates with the back and normally urges the lower portion of the back forwardly away from a rearward position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims the benefit of priority to U.S. Provisional Patent Application No. 60/671,898, filed on Apr. 15, 2005, entitled “Translucent Resin Wall System,” the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
This invention relates to systems and methods for creating and installing resin-based panels that can be used as decorative architectural walls.
2. Background and Relevant Art
Some recent architectural designs have implemented synthetic, polymeric resins, which can be used as windows, ceiling panels, partitions, walls, etc., in offices and homes. Present polymeric resin-based materials generally used for creating decorative resin-based panels comprise polyvinyl chloride or “PVC” materials; polyacrylate materials such as acrylic, and poly(methylmethacrylate) or “PMMA;” polyester materials such as poly(ethylene terephthalate), or “PET;” poly(ethylene terephthalate modified with a compatible glycol such as 1,4-dimethanol or 2,2-dimethyl-1,3-propanediol) or “PETG” (or “PCTG”); as well as polycarbonate materials.
In general, resin-based materials such as these are now popular compared with decorative cast glass or laminated glass materials, since resin-based materials can be manufactured to be more resilient, and to have a similar transparent, translucent, or colored appearance as cast or laminated glass, but with less cost. Decorative resin-based panels can also provide more flexibility, compared with glass, in terms of color, ability to texture, gauge availability, lower material density (implying lower panel weight) and considerably higher impact resistance. Furthermore, decorative resin-based panels have a fairly wide utility since they can be manufactured and fabricated to include a wide variety of artistic colors and images. This stated flexibility applies both in the manufacturing phase, as well as in the post-manufacturing, or ultimate-use, phase.
One use-based application of polymeric resins in architectural environments is that of a decorative panel, which can be used to decorate an existing wall, an interior wall or ceiling finish, or as a new wall partition. For example, a 4×8 foot resin-based panel could be used as a partition wall by inserting the resin-based panel inside a wood, plastic or metal frame that has bottom, side, and top grooves for holding the resin-based panel securely. If the resin-based panel is translucent, the resin-based panel might also be formed with embedded decorative materials, which could provide additional creative features to the partition or interior finish. Light transmitted on either side of the wall will provide an aesthetic effect to viewers on the opposing side.
In other cases, such as with existing, non-partition walls, a colored, resin-based panel can also be mounted directly against the existing wall (e.g., existing drywall) to provide another kind of aesthetic effect. This is ordinarily done using a combination of adhesives and/or other mounting materials such as two-sided tapes, screws, glues and the like. Unfortunately, the aesthetic effect of this type of resin-based panel material is limited since the resin-based panel's opacity is important for obscuring the mounting materials (e.g., adhesives, existing dry wall, and so forth). In particular, resin walls used in this type of environment will not ordinarily include decorative objects, and are not constructed to allow light to transmit through the resin-based panel as such translucency can often exhibit a shadowing effect, which is considered undesirable by designers and architects.
There are yet additional challenges for mounting these types of resin-based panels directly to an existing wall. For example, the resin-based panels can be fairly heavy relative to the adhesives, and the materials and methods for mounting these materials are often not readily configured for the type of expansion and/or contraction that can effect the resin-based panels over time. Furthermore, existing wall treatment systems designed for polymeric materials also suffer from issues associated with the “creep” of resin-based material over time. Creep occurs when the resin-based material flows over time in the direction of gravity, such that some resin-based panels can gain a slight degree visual distortion in a portion of the panel. Furthermore, creep, in addition to any expansion and contraction of material due to temperature changes, can cause the polymeric-based or resin-based panels to buckle and/or deflect where held in a rigid fashion. For this reason, polymeric materials used in wall panel systems have traditionally been limited to materials that may be more dimensionally stable such as glass, woods, concrete, gypsum, metals and the like, but nevertheless less aesthetically desirable materials due to their lack of translucency.
There are other ways in which decorative walls can be fastened to an existing wall to create decorative effects, which can avoid some of the disadvantages of using primarily opaque materials. For example, some builders will mount a translucent glass panel to an existing wall using one or more “standoffs” that are designed to mount into a specifically designed frame for the existing wall, or, in other configurations, to mount directly to metal or wood studs in the wall, or some other concrete or steel substrate. This type of mounting allows light to pass from the gap—created by the standoffs—between the frame that was mounted to the existing wall and the translucent glass panel, and to the other side of the panel to thereby create an aesthetic effect.
Unfortunately, glass is a heavier, often more expensive, and typically more fragile material than polymeric resin-based panels. In particular, the weight of glass makes it fairly difficult, if not impossible, to mount a glass panel to common drywall or wood wall substrates. Furthermore, the frame systems used to mount the glass panels in a standoff position from an existing wall tend to be quite complicated, tend to need precise measurements of the existing wall, and also tend to involve a significant amount of labor to install. Still further, glass panels cannot be easily modified to incorporate decorative materials, and so are limited in the type of aesthetic effect they can provide, even after taking the time to create and install them in a specific environment. Yet still further, glass systems that use standoffs attached directly to the wall must be pre-fabricated to accommodate the natural expansion and contraction that could otherwise be field-fabricated with resin-based panels.
Another of the problems with existing panel systems is that many attachment points are typically needed in order to counter the tendency of the attached material to deflect under its own weight. This is partially because systems generally rely on supporting the panel from the bottom portion of the panel. In addition, existing panel or wall systems are configured to hold the given panels in their existing shape, which tend to be either flat or curved, with little additional variation thereof. Unfortunately, to achieve a curved wall surface, the wall system frame (or relevant attachment objects) will ordinarily need to be constructed to match the curves of the material, which can result in significant expense, complexity, and still other aesthetic limitations.
BRIEF SUMMARY OF THE INVENTION
The present invention solves one or more problems in the art with systems, methods, and apparatus configured to provide existing walls with decorative, translucent resin-based panels in a simple, cost-effective, and aesthetically pleasing manner. In particular, systems and methods in accordance with implementations of the present invention relate to mounting polymeric resin-based panels, which can be modified to provide a wide range of aesthetic effects, such as having a light source shine through from behind the resin-based walls compared to an existing wall constructed with other materials.
For example, a translucent wall assembly in accordance with at least one implementation of the present invention includes a frame having one or more vertical members and one or more horizontal members. The frame is configured to be vertically positioned adjacent an existing wall. The frame also has one or more standoffs connected thereto, which are ultimately used to fasten one or more polymeric resin-based panels to the frame in an at least adjacent fashion. The translucent wall assembly also includes a polymeric resin-based panel connected to the frame via at least a portion of one or more standoffs. The distance provided by the standoffs relative to the frame allows light to pass from a front side that opposes the frame to a back side that faces the frame, and from the back side that faces the frame to the front side that opposes the frame.
Alternately, a frame assembly for mounting one or more resin-based panels to an existing wall at an extended position includes, for example, a plurality of horizontal members having a groove formed therein, as well as a plurality of vertical members also having a groove formed therein. The frame assembly further includes a plurality of standoffs slidingly-coupled to the groove of one of the plurality of horizontal members or to the groove of one of the plurality of vertical members. The plurality of standoffs are also coupled on an opposing end to either one or more resin-based panels, or to a secondary frame to which the one or more resin-based panels are mounted.
Accordingly, implementations of the present invention provide a number of advantages to builders and/or architects looking to enhance existing walls, such that the existing walls can take on the aesthetic properties of the resin-based panels, including incorporating lighting from behind. These aesthetic properties can be many and varied, and can include variations in color, texture, inclusion of different types of decorative objects, as well as differing shapes. Furthermore, wall and/or frame systems in accordance with the present invention can be readily adjusted in the relevant attachment positions over time to account for any potential creep and/or expansion/contraction of the given polymeric panels. Still further, the panels and systems described herein can also be made to include fire resistance properties, such as may be needed in certain types of manufacturing or building environments as sometimes required by building officials or local building codes.
Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1A illustrates a resin-based wall panel mounted to an existing wall at a standoff position in accordance with an implementation of the present invention;
FIG. 1B illustrates a close up perspective view of at least one standoff assembly used to mount the resin-based wall panel illustrated in FIG. 1A ;
FIG. 1C illustrates an exploded perspective view of the standoff assembly illustrated in FIG. 1B when used to mount a top portion of the resin-based wall panel;
FIG. 1D illustrates an exploded perspective view of the standoff assembly illustrated in FIG. 1B when used to mount a lower portion of the resin-based wall panel;
FIG. 2A illustrates another implementation of a resin-based wall panel in accordance with the present invention in which one or more resin-based wall panels are modified for a curved effect;
FIG. 2B illustrates a back perspective view of the resin-based wall panel illustrated in FIG. 2A ;
FIG. 2C illustrates a facing diagrammatic view of a panel and a frame configured to create the wave effect illustrated in FIG. 2A ;
FIG. 3A illustrates still another implementation of a resin-based wall panel in accordance with the present invention in which one or more resin-based wall panels are mounted within a grid system;
FIG. 3B illustrates a close up perspective view of a grid intersection of the resin-based wall panel illustrated in FIG. 3A ;
FIG. 3C illustrates an exploded perspective view of an intersection assembly of the frame used in creating the grid intersection illustrated in FIG. 3B ;
FIG. 4A illustrates a top perspective view of another implementation of a resin-based wall panel system, wherein one or more resin-based wall panels are positioned between ridged frame members to create a curved effect;
FIG. 4B illustrates an exploded view of resin-based wall panels and frame members of the resin-based wall system shown in FIG. 4A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention extends to systems, methods, and apparatus configured to provide existing walls with decorative, translucent resin-based panels in a simple, cost-effective, and aesthetically pleasing manner. In particular, systems and methods in accordance with implementations of the present invention relate to mounting polymeric resin-based panels, which can be modified to provide a wide range of aesthetic effects, such as having a light source shine through from behind the resin-based walls compared to an existing wall constructed with other materials.
In particular, and as will be understood more fully from the following specification and claims, one aspect of the invention includes positioning one or more translucent resin walls at a standoff position from an existing wall. Another aspect of the invention includes providing an existing walls with resin-based panels that have been enhanced in one or more ways for color, degree of translucence, fire-resistance, and/or to include one or more decorative objects. Still another aspect of the present systems includes mounting the one or more resin-based panels to an existing wall using any number of techniques in order to provide a wide variety of formational effects such as straight, grid-like, or curved effects. A further aspect of the invention includes providing ease of installation, as well as greater durability of the resin wall by accounting for material creep, and/or allowing for natural expansion and contraction.
For example, FIG. 1A illustrates a resin wall that has been mounted to a frame, and that can further be mounted to an existing wall. As shown, the resin wall 100 a includes resin-based panels 105 a - b that are mounted at a standoff position with respect to the frame 103 in accordance with an implementation of the present invention. Due to the resin wall's translucent properties, light can be transmitted from the frame 103 side of the resin wall 100 a to an opposing side, since the resin wall 100 a is translucent. The composition of the resin wall 100 a , as well as resin walls 100 b and 100 c (as in the subsequent Figures), can be any suitable polymeric resin for creating a sufficiently solid vertical panel.
Examples of suitable polymeric resins include any copolyesters such as PET, PETG, PCTG, and the like; any acrylics such as PMMA; any polycarbonate material; and any combinations thereof. Panels made from these polymeric resins can be of varying color, translucence, and texture, and can also be made to include decorative objects. Panels made from these polymeric resins can also be made to have fire-resistance properties without sacrificing translucence, and so can be helpful when used in building applications, such as interior finishes, that carry additional flammability performance requirements as regulated by local or national building codes (e.g., flame spread and smoke tests characterized American Society for Testing and Materials E84—“ASTM E84”).
Examples of adding color or decorative objects to a resin-based panel are found in commonly-assigned U.S. patent application Ser. No. 10/465,465, filed on Jun. 18, 2003, entitled “Laminate Structure with Polycarbonate Sheets and Method Of Making,” which is a continuation-in-part of commonly-assigned U.S. patent application Ser. No. 10/086,269, filed on Mar. 1, 2002, entitled “Laminated Article and Method of Making Same,” which claims the benefit of priority to U.S. Provisional application Ser. No. 60/273,076, filed on Mar. 5, 2001, entitled “Lamination of Dissimilar Materials and Method for Making Same.” Examples of forming a polymeric resin-based panel with decorative objects are found in commonly-assigned U.S. patent application Ser. No. 10/821,307, filed on Apr. 9, 2004, entitled “Architectural Laminate Panel with Embedded Compressible Objects and Methods for Making the Same.”
In addition, examples of adding fire-resistant properties to translucent polymeric resin-based materials, which are suited for use in interior finish applications, are found in commonly-assigned U.S. patent application Ser. No. 11/103,829, filed on Apr. 12, 2005, entitled “Fire-Resistant Architectural Resin-based materials,” which claims the benefit of priority to U.S. Provisional Patent Application No. 60/579,004, filed on Jun. 11, 2004, entitled “Fire-Resistant Architectural Resin-based materials.” The entire content of each of the aforementioned U.S. patent applications is incorporated by reference herein.
Referring again to the figures, frame 103 is configured to be easily assembled into a cross section that can be adjusted to the size and width of virtually any existing wall. For example, the frame 103 includes two or more horizontal frame members, such as horizontal frame members 110 a and 110 b , and two or more vertical frame members, such as vertical frame members 120 a - b . The horizontal and vertical frame members in turn can be expanded or shortened, and reduced or multiplied in number as appropriate. Furthermore, the frame members 110 and 120 comprise multiple grooves, oz perforations, and/or tracks for adjustably receiving one or more mounting components or fasteners, such that the frame 103 can be adjusted and mounted to virtually any size or shape of existing wall.
As shown in the close up perspective view of FIG. 1B , the frame 103 can also be configured to receive any other support members, such as support member 112 . For example, support member 112 is inserted in corresponding “Z-grooves” of the frame 103 on the side ultimately proximate to an existing wall, and can be used to stabilize the frame 103 in any of an X or Y orientation. In one implementation, the support member 112 is mounted inside an existing wall; while in other implementations, the support member 112 is mounted directly to an existing wall, and the vertical members 120 (e.g., 120 a - d ) mounted to the support member 112 essentially hang from the support member 112 . The hanging effect of the support member 112 can be helpful for providing side-to-side adjustability of the overall frame 103 .
The one or more support members 112 can be anchored to the frame 103 against the existing wall using any number of fasteners or anchor apparatus (not shown). As such, the one or more support members 112 also comprise any suitable grooves, perforations, and/or tracks, which can be used to help mount the frame to the existing wall (not shown). The horizontal members 110 , vertical members 120 , and/or support structure(s) 112 can be made of any suitably strong metal, alloy, polymeric material, and/or combinations thereof. (In one implementation, the frame members are selected for their aesthetic properties since they will be seen through the translucent resin-based materials.)
The grooves, perforations, and/or tracks of horizontal frame members 110 a - b and vertical frame members 120 a - c can also be configured to receive one or more securing members, such as standoffs 115 , at one or more X/Y positions. As shown, standoffs 115 are configured in turn to receive a corresponding resin-based panel 105 a on one end, and secure the given panel (e.g., 105 a - b ) at an extended position relative to the frame 103 .
FIG. 1C illustrates a close up exploded perspective view of a standoff assembly 115 positioned between a resin-based panel 105 a and a vertical member. In particular, FIG. 1C shows that standoff 115 comprises a body 113 configured with a threaded recess for receiving a threaded stem 119 that extends from a cap 117 . The standoff body 113 in turn receives a threaded connector 111 , which secures the standoff body 113 to the resin-based panel (e.g., 105 a ) on one side. The standoff body 113 also attaches to a slidable brace 107 on an opposing side. The brace 107 is further configured to slide within a groove 127 of the vertical member 120 a . Thus, the body 113 , connector 111 , and brace 107 can slide in concert along groove 127 until the body 113 is tightened to a certain point with respect to the brace 107 and member 120 a . The standoff 115 , including cap 117 , threaded member 119 , body 113 , connector 111 and brace 107 can be made of any appropriate metal, alloy, or polymeric materials, or combinations thereof, for holding a weight of a resin-based panel by itself, and/or with one or more other standoffs 115 .
As also shown, the cap 117 secures the resin-based panel 105 a to the standoff by inserting the threaded member 119 through a specifically sized eyelet 123 a . In particular, FIG. 1C shows that threaded member 119 is inserted through eyelet 123 a before being inserted and screwed into body 113 . As shown, the eyelet 123 a is about the same size (or slightly larger) in diameter as the threaded member 119 , since what is shown is the upper portion of the panel 105 a . This relatively precise size or diameter of eyelet 123 a ensures that the resin-based panel 105 a is secured where the relevant standoff body 113 is secured to the frame 103 , and thus allows for little variation or modifiability of the same. In general, however, a manufacturer may desire to implement greater variability in this or other eyelets of the relevant panel.
For example, FIG. 1D shows a wider eyelet 123 b that has been implemented in the lower portion of the panel 105 a . In particular, FIG. 1D shows that the wider eyelet 123 b provides at least a greater ±Y variability for positioning the panel 105 a with respect to the standoff 115 (and hence to the relevant vertical or horizontal frame member). This variability in the lower eyelets (e.g., 123 b ) can help the resin-based panel 105 a maintain appearances in spite of any natural degradation that might be associated with age. In particular, this type of ±Y variability in the lower portion can be helpful for resin-based panels made of materials that may be prone to some material redistribution. In one implementation, for example, these larger, oversized eyelets 123 b are configured to account for expansion/contraction, while, in conjunction with standoff 113 (i.e., due to the ability to adjust the position of the standoff point support by sliding it up and down in the given vertical frame member) are duly configured to accommodate material creep. Accordingly, a manufacturer may find a wide variety of advantages by creating differently sized eyelets for different portions of each of the resin-based panels, as desired. That is, exact or differently sized eyelets 123 a - b can provide flexibility to the assembler as well as durability in aesthetic appearance.
FIGS. 1A through 1D therefore show how the frame 103 and corresponding parts can be configured so that thread receptors can be readily positioned and matched with corresponding eyelets of the primarily flat, translucent resin-based panels. By contrast, FIG. 2A illustrates another implementation of a resin wall, or resin wall 100 b in accordance with the present invention where one or more resin-based panels 130 a , 130 b , and 130 c are configured to provide alternating, curved aesthetic effects.
For example, FIG. 2A shows a facing perspective view of resin wall 100 b , in which horizontally lain, vertically stacked panels 130 a - c are formed with alternating and opposing curvatures. In particular, from left to right, panel 130 a is convex (extending away from frame 103 ) between members 120 a to 120 b , and concave (extending toward frame 103 ) between vertical members 120 b and 120 c . By contrast, panel 130 b is concave between vertical members 120 a to 120 b , but convex between vertical members 120 b to 120 c , and so forth. Panel 130 c , in turn has a similar convex/concave pattern as panel 130 a , or is another sequence of curvatures, as desired.
FIG. 2B shows a back perspective view of the resin wall 100 b . As shown each standoff 115 is substantially the same length between a given frame member (e.g., 120 a - e ) and the resin-based panel 130 a - c , and hence provides the same length of distance between the relevant resin-based material and the existing wall at the given attachment point (e.g., 117 attached at an eyelet 123 , FIG. 2C ). One will appreciate, however, that the length of the given standoff 115 can be varied by a manufacturer to enhance this curved effect as desired, or to create other types of shapes using curvature. For example, in one implementation, the manufacturer implements progressively longer standoffs (not shown) from vertical member 120 a through 120 e , thereby creating a waved effect that progressively extends toward the viewer. In sum, there are a wide variety of ways in which a manufacturer can create and/or enhance a curved aesthetic effect.
In any event, in order to create the curved effect in the first instance, FIG. 2C illustrates one way in which this can be accomplished. In particular, FIG. 2C shows each of the vertical members 120 a , 120 b , and 120 c of an eventual frame 103 are separated an equal distance of “x” from the next vertical member. By contrast, an exemplary panel 130 has a first position of eyelets 125 a and a second set eyelets 125 b that are separated a distance of “x+n” (i.e., where “n” is greater than 0). Panel 130 further has a third set eyelets 125 c , which are positioned a distance “x” from the second position of eyelets 125 b.
The first position of eyelets 125 a are configured to receive a threaded member 119 , which fastens into a corresponding standoff bodies 113 that has been previously secured to vertical member 120 a . The second position of eyelets 125 b are similarly configured to receive a threaded member 119 that will also be fastened into the standoff bodies 113 , albeit one positioned in vertical member 120 b . Similarly, the third position of eyelets 125 c are configured to align with the standoff bodies 113 positioned in vertical member 120 c . Since there is a greater amount of distance (i.e., “x+n”) in the between the first position of eyelets 125 a and the second position of eyelets 125 b than the spacing between vertical members 120 a and 120 b , the resin-based panel 2 C will bow outwardly or inwardly as desired, based on the flexibility or thickness of the chosen material. For example, in one implementation, the manufacturer uses a thicker, lower-modulus resin-based material that is subject to bending. In another implementation, the manufacturer uses a more rigid material that is made flexible due to its relative thickness (e.g., quarter inch or thinner).
By contrast, where the distance “x” between the second position of eyelets 125 b and third position of eyelets 125 c of caps 117 is equal to the spacing between vertical members 120 b and 120 c , the resin-based panel 130 will simply be held in a flat conformation. This spacing, therefore, is merely exemplary, and contrasts with FIGS. 2A and 2B , which show either concave or convex bowing between vertical members 120 a - e . Accordingly, FIGS. 2A through 2C show that a manufacturer can adjust the spacing or positioning of eyelets in a given polymeric resin-based panel to achieve a wide range of aesthetic effects, such as that provides each given panel with a desired shape or lay with respect to the frame 103 .
FIG. 3A illustrates still another implementation of a resin wall, or resin wall 100 c , in accordance with the present invention, wherein one or more resin-based panels 140 are mounted to a frame assembly in a grid-like fashion. In contrast with the preceding Figures, however, none of the panels 140 include eyelets through which a threaded member 119 of a cap 117 is inserted to join with a standoff body 113 . Rather, as further shown in FIG. 3B , resin wall 100 c comprises two frames, such as frame 103 and secondary frame 160 , set apart by standoffs 115 . The resin-based panels 140 are then held in place by overlapping caps 117 , which overlap and secure the peripheral edges of each panel 140 . For example, in FIG. 3B , secondary frame 160 is held at an extended position from frame 103 via standoffs 115 , while each of resin-based panels 140 are held in place by overlapping caps 117 .
FIG. 3C illustrates an exploded perspective view of one implementation of the grid intersection illustrated in FIG. 3B . In particular, a grid intersection of secondary frame 160 can be created using a mitered intersection connector 167 , which includes vertical arms for receiving vertical members 150 a and 150 b , as well as perpendicular, horizontal arms for receiving horizontal members 155 a and 155 b . Each of horizontal members 155 a - b and vertical members 150 a - b include a groove 163 , through which an assembler inserts brace 107 . The vertical members 150 a and 150 b , and horizontal members 155 a - b may be the same vertical members as any of 120 a - c and/or the same as any of horizontal members 110 a - c shown previously, or may be different vertical or horizontal members, or some other modified portions thereof.
In one method of assembly, an assembler mounts the various horizontal frame members 110 (e.g., 110 a - c ) and vertical frame members 120 (e.g., 120 a - d ) with any necessary support members 112 against an existing wall (not shown). The assembler then creates the secondary frame 160 by inserting each of the horizontal frame members 155 a - b and vertical frame members 150 a - b (or portions of members 110 and/or 120 ) into an intersection connector 167 . The assembler also secures a standoff body 113 to a position of a vertical frame member (e.g., 120 b ), and inserts any appropriate braces 107 within grooves 163 of the vertical frame members 150 a - b and horizontal frame members 155 a - b of the secondary frame 160 . The intersection connector 167 is then secured to the standoff body 113 , and the assembler then aligns each panel 140 in the appropriate grid position. The assembler then secures each panel 140 by screwing any appropriate number of caps 117 into the braces 107 of the secondary frame 160 . When all panels 140 and frames 103 (or also 160 ) are assembled together, the resulting structure resembles the structure shown in FIGS. 3A and 3B .
FIG. 4A illustrates a top perspective view of another implementation of a resin wall system, wherein one or more resin-based panels are positioned between ridged frame members to create a curved effect. In particular, a resin-based panel 205 a can be placed inside another form of a securing member, or elongate groove 210 a , which is mounted on one frame member 220 a , and inside another securing member, or elongate groove (not shown), of a next/adjacent frame member (not shown). For example, FIG. 4A shows that panel 205 b is placed in the opposite elongate groove 210 b of the frame member 220 a . If the frame members (e.g., 220 a , and other frame members not shown) are placed sufficiently close together, the resin-based panel will bow in one of a concave or convex direction, as desired. Alternatively, the manufacturer or assembly might opt to straighten the panels by separating the relevant frame members 220 .
FIG. 4B illustrates a dissembled view of resin-based panels and frame members of the resin wall system shown in FIG. 4A . In particular, FIG. 4B shows that a frame member 220 a comprises an elongate attachment 230 , which is inserted over a protruding neck portion 225 . The elongate attachment 230 comprises corresponding elongate grooves 210 a - b (or securing members) formed on opposing sides. There are, of course, other ways of providing grooves into which a resin-based panel can be inserted, and ultimately made to curve. For example, the elongate groove 210 a - b can be formed directly in the frame member itself, rather than in a separate attachment. Alternatively, the grooves 210 a - b may be less elongate, and more sporadically spaced, or may be evident as a combination of multiple clips providing similar function. As such, one will appreciate that the apparatus and systems shown in FIG. 4B are merely exemplary.
Accordingly, the present invention provides a wide variety of systems and apparatus for mounting translucent resin walls to existing walls, and for adding a decorative, aesthetically pleasing appearance to existing walls. Furthermore, implementations of the present invention allow for existing walls to take on a pleasing appearance without significant hassle, at least in part since the frame systems can be easily modified to accommodate virtually any existing wall. Still further, implementations of the present invention provide for one or more frames that can be easily assembled with pre-cut, pre-drilled components that are configured for any number of conformations or designs, and that are configured to hold their designs in a pleasing manner even after some natural changes occur to the resin-based materials. Thus, implementations of the present invention provide a number of important advantages over conventional glass or resin wall systems.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A translucent wall in accordance with the present invention is configured to provide aesthetic qualities to existing walls using resin-based panels. In one implementation, one or more resin-based panels are mounted to an existing wall using one or more easily assembled frames and one or more standoffs. The panels, frames, and standoffs are configured to mount the resin-based panels away from the wall by a specific distance, thereby allowing light to be transmitted through the resin-based panels. This light transmittance in turn provides a number of decorative advantages in terms of coloring, texturing, and in terms of exhibiting decorative objects embedded in the resin-based panels. The one or more frames used in accordance with the present invention can be easily adapted to any interior or exterior space or finish, such that the disclosed systems can benefit from mass-production techniques.
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FIELD OF THE INVENTION
The invention relates to a process according to the introductory part of claim 1 for the manufacture of chemimechanical and/or chemithermo-mechanical wood products from raw materials containing wood cellulose, such as wood particles, wood chips, raw wood fibers or sawdust.
BACKGROUND OF THE INVENTION
The manufacture of wood materials in refiners under optimal conditions permits better qualities than does stone grinding production. But thermal treatment or thermal and chemical treatment of the wood is required prior to defibration. The purpose of such preliminary treatment is to soften the lignin, thereby reducing the energy needed for the release of the fibers from the tissue and producing breaking points in the area of the primary wall and S1. The resultant fiber surfaces are rich in carbohydrate and therefore are well qualified for the formation of hydrogen bridges between the surfaces of these fibers. The temperatures to be applied in the preliminary thermal treatment are between 125° and 150° C. In the case of a treatment time of a few minutes, the above-mentioned aim of lignin plastification is to be reached, but it is not to be so extensive as to result in separation of the fibers in the middle lamella area, which would result in an intact fiber but it would have a hydrophobic lignin coating on the surface. Higher temperatures or longer treatment also have the disadvantage that the lignin structure is changed by condensation reactions and the fibers darken considerably.
By sulfonating the wood at the breaking points a controlled defibration of the wood is achieved, loss of whiteness is prevented and a more hydrophilic lignin is produced at the later fiber surface. The production of more flexible fibers is to be considered as an additional positive aspect of sulfonation.
The energy needs for the isolation of fibers from the wood tissue are diminished by a thermal or chemical pretreatment of the wood. For the production of high-quality fiber materials for paper and linerboard production, however, they have to be additionally defibrillated. In this case wall layers or fibrils are stripped from the surface of the fibers by mechanical action, thereby increasing the specific surface area of the fibers and thus improving their bonding capacity and their flexibility. Such processes are described extensively in "Pulp and Paper Manufacture," vol. 2, Mechanical Pulping, Tappi, Atlanta 1987.
In comparison to the stone grinding process the power requirements in all refiner wood pulp processes are significantly higher. In the stone grinding process the defibering energy is delivered directly to the wood layer in direct contact with the stone surface. In refiner processes the energy transfer is less controlled, since energy is consumed in the acceleration of the pulp, in the rubbing of the wood particles on one another and on the disks, in the forming of the particles and in the fluid friction. In the stone grinding process the forces are always applied transversely of the fiber direction, where the wood has less strength. Since the fibers of the chips of wood in the refiner are not always aligned parallel to the centrifugal force, the energy expenditure on defibration is in this case higher. The thermal and chemical pretreatment can lower the energy needed for releasing the fibers from the wood tissue, but the total energy required for the production of a more or less thoroughly defibrillated wood pulp does not diminish, since the fibers have been made more flexible by the treatment, and can escape the action of the grinding segments of the refiner, so that a more controlled defibrillation becomes possible, but it requires more stressing and relieving processes.
If approximately 1500 kWh/t has to be expended for a high-quality softwood stoneground pulp, thermomechanical pulp (TMP) requires about 2000 and chemithermo-mechanical pulp (CTMP) 2500 kWh/t.
For the production of high-quality wood pulps, a sulfonation of the lignin is necessary, as already mentioned. This is usually performed by using sodium sulfite in an alkaline medium, since a swelling of the fiber also takes place simultaneously, which creates good conditions for the defibration that follows. A sulfonation reaction also takes place in the acid pH range, and the lower the pH is, the faster it goes. However, competing condensation reactions of the lignin are also promoted by low pH values. Lignosulfonates with a high degree of sulfonation are insoluble in water and therefore reduce the fiber yield. On the other hand, acids attack the carbohydrates, depolymerize them and lead to weakening of the fiber bond.
The high energy requirements, especially of the CTMP pulps, limits their production to countries with low energy prices. Future developments in the field of wood pulp manufacture is therefore dependent substantially on the energy requirements of the process. A definite reduction of the energy input appears to be essential.
OBJECTS OF THE INVENTION
It is therefore the purpose of the development of an energy-efficient wood pulp manufacturing process to find conditions which will permit a controlled sulfonation to a slight degree, prevent condensation of the lignin, avoid losses of yield, and reduce the amount of energy required for the defibration of the wood and for the defibrillation of the resultant fibers. For the environmental safety of such a process it would also be very advantageous if the chemicals used in treatment could be completely or at least largely recoverable. This purpose is accomplished by the specific part of claim 1. Additional advantageous developments are stated in the secondary claims.
DESCRIPTION OF THE INVENTION
In J. Jackson et al., "Chemithermomechanical pulp production and end-uses in Scandinavia," Tappi Journal, vol. 85, No. 2, February '85, Easton, U.S., pages 64-68, CTMP/CMP processes in accordance with the generic part of claim 1 are disclosed.
The use of aqueous acid digesting solutions of aliphatic, water-miscible alcohols and sulfur dioxide in the manufacture of paper has long been known from U.S. Pat. No. 2,060,068. Schorning has also reported on sulfite digestion without bases with the use of methanol for the manufacture of wood pulps in "Faserforschung und Textiltechnik 12, 487 to 494, 1957." The method described has not been employed in practice in spite of the described advantages. Although the Schorning process was published back in 1956, experiments in cellulose-alcohol digestion were again taken up in the mid-70's, and only then did they lead to partial success, as is proven by DE-A-32 17 767.
On the basis of the results reported by Schorning, the aim of all studies conducted was to discover a formula for cooking wood pulp that would offer a highly deligninized cellulose for further processing to synthetic fiber cellulose. The yields of the pulping processes found to be good ranged from 40 to 50 wt. %. Pulps of higher yields were discarded. No proof that such pulps might also be used for paper manufacturing purposes is to be found in this literature reference. In particular, there is no information on strength tests that might have permitted any hint as to the suitability of such pulps for papermaking purposes.
If milder temperature conditions and/or shorter reaction times are selected, the lignin can be surprisingly sulfonated without great losses of yield and without the occurrence of the unwanted condensation reactions. The power needed in the subsequent defibration of the wood can then easily be reduced to about 50%, depending on the conditions of treatment, and the resultant wood pulps have excellent technological qualities. At the same time the specific grind is selected in a range from 1200 to 1900 kWh/t depending on the desired degree of fineness.
The use of the acid system, of aliphatic alcohol/water/SO 2 not only succeeds in sulfonating lignin, wherein the alcohol serves as the base, but also the impregnation is improved by the presence of the alcohol, condensation reactions in the lignin are suppressed, and resin acids and fatty acids are dissolved. The alcohol additionally improves the solubility of the sulfur dioxide in the water. This system is active at temperatures even lower than 100° C., but higher temperatures can also be used. It is to be noted, however, that the sulfonation is conducted only until the lignin softens at the desired breaking points between the primary wall and S1 of the fiber bond. Further sulfonation results in losses of yield and fiber damage due to the loss of the lignin that is dissolved out.
An important advantage in this kind of pulping is that the chemicals used can easily be recovered. The alcohol can be removed quantitatively, while in the case of sulfur dioxide only the part that does not react with the wood is recyclable. In comparison to neutral or alkaline sulfite systems containing bases, with their more complicated recovery, this is an important advantage.
The aqueous cooking liquor used in the process of the invention contains 10 to 70% by volume of aliphatic, water-miscible alcohols and 1.0 to 100.0 g/l of sulfur dioxide. The pH of the cooking liquors is between 1.0 and 2.0 depending on the SO 2 content. The wood particles are suspended in this liquor, selecting a ratio of 1:3 to 1:6, i.e., 1 kg OD of wood particles are suspended in 3 to 6 kg of liquor. In selecting the bath ratio, the wood particle moisture which lowers the concentration of the bath liquor must be taken into account. The percentage of sulfur dioxide contained in the bath liquor depends on the percentage by volume of the alcohol content. Other criteria for the selection of the sulfur dioxide concentration are the desired degree of lignin sulfonation according to the desired yield, and the temperature and time selected for the lignin sulfonation. After the wood particles are imbibed with the cooking liquor they are heated to 50° to 170° C. to start the lignin sulfonation reaction. After the particles are imbibed excess cooking liquor can be removed, especially when the lignin sulfonation is to be performed in the vapor phase. The heating can be performed indirectly by circulating the cooking liquor through a heat exchanger or directly by the introduction of steam.
The end temperature is chosen again in accordance with the desired yield, the concentration of the cooking liquor and the cooking time. If the cooking time is to be short a higher end temperature can be preselected and vice versa. If the end temperature is to be over 70° C., it is necessary to perform the reaction in a pressure cooker to prevent premature outgassing of the alcohol and sulfur dioxide.
After the preselected end temperature is reached it is maintained for a holding period of 1 to 300 minutes. At low end temperatures long holding periods are necessary, and vice versa, again according to the desired yield.
At the end of the holding period, first the mixture of alcohol, water vapor and unconsumed sulfur dioxide gas can be withdrawn and subject to further processing, e.g., by condensation. Alcohol and sulfur dioxide still present in the liquid can also be vaporized by lowering the pressure or injecting steam, and can be recovered. The recovery of the alcohol and unconsumed sulfur dioxide, however, can also be performed in a heat recovery apparatus with condensation stage, known in itself, following the defibration system.
After that, the wood chips are delivered by conveying systems known in themselves to a known defibrator, such as a disk refiner, and mechanically defibered. If desired, the defibrator can be preceded by a wood particle washing apparatus. A preselected degree of fineness of the chips to be defibrated is achieved by controlling the throughput per unit time and the energy absorption of the driver of the disk refiner in kilowatt-hours per metric ton of fiber.
The alcohols used in the cook liquor, are preferably those with straight or branched chains, individually or in mixtures.
In order to assure a complete and technically simple recovery of the alcohols after the lignin sulfonation has ended, alcohols are preferred whose boiling point at standard pressure is less than 100° C. These alcohols include methanol, ethanol, propanol, isopropanol and tertiary butyl alcohol. On account of its great availability and economical price, methanol is preferred.
The ratio of admixture between water and alcohol can vary within wide limits, but preferably the alcohol content is between 20 and 50 vol.-%, especially between 20 and 40 vol.-%.
Since the rate of lignin sulfonation depends on the sulfur dioxide concentration, high concentrations are basically desirable. However, at elevated temperature during the holding period, high concentrations can lead to undesirable losses of yield, so that a sulfur dioxide content in the cooking liquor of 5 to 40 g/l is preferred.
The stated end temperature range during the holding period can be freely chosen within the stated limits, in accordance with the length of the period and the concentration of the cooking liquor. Higher temperatures, however, require a greater input of heat as well as special design measures in the reaction vessel on account of the increase in pressure that they cause. Consequently, it is preferred that the cooking liquor containing the wood particles be heated to a temperature of 80° to 120° C. If alcohols with a boiling point close to 100° C. are used, a temperature of 100° to 120° C. is selected.
The holding time at the end temperature affects, on the one hand, the degree of the yield, and on the other hand it will depend on the capacity of the reaction vessel and the mass stream of cooking liquor and wood chips that is to be passed through it. Therefore a holding period at end temperature of 2 to 120 minutes is preferred, especially in continuous processes.
If provision for energy reduction in the manufacture of chemithermo-mechanical wood pulps by impregnation with an alcohol/water/sulfur dioxide liquor is to be combined with a very gentle defibration, the actual impregnation can be preceded by a treatment wherein the wood particles are pretreated with an aqueous alcoholic solution containing a neutral and/or alkaline sodium compound.
Such sodium compounds can consist of sodium sulfite and/or sodium hydroxide and/or sodium carbonate, the solution containing preferably a concentration of 1 to 10 g/l total alkali, reckoned as NaOH.
The purpose of these sodium compounds is to buffer the organic acids, such as formic and acetic acid, which in the course of the actual lignin sulfonation reaction form from the wood during the holding period at end temperature, to prevent lignin condensation due to an excessively low pH, and to promote the swelling of the wood.
Another advantage of adding the sodium compounds is the preservation of the white content of the wood particles being defibered, especially by the addition of sodium sulfite.
The treatment of the wood particles with an aqueous solution containing a sodium compounds can also be performed in the reaction vessel after the lignin sulfonation reaction and after the alcohol and sulfur dioxide have been driven out and withdrawn from the remaining cook liquor. For this purpose the wood particles are first separated from the remaining cook liquor by means of apparatus known in themselves, and then treated with a solution containing the sodium compound, at a temperature of 20° to 150° C. A solution containing 1 to 10 g/l of sodium sulfite, sodium hydroxide or sodium carbonate, reckoned as NaOH, alone or in mixture, is preferred. In this way it is also possible to have a positive influence on the technological properties of the wood pulp being produced.
The present process can also be applied to fiber that has already been defibered mechanically, such as the "sauerkraut" waste produced in the production of wood flour.
The process according to the invention will be further explained in the following examples.
EXAMPLE 1
Spruce chips are treated at 120° C. for 10 minutes with a 40:60 vol.-% methanol/water mixture containing 12.5 g/l SO 2 . The bath ratio is 1:4. After the treatment period the methanol as well as the consumed SO 2 are recovered in the gas phase and the wood is defibered in a refiner. In a grind to 70° SR, the grinding energy consumption amounts to only 1400 kWh/t, while sprucewood chips pretreated with 25 g/l of Na 2 SO 3 required 2500 kWh/t to achieve the same fineness. The energy saving thus amounts to 44%.
The yield amounts to 95%, and the pulp has the following technical qualities:
______________________________________Breaking length 3,280 mTear propagation strength (Brecht/Imset) 1.04 J/mSpecific volume 2.30 cm.sup.3 /gLight scattering coefficent per SCAN C27:69 42.5 m.sup.2 /kg______________________________________
EXAMPLE 2
Spruce chips are first treated for 15 minutes at 100° C. with a methanol/water mixture containing 5 g/l of Na 2 SO 3 , and then an aqueous SO 2 solution containing 50.0 g/l is added and the chips are pulped for 60 minutes at 100° C. The bath ratio after adding the SO 2 solution is 1:4. After recovery of the gaseous pulping chemicals the chips are defibered in the refiner to a fineness of 70° SR. The energy demand amounts to 1,850 kwH/t, which signifies a saving of 25% in comparison to a standard CTMP.
The yield is 96%, the fiber has the following technical qualities at 70° SR:
______________________________________Breaking length 4,070 mTear propagation strength (Brecht/Imset) 1.23 J/mSpecific volume 2.22 cm.sup.3 /gLight scattering coefficient per SCAN c27:69 46.7 m.sup.2 /kg______________________________________
EXAMPLE 3
A wood pulp defibered in the refiner without pretreatment, to a fineness of 15° SR is treated for 10 minutes at 100° C. with the methanol/water/sulfur dioxide liquor described in Example 1 and then additionally ground in a Jokro mill under standard conditions. To achieve a fineness of 70° SR, 6,750 revolutions were needed. The untreated reference pulp required 15,750 revolutions to achieve a fineness of 63° SR.
EXAMPLE 4
Spruce wood chips are treated at 600° C. for 60 minutes with a methanol/water mixture of 30:70 vol.-%, containing 50 g/l of sulfur dioxide. After the treatment the methanol and the unconsumed sulfur dioxide are recovered and the chips are defibered in a refiner. 1,390 kWh/t are required for the achievement of a fineness of 77° SR.
The yield is 92.0%, and the fiber has the following technical qualities:
______________________________________Breaking length 4,070 mTear propagation strength (Brecht/Imset) 0.9 J/mSpecific volume 2.03 cm.sup.3 /gLight scattering coefficient per SCAN C27:69 39.9 m.sup.2 /kg______________________________________
EXAMPLE 5
Spruce wood chips are steamed for 20 minutes and put into a 50:50 vol.-% methanol/water mixture containing 100 g/l of SO 2 . After an impregnation period of 30 minutes the excess liquor is drawn off. The chips impregnated in this manner are treated in a defibrator for 5 minutes with 150° C. steam and then defibered under pressure. The grinding energy to achieve a fineness of 68° SR is about 1,510 kWh/t.
The fiber material thus produced has the following technical qualities:
______________________________________Breaking length 4,130 mTear propagation strength (Brecht/Imset) 1.02 J/mSpecific volume 2.28 cm.sup.3 /gLight scattering coefficient per SCAN c27:69 41.5 m.sup.2 kg______________________________________
EXAMPLE 6
An additional pulping test was performed in accordance with the invention with a methanol/sulfur dioxide liquor which contained 70 vol.-% of methanol and 23 g/l of SO 2 , at a temperature of 160° C., for a cook time of 8 minutes. These chips were then defibered in a disk refiner.
The results of the technical tests are contained in Table 1, including the pumping parameters.
EXAMPLES 7 and 8, for comparison purposes
Pulping was performed on spruce wood chips in a manner similar to Schorning's with a methanol/SO 2 liquor containing 50 vol.-% of methanol and 55 g/l of SO 2 , at a temperature of 130° C. during a cooking period of 205 minutes, Example 7, and 300 minutes, Example 8.
In the Schorning tests the yield, the whiteness, the breaking length and the tear strength are surprisingly low. A pulp of this kind is absolutely unsuitable for papermaking. Also the very high splinter content--according to Schorning the pulp should be free of splinters--does not permit use for papermaking purposes.
______________________________________Example 6 7 8______________________________________Temperature °C. 160 130 130Cooking Time min 8 205 300SO.sub.2 Input %/liter 2.3 5.5 5.5 %/OD 13.9 33.0 33.0Methanol content vol.-% 70 50 50Initial pH -- 1.1 1.0 0.9Yield % 92.5 43.5 39.2Splinter content % 0.8 13.1 10.6Splinter-free Yield % 91.5 30.4 28.6Whiteness % ISO 61.6 22.8 19.0Residual Lignin Content % 22.2 7.8 7.4Kappa No. -- 148 51.7 49.5Limiting Viscosity dm/kg -- 544 458Fineness SR 70 20 19Breaking Length km 4480 1970 1670Burst length kPa -- 50 40Breaking Strength cN 70.2 13.2 11.3______________________________________
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In a process for manufacturing chemo-mechanical and/or chemothermal-mechanical wood pulps, raw materials containing lignocellulose, such as wood shavings, wood chips, pre-ground wood or sawdust, are first impregnated with an aqueous alcoholic SO 2 solution and then heated to a temperature between 50° and 170° C. for a period of 1 to 300 minutes. The wood shavings are then ground to the desired degree of fineness in a defibrinating device. The process makes it possible to achieve up to 50% reduction in grinding energy in comparison with known chemothermal-mechanical processes.
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The present application is the national stage of PCT Application No. PCT/DE98/01912, filed on Jul. 9, 1998, which claims priority to German Application No. 19743784.2, filed Oct. 2, 1997.
BACKGROUND OF THE INVENTION
The subject invention is directed to the art of measuring systems and, more particularly, to display devices such as gauges or the like for visual presentation of associated parameters.
Measuring systems including gauges of the type under consideration are commonly used in the automotive arts to display associated parameters derived from a motor vehicle such as, for example, vehicle speed, engine rotational speed in revolutions per minute, fuel gauge indicia, and other parameters. Typical analog display instruments include a movable indicator needle that is operated by means of an underlying control mechanism such as, for example, a stepping motor or a rotor coil. The indicator needle typically extends adjacent a graduated scale providing indicia of the value range of the parameters of interest. The rotor coil or stepping motor in the underlying measuring system control actuates motion of the movable indicator needle relative to the graduated scale for a representation of the subject parameter.
In many known display systems, separate measuring systems are typically used for the display of each individual parameter. Each separate measuring system includes a set of connection contacts for supplying the respective signals to the measuring system from the corresponding parameters. Also, each measuring system typically includes a separate driven shaft provided in a housing or the like of the measuring system. The driven shaft is typically connected with an indicator needle which is moved relative to a graduated scale in a manner described above.
One problem arises, however, with respect to combination instruments of the type described above. Frequently, the desire to place the required number of measuring systems within the housing of a single combined gauge or instrument presents a space constraint problem. Often, it is desired to arrange the analog displays in close proximity to each other. However, the measuring systems that drive the analog displays often restrict the ability to do so.
One solution to the above problem consists of providing two or more measuring systems with corresponding controls in a single housing together with the use of gears or the like to effect the transfer of rotary motion between an output shaft of the measuring system and the one or more indicator needles. This solution facilitates a more remote arrangement between the respective measuring systems and the controls. Both of these solutions, however, are often costly and are therefore expensive to implement.
It is therefore desirable to provide a measuring system such as an automotive gauge system or the like that is inexpensive, occupies a small space, and has the ability of displaying the status of at least two monitored parameters simultaneously.
SUMMARY OF THE INVENTION
The subject invention provides a compact dual integrated gauge system for visual display of at least two associated parameters simultaneously. The gauge system includes first and second intermateable independently operable control devices. The first control device includes a first housing and a first hollow driven shaft extending from the first housing. The second control device includes a second housing and a second driven shaft extending from the second housing. The second driven shaft extends coaxially through the first hollow driven shaft thereby realizing the smallest possible overall construction dimensions of the subject measuring system.
The coaxial arrangement of the two driven shafts extending from two respectively independently actuatable controls enables analog display of at least two parameters within an extremely small area. The present invention conserves on space both with respect to the display elements or the display scales as well as with respect to the measuring system.
In accordance with one aspect of the invention, the measuring system includes at least two separate housings, each of which including a control and a driven shaft. At least one of the driven shafts includes a hollow opening so that the two separate housings can be assembled into a single measuring system in a stacked relationship with the hollow driven shaft of a first individual measuring system being penetrated by the driven shaft of the other individual measuring system. The inner driven shaft is coaxially received in the outer driven shaft with the free end of the inner shaft extending beyond the free end of the outer shaft for ready attachment to a display needle or the like.
In accordance with another aspect of the invention, the two measuring system are substantially identically formed except for the driven shafts and the related components or areas influenced by the shafts. This arrangement is conducive to high volume industrial production resulting in significant cost savings.
In accordance with yet another aspect of the invention, a guide sleeve is disposed on the housing of the second individual measuring system. The guide sleeve supports the second driven shaft of the second individual measuring system. Further, the guide sleeve protects the second driven shaft from movement or the like that may occur in the first hollow driven shaft or the first measuring system.
Similarly, in accordance with another aspect of the invention, a positioning collar is provided at the housing of the first individual measuring system. The positioning collar surrounds and supports the first hollow driven shaft. In addition, the positioning collar provides an installation aid for guiding the first and second driven shafts into a hole or the like of an associated installation component such as a support member or a conductor plate for mounting the assembled subject measuring system in an installed position.
In accordance with yet a further aspect of the invention, the first and second individual measuring systems include electrical connection contacts extending from the first and second housings thereof, respectively. The first individual measuring system includes a first set of electrical contacts extending from the first housing. Similarly, the second individual measuring system includes a second set of electrical connection contacts extending from the second housing. The second set of electrical contacts have a height sufficient to extend in a first direction beyond the first housing and substantially adjacent to the first set of electrical connection contacts when the first and second individual measuring systems are arranged in the preferred stacked relationship to form the assembled subject measuring system. The size and orientation of the sets of electrical connection contacts in this fashion enables electrical connection to the overall measuring system from one side thereof.
In accordance with yet another aspect of the invention, a locking means is provided to enable the selective stacked joining of the first and second individual measuring systems to form the subject dual integrated gauge system.
In addition to the above, the individual measuring systems of the present invention can be connected by means of screws, application of pressure, or the like. In addition, the present invention contemplates initially joining the two individual measuring systems by simply inserting the two driven shafts into each other and then connecting the combination of the two individual measuring systems via screws, holding clamps, or the like to an associated assembly component such as, for example, an associated conductor plate of a combination instrument. In this arrangement, one or more connection contacts of the individual measuring system can penetrate the housing of the other individual measuring system and thereby fix the relative position between the measuring systems.
In accordance with another aspect of the invention, a support member is further provided having separate retaining recesses adapted to receive the first and second individual measuring systems. A guide sleeve is preferably provided at the second individual measuring system for penetrating the support member and engaging the first individual measuring system through the support component. This advantageously results in the benefit that the second individual measuring system is fixed in place relative to the support member by means of the guide sleeve which concurrently serves as a support mechanism for the hollow second driven shaft.
In accordance with yet still a further alternative form of the invention, the support member is eliminated and the guide sleeve of the second individual measuring system is used to engage and support the hollow driven shaft of the first individual measuring system. In addition, the guide sleeve is selectively adapted to provide a means of retaining the individual measuring systems in their relative stacked relationship by means of an appropriate passage aperture provided in the housing of the first individual measuring system.
In a yet further aspect of the invention, the support element includes a locking area for engaging first and second locking means provided on the first and second housing members, respectively. The locking area holds the first and second measuring systems in place relative to the support element. This results in a simple installation of the subject measuring system.
In addition, the support element is further provided with connection means adapted to cooperate with corresponding connection means provided on an associated installation element for fastening and retaining the subject measuring system thereto. These connection means can be formed as locking members, screw connections, crimping connections including assembly pins penetrating the assembly element with pin ends twisted under pressure, or the like.
Still other aspects, advantages, and benefits the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
FIG. 1 is an exploded perspective view of an integrated dual measuring system formed in accordance with the preferred embodiment of the invention;
FIG. 2 is a partial cross-sectional view of the measuring system shown in FIG. 1 on a plane through the coaxial driven shafts; and,
FIG. 3 is a schematic representation of a combination instrument system for use in motor vehicle applications using several measuring systems of the type formed in accordance with the present invention and shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for the purposes of illustrating the preferred embodiment of the invention only and not for purposes of limiting same, the overall arrangement of the preferred form of an integrated dual measuring system formed in accordance with the invention can best be seen with reference to FIG. 1 . As shown therein, the dual gauge system 1 includes a first individual measuring system 3 , a second individual measuring system 5 , and a support element 7 . The support element serves for fastening the first and second individual measuring systems 3 , 5 in the stacked relationship substantially as shown. Each of the individual measuring systems 3 , 5 respectively comprise a housing 9 , 11 as well as respective control devices arranged in the housings 9 , 11 . Preferably, the control devices include stepping motors, or the like, or any other devices known in the art for providing control to components in a gauge system.
It is a primary advantage of the present invention that the first measuring system 3 includes a first hollow driven shaft 17 adapted to receive a second driven shaft 19 extending from the second measuring system 5 . In that regard, the second driven shaft 19 is preferably coaxially received within the first driven shaft 17 . It is to be noted that except for the above-described form of the driven output shafts and several other items related thereto to be described in detail below, each of the individual measuring systems are formed in accordance with well known techniques. More particularly, it is to be appreciated that, according to the invention, known individual measuring systems can be modified to provide a hollow driven output shaft so that the driven output shafts of known individual measuring systems can be coaxially arranged in accordance with the teachings of the present invention.
With continued reference to FIG. 1, each housing 9 , 11 of the first and second individual measuring systems 3 , 5 are provided with pin-shaped connection contacts 13 , 15 . The connection contacts provide means of applying appropriate electrical control signals, or the like to actuate the individual measuring systems independently. In addition, as further shown, each of the housings 9 , 11 of the individual measuring systems 3 , 5 include driven output shafts 17 , 19 extending in a manner as shown. Each of the driven shafts 17 , 19 is selectively connectable with a separate display element such as, for example, an indicator needle.
In the preferred embodiment shown in FIG. 1, the driven shaft 17 of the first individual measuring system 3 includes a hollow opening. The driven shaft 19 of the second individual measuring system 5 is preferably formed as a solid shaft. The opening in the driven shaft 17 enables the second shaft 19 to be received coaxially therein.
The support element 7 includes a pair of recesses 21 , 23 adapted to receive the individual measuring systems 3 , 5 , respectively. Locking projections 9 a , 11 a are provided on the first and second housings 9 , 11 of the individual measuring systems for fastening and retaining each of the individual measuring systems 3 , 5 to the support element 7 . Preferably, the locking projections are formed as spring shackles and are adapted to engage counter locking projections 21 a , 23 a formed in areas of the assembly recesses 21 , 23 of the support element.
In addition to the above, as shown, the support element 7 includes a passage bore 25 adapted to receive the second driven shaft 19 and a guide sleeve 27 provided on the second housing 11 of the second individual measuring system 5 . A first portion of the guide sleeve 27 guides and stabilizes the second driven shaft 19 . A second portion of the guide sleeve fixes the second individual measuring system 5 in the assembly recess 23 of the support element 7 .
It is an advantage of the present invention that in order to assemble the individual components of the measuring system 1 into an integrated measuring system, it is only necessary to install the two individual measuring systems 3 , 5 into the assembly recesses 21 , 23 of the support element 7 and then lock the individual measuring systems in place therein. Final assembly of the system is thus simplified.
In the preferred embodiment of the invention shown in FIG. 1, the second set of connection contacts 15 of the second individual measuring system 5 extend from the interior side of the second housing 11 relative to the support element 7 . The length of the second set of connection contacts 15 is selected in such a fashion that, following assembly of the first and second measuring systems into the support element in a stacked relationship, the second set of connection contacts 15 extend into an area substantially adjacent to the first set of connection contacts 13 of the first individual measuring system 3 . In that regard, the first set of connection contacts 13 extend from the exterior side of the first housing 9 relative to the support element 7 .
Preferably, as further shown in FIG. 1, the assembly recesses 21 , 23 formed by the support element 7 are mutually offset in a radial direction relative to the coaxial driven shafts on the top side and under side of the support element body. The individual measuring systems 3 , 5 are selectively installed into the assembly recesses 21 , 23 of the support element 7 at a 180 degree relative angle of rotation. This provides a further advantage of the present invention whereby it becomes unnecessary to penetrate the first individual measuring system 3 with the second set of connection contacts 15 extending from the second individual measuring system 5 .
In order to accommodate the elongate second pin-shaped connection contacts 15 of the second measuring system 5 , a set of penetration apertures 29 are provide toward the rear portion of the support element 7 . In addition, a set of recesses 31 are formed in the outer housing wall of the first individual measuring system 3 . Lastly, in order to accommodate the second pair of connection contacts 15 , the bottom wall of the assembly recess 21 of the support element 7 includes a set of appropriately located passage apertures 33 .
Turning now to FIG. 2, a portion of a cross section taken through the dual integrated gauge system 1 of FIG. 1 is shown. As illustrated, the driven shaft 19 of the second measuring system 5 is propelled by means of a pinion 35 which is adapted for coupling to an associated drive means such as, for example, a stepping motor or the like (not shown). Preferably, the pinion 35 is directly injection-molded onto the driven shaft in an area of a recess 19 a which is provided for torsion-proof seating of the pinion 35 onto the driven shaft 19 . A guide sleeve 27 provided at the housing 11 of the second individual measuring system 5 penetrates the passage bore or passage aperture 25 in the support element 7 and protrudes up to the hollow shaft 17 of the first individual measuring system 3 . The hollow shaft 13 is formed having an appropriate diameter. In addition, preferably, the hollow shaft 17 is formed with a pinion 37 injection-molded onto the hollow shaft 17 . The pinion 37 is propelled as a component of an associated gearing means such as a stepping motor or the like (not shown) of the first individual measuring system 3 . The engagement between the guide sleeve 27 and the hollow shaft 17 protects the second driven shaft 19 from movement of the first hollow shaft 17 . More particularly, rotational movement of the hollow shaft 17 is prevented from being transferred in a detrimental fashion onto the second shaft 19 .
As shown in FIGS. 1 and 2, a fastening collar 39 surrounds the first driven shaft 17 . The fastening collar 39 preferably is formed on the outside of the first housing 9 of the first individual measuring system 3 . As shown best in FIG. 2, a first portion of the fastening collar 9 guides the hollow shaft 17 . A second portion of the fastening collar is advantageously used to selectively connect the subject measuring system to an associated support member or plate of a combination instrument, or the like (not shown).
As illustrated, the upper free end of the hollow shaft 17 extends beyond the upper end of the fastening sleeve 27 . The upper end of the hollow shaft 17 has reduced diameter and extends substantially as shown relative to the second shaft 19 without contacting the second shaft. The upper end of the hollow shaft 17 is adapted to receive an associated display element such as, for example, an indicator needle, or the like. Similarly, a second associated display element is preferably fastened onto the free end of the solid shaft 19 extending beyond the free end of the hollow shaft 17 . In this manner, a simply constructed dual integrated gauge system is formed.
It is to be appreciated that the subject measuring system with dual associated display elements can be formed by use of slightly modified conventional individual measuring systems utilizing a support element and coaxially arranged first and second driven output shafts. Assembly of the components comprising the present invention merely requires two operating steps and can be easily automated. In that regard, preferably, the support element includes locking tongues 41 for selectively connecting the entire measuring system 1 onto an associated support element. In addition, the subject measuring system 1 can also be connected with an associated assembly element by means of screw connections, or other connections.
With reference next to FIG. 3, a schematic representation of a combination instrument for use in a motor vehicle is shown. FIG. 3 depicts three (3) dual integrated gauge systems 1 , 1 ′, and 1 ″ as shown in FIGS. 1 and 2 integrated into a composite gauge system 42 . Each of the dual measuring systems 1 , 1 ′, and 1 ″ is respectively connected with two indicator needles 43 a , 43 b , 43 ′ a , 43 ′ b , or 43 ″ a , 43 ″ b . The longer of the two indicator needles is preferably passed under a diaphragm 45 , 45 ′, 45 ″ on which is respectively provided a scale 47 , 47 ′, 47 ″ for the parameter to be represented by the respective shorter indicator needle 43 b , 43 ′ b , 43 ″ b.
In a similar fashion, diaphragms with corresponding scales 49 , 49 ′, 49 ″ for representation of the respective parameters are further provided underneath the longer indicator needles 43 a , 43 ′ a , 43 ″ a.
Utilization of the dual measuring system 1 , 1 ′, 1 ″ formed in accordance with the present invention results in an extremely simple and space saving construction in a combination instrument system 42 .
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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The invention relates to a measuring system, especially for display devices in the automobile technology, with at least one first and one second separately actuated control, as well as a first and second driven shaft ( 17, 19 ) which can be rotationally fixed to a display element. The second driven shaft ( 19 ) of the second control is co-axially driven by the driven shaft ( 17 ) which is designed as a hollow shaft in the first control and the second driven shaft ( 19 ) protrudes above the end of the first driven shaft ( 17 ).
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CONTRACTUAL ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy (DOE) and The University of Chicago representing Argonne National Laboratory.
BACKGROUND OF THE INVENTION
Using magnetic particles as seeds for delivering drugs and therapy to targeted areas such as brain tumors and blood clots has been pursued for several decades. One area of research is to magnetically maneuver catheters through the vasculature for both diagnosis and delivery of therapy, and another is to magnetically manipulate small volumes of magnetic particles or powder after injection into the blood stream. This technique was to be used to induce thrombosis of intracranial aneurysms, and for the precise placement of ferromagnetic contrast agents for x-ray imaging. Other medical applications (such as urological, pulmonary, and orthopedic uses of the magnetic manipulation of magnetic particles and catheters) have been disclosed in the art.
Industrial applications of manipulating magnetic particles include magnetic separations and magnetic conveyer systems. The principle of magnetic control in either medical or industrial systems is to generate enough magnetic forces to move the magnetic parts or particles in the desired direction. Magnetic forces are proportional to the product of the magnetic field and its gradient. Therefore, generation and control of magnetic fields and its gradients are the main focus of a magnetic manipulation system. The magnetic particles or the tip of a catheter can be either soft magnetic (ferromagnetic) materials or hard ferromagnets such as NdFeB. For medical applications, the key issue is how to move the magnetic particles in a precise trajectory through human tissues, including blood vessels.
Currently, there are two methods of producing magnetic fields and field gradients for manipulating the magnetic particles in human tissue. The first method is to use permanent magnets and the second method is to use electromagnets (either conventional copper coil at room temperature or superconducting coil at liquid helium temperature). However, both methods have serious drawbacks in the amount of heat produced or in the size of the magnetic field produced by the magnets.
SUMMARY OF THE INVENTION
According, it is a principal object of the present invention to provide a method, system and apparatus of controlling magnetic material using high temperature superconductors.
Another object of the present invention is to provide a method, system and apparatus for controlling movement of magnetic material by introducing persistent currents in high temperature superconductors which can be reduced to zero in selected ones, thereby selectively creating and dissipating magnetic fields thereby moving magnetic material.
Another object of the invention is to provide trapped magnetic fields in a plurality of high temperature superconductors located at predetermined spaced locations.
Still another object of the present invention is to provide a method of controlling movement of magnetic material, comprising providing at least first and second high temperature superconductors at spaced locations, magnetizing at least one of the high temperature superconductors to establish a first magnetic field, magnetizing at least one other of the high temperature superconductors to establish a second magnetic field, and demagnetizing at least one of the high temperature superconductors to reduce the first magnetic field substantially to zero, whereby magnetic material near the first magnetic field will be attracted thereto during the presence thereof and when the first magnetic field is reduced substantially to zero the magnetic material will be attracted to the second magnetic field, thereby causing movement of magnetic material toward and away from the first and second magnetic fields.
A further object of the invention is to provide a method of controlling movement of magnetic material, comprising providing at least first and second high temperature superconductors at spaced locations, introducing a persistent current in at least one of the high temperature superconductors to establish a first magnetic field, introducing a persistent current in at least one other of the high temperature superconductors to establish a second magnetic field, and demagnetizing at least one of the high temperature super-conductors to reduce the first magnetic field substantially to zero, whereby magnetic material near the first magnetic field will be attracted thereto during the presence thereof and when the first magnetic field is reduced substantially to zero then the magnetic material will be attracted to the second magnetic field, thereby causing movement of magnetic material toward and away from the first and second magnetic fields.
A final object of the invention is to provide a system of controlling movement of magnetic material, comprising at least first and second high temperature superconductors at spaced locations, a plurality of solenoids associated with the superconductors to induce persistent currents in preselected high temperature superconductors establishing a plurality of magnetic fields in response to pulsed currents introduced to one or more of the solenoids, and control mechanism in communication with the solenoids and/or the high temperature superconductors to demagnetize selected ones of the high temperature superconductors to reduce the magnetic fields substantially to zero, whereby magnetic material is moved between magnetic fields by establishing the presence thereof and thereafter reducing magnetic fields substantially to zero and establishing magnetic fields in other superconductors arranged in a predetermined configuration.
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
FIG. 1 is a schematic diagram of the system of the present invention;
FIG. 2 is a graph of experimental apparatus for practicing the present invention;
FIG. 3 is a graphical representation of the relationship between pulsed current in amperes and time in milliseconds for persistent currents and trapped magnetic fields;
FIG. 4 is a graphical representation showing the relationship between trapped magnetic fields in kilo-gauss and peak currents in amperes for a superconducting ring and coil combination;
FIG. 5 is a graphical representation of the relationship between a trapped field in kilo-gauss and peak current in amperes for a disc/coil apparatus;
FIG. 6 is a schematic representation of a one-dimensional arrangement of coil/superconductor units along the path of particle motion; and
FIG. 7 is a two-dimensional array arrangement of coil/superconductor units at a given location or elevation along the path of particle motion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventive method and system employs pulsed-field solenoid coils with high-Tc superconductor inserts in the form of cylindrical disks or rings. Pulsed current is used to magnetize and de-magnetize the superconductor insert. The method and system utilizes the unique property of magnetic flux pinning and flux trapping in high-Tc superconductors. Furthermore, unlike the conventional methods and systems, the inventive system and method of generating magnetic field and magnetic field gradient is fully reversible by de-magnetizing the superconductor. Moreover, the combination of pulsed-field solenoids and high-Tc superconductor inserts provides additional capability and flexibility in propelling and controlling of the magnetic particles in human tissue beyond that achievable from either permanent magnets or electromagnets.
Using superconductor inserts to trap magnetic field is known in the art. Magnetic fields much larger than that produced by permanent magnets can be trapped in and around high-Tc superconductors. For example, magnetic flux density of 2 Tesla can be trapped in SmBa 2 Cu 3 O 7 disk (30–36 mm in diameter, and 15 mm in thickness) at 77 K. At 50 K, the trapped field increased to 6 Tesla. It has been reported that 4.6 Tesla can be trapped at 57.9 K in a YBa 2 Cu 3 O 7 (YBCO) disk with a diameter of 26 mm. Maximum trapped fields can be further increased by doping the superconductor with silver or by irradiation. Because trapped fields increase with decreasing temperature, even larger trapped fields can be achieved at still lower temperatures. As mentioned previously, this invention uses the combination of magnetizing (flux pinning and trapping) and de-magnetizing (de-pinning and untrapping) of high temperature superconductors to control the movement of the magnetic materials.
Referring to FIG. 1 , there is shown a schematic diagram of how magnetic material, such as particles or parts can be manipulated in human tissue. In order to hold the magnetic material in position A for a certain period of time to collect all the material coming in from an injection point, and then move the magnetic material to position B and hold it there for a certain period of time, and then repeating the same procedure until the material reach the desired position C in the tissue or the blood vessel, the system or apparatus of FIG. 1 can be used.
As shown in FIG. 1 , two solenoid coils 10 , 11 are located near position A and B, respectively. Inside each coil 10 , 11 is a cylindrical high-Tc superconductor disk 15 , 16 , respectively. The solenoid coil 10 , 11 is connected electrically to a current supply 20 , which can generate either pulsed or DC current. The solenoid coils 10 , 11 and the high-Tc superconductors 15 , 16 are cooled in liquid nitrogen at 77 K.
Just before the injection of the magnetic material, such as for instance, particles, into the human tissue or blood vessel, a pulsed current is applied to the solenoid 10 near position A. After the pulsed current is gone, there remains a very large persistent current in the superconductor disk 15 . This is the result of flux pinning, which is a unique property of type-II superconductors (high-Tc superconductor is type II). The consequence is that a very strong magnetic filed is trapped inside and around the superconductor disk 15 . The superconductor disk 15 now becomes a strong permanent magnet. The advantage of using a trapped-field superconductor disk 15 , instead of a normal permanent magnet, is that the superconductor can be de-magnetized by reversing the current flow in the solenoid 10 .
After the superconductor disk 15 has been magnetized, the injection of the magnetic particles can begin. The magnetic particles will be attracted towards the superconductor disk 15 and eventually remained pinned near the surface of the superconductor disk 15 . The magnetic particles will remain at the surface of the superconductor disk 15 as long as the persistent current is circulating in the superconductor 15 . To move the magnetic particles from position A to position B, a pulsed current is first sent to the solenoid 11 near position B to trap magnetic field in the superconductor disk 15 in the coil. Then a second pulsed current, in the opposite direction of the original pulsed current, is sent to the solenoid coil 10 near position A. This second pulsed current will tend to demagnetize the superconductor disk 15 in the solenoid coil 10 near position A so that it can no longer hold the magnetic particles there. The magnetic particles will be attracted toward the superconductor disk near position B because it has been magnetized and a persistent current is flowing inside the superconductor disk 16 . By placing the solenoid coil/superconductor disk combination (such as combination 12 , 17 at position C) at strategic locations, the magnetic material, including particles, can be moved to the final destination and held there as long as it is needed. If it is desirable to retrieve the magnetic particles, the process can be reversed, all with the use of a standard control system 25 for introducing various pulsed currents to the solenoids and for changing directions of the current as needed.
An alternate method of de-magnetizing the superconductor disk or coil is to increase the temperature of the superconductor by using resistance heaters wrapped around the disk. By increasing the temperature of the superconductor to near or above the critical temperature (92 K for YBCO), the superconductor material will be de-magnetized, because the superconductor can no longer sustain a persistent current at temperatures above the critical temperature. The example given here is for moving magnetic particles in human tissues, including blood vessels is for illustration and is not to limit of the invention which also includes the use of magnetic particles for delivering drugs and therapy. Delivery of radioactive isotopes for cancer treatment and drugs for blood clots are two prominent examples. Moreover, the inventive method can also be used to move catheters with magnetic tips for drug delivery and therapy. In addition, the ability to modulate motion and reverse direction in the inventive method, apparatus and system enables application for nondestructive remote blood flow control. The invention is applicable to surgery and for prompt hemorrhage control in stroke victims. Furthermore, the inventive method and apparatus are not limited to medical applications, but applies to various industrial processes such as magnetic separations and magnetic conveyer systems (different types of magnetic separation and conveyer systems as found in Perry's Chemical Engineers' Handbook, McGraw-Hill Book Company, 6 th edition, by R. H. Perry and D. W. Green, Section 21, pp. 33–41, 1984) the disclosure of which is incorporated by reference. This proposed method of propulsion and control is relevant to those applications.
The advantages of using a pulsed current, instead of a DC (constant current), are well known. The most important advantage of using a pulsed current is that less heat is generated in the solenoid coil, which translates into reduced cooling requirements, less bulky devices, and much higher magnetic fields. All are important for the present applications. Another advantage of using a pulsed current is that during the period while the current is changing, eddy currents are induced in the magnetic particles. The eddy currents in the magnetic particles may generate a repulsive force between the particles and the solenoid coil. Furthermore, the ability to rapidly switch the attractive force on the magnetic particles off and on can offer significant advantages over stationary or moving permanent magnets. One is the ability to synchronize the particle motion with the patient's heart beat. The inventive system is more flexible and can achieve better control than current devices using permanent magnets.
The superconductor can be either a cylindrical disk or a cylindrical ring or coil. The superconductor can also be a stack of rings (a cylindrical tube), or a stack of disks (a solid cylinder). The superconductor disk/ring can be BSCCO, YBCO, or other types of high-Tc superconductors, such as for example SmBa 2 Cu 3 O 7 , TlBa 2 Ca 2 Cu 3 O 9 , Tl 2 Ba 2 Ca 2 Cu 3 O 10 , HgBa 2 Ca 2 Cu 3 O 8 , and MgB 2 .
Superconductors must be cooled to below the critical temperature thereof to sustain persistent currents and trapped fields. Liquid nitrogen cooling or a cryocooler is required to remove heat. The solenoid coils can be either a superconductor coil or a conventional copper coil. The former has to be cooled cryogenically with the superconductor disk and the latter can be cooled by air, water, or liquid nitrogen. If the copper solenoid coil is cooled by liquid nitrogen, then the system becomes simpler because both the superconductor disk and the copper coil can be submerged in liquid nitrogen in the same cryogenic container. This design has the added advantage of achieving very high pulsed current because the resistance of copper also decreases with decreasing temperature. If the targeted area is well inside the human body or head and a high magnetic field is required to propel and control the magnetic particles, the solenoid/superconductor is placed on either side of the body or head. For example, a pair of solenoid/superconductor system is placed on either side of the ears of a human head. Other possible arrangement of the coil/superconductor array are hereinafter disclosed. To trap larger fields (>1 Tesla), it is believed temperatures below 77 K are required.
As described previously, the inventive method of moving magnetic particles in human tissues and other systems depends on using pulsed current to magnetize (flux pinning) and de-magnetize (de-pinning) the superconductor disk or ring coil in the solenoid coil. The shape and duration of the pulsed current thus play a very important role in achieving the optimum conditions for effectively propelling the magnetic material (particles) to the desired location.
Magnetization and de-magnetization experiments were conducted for both a superconductor ring/coil system and a superconductor disk/coil system. The experimental apparatus is shown schematically in FIG. 2 . A YBCO or other high temperature superconductor ring is placed inside a copper coil 35 . The superconductor ring 30 has an outside diameter of 26.3 mm, a wall thickness of 8.2 mm, and a height of 8.0 mm. The copper coil 35 has a total number of turns of 100 and is made of copper wire with a diameter of 1.65 mm. The coil 35 has an outside diameter of 45.4 mm, an inside diameter of 28.9 mm, and a height of 44.7 mm. The top of the ring 30 is mounted just slightly below the top of the copper coil 35 so that a transparent non-magnetic container (not shown) can be placed directly on top of the superconductor ring. The copper coil 35 is electrically connected to a pulsed current supply. A hall probe 40 is placed at the center of the ring at a level just slightly above (1 mm) the top of the superconductor ring. The Hall probe 40 is connected to a Gaussmeter (not shown), which provides the reading of the magnetic field.
When the copper coil/superconductor ring is cooled to liquid nitrogen temperature (77 K), a pulsed current is sent through the copper coil 35 to magnetize the superconductor ring 30 . A typical current profile is shown in FIG. 3 for a superconductor disk, the current profile for a superconducting ring will be similar but not identical.
FIG. 3 shows that the pulsed current of approximately 700 amperes, a trapped magnetic field is established which at its maximum is about 850 kilo-gauss and decays toward a steady state of 2.2 kilo-gauss.
To demonstrate that the trapped field can attract magnetic particles, the Hall probe 40 was removed from the test section to make room for the non-magnetic container. Ferromagnetic particles made of iron in fine powder form were placed inside the container. When the container was far away from the superconductor ring, the iron powder was spread over the entire area of the container randomly. As soon as the container was brought in and placed on top of the superconductor ring, the magnetic particles (powder) moved immediately towards the superconductor ring and formed a different and concentrated pattern, because the trapped field in the superconductor ring produced an attractive force between the magnetic particles and the superconductor ring.
The magnetized superconductor disk/ring possesses the property of a permanent magnet and attracts magnetic particles, but also can be de-magnetized by reversing the direction of the pulsed current. FIG. 4 shows the result of the de-magnetization experiment. Starting with a trapped field of approximately 1.30 kilo-gauss, generated by a pulsed current with a peak amplitude of approximately 400 A, two different paths for de-magnetization are illustrated. The first path is indicated by the solid circles in FIG. 3 . By reversing the direction of the pulsed current and using a peak current of −200 A, the trapped field is reduced to 0.1 kilo-gauss after seven pulses as shown in FIG. 9 . The second path for de-magnetization is indicated by the solid triangles. By reversing the direction of the pulsed current and using a peak current of −340 A, the trapped field is reversed to −0.67 kilo-gauss. If the direction of the pulsed current is reversed again with a peak current of 200 A, the trapped field is returned to zero. There are other paths one can take to de-magnetize the superconductor ring. The objective is to illustrate that the superconductor ring/disk can be de-magnetized by reversing the pulsed current (with various amplitudes). This feature provides considerable flexibility for controlling the movement of magnetic particles.
A permanent magnet cannot be easily de-magnetized. Furthermore, the magnitude of the magnetic field generated by a permanent can not be changed either. The magnitude and direction of the trapped field in a superconductor disk/ring can be varied using pulsed current of various amplitudes and directions. In addition to flexibility and better control, a superconductor can trap a field much larger than that produced by permanent magnet. All this factors make the inventive pulsed-current superconductor system much more attractive than a system utilizing permanent magnets. Present superconducting solenoids use low-Tc superconductors, which require the use of liquid helium to cool the system to 4.2 K. A liquid helium system is more expensive and difficult to operate than a liquid nitrogen system. Furthermore, a low-Tc based superconducting solenoid cannot be easily magnetized and de-magnetized as can the inventive solenoid/superconductor disk system. Quenching the superconducting magnet is another limitation of the low-Tc based superconducting system. Therefore, the low-Tc superconductor based superconducting solenoid system cannot provide the flexibility offered by the inventive system.
Both disks and rings were used in the experiments. Two almost identical superconductor rings were stacked together and placed inside a copper coil. The top of the two rings were mounted just slightly below the top of the coil. The disk/coil system was placed in the open foam dewar. The superconductor disk had a diameter of about 19.4 mm and the height was equal to 3.7 mm. The total height of the two disks was equal to 7.4 mm. The copper coil had 100 turns with an inside diameter of 20.6 mm (slightly larger than the diameter of the superconductor disks). The outside diameter of the coil was 35.4 mm. The coil had an axial length of 33.3 mm.
The result of a de-magnetization test is shown in FIG. 5 . The numbers indicate the sequence of the test. First, the superconductor disks were magnetized to 2.2 kilo-gauss (data point 1 ) by using the a pulsed current with a peak amplitude of 700 A. Data points 2 to 7 indicate the path of the de-magnetization process. In this particular de-magnetization test, we alternated the pulsed current direction in decreasing peak amplitude. The superconductor disks were almost completely de-magnetized with 6 pulses (data point 7 ). As mentioned previously, de-magnetization can follow many different paths and the result in FIG. 5 is just one of them.
The configuration shown in FIG. 1 is just one particular arrangement of the solenoid coil/superconductor units. Other array arrangements are also possible and may be more effective (depending on specific applications). For example, instead of placing the coil/superconductor unit along one side of the physical boundary of the system, one coil/superconductor unit can be placed on either side of the system boundaries as shown in FIG. 6 . This arrangement can provide stronger magnetic field and field gradient (hence the forces) than that shown in FIG. 1 . A two-dimensional array of coil/superconductor unit can also be employed as shown in FIG. 7 . This further increases the magnetic forces for moving the magnetic particles and provides better control. If space is available, one can even use a three-dimensional array similar to that employed by the Magnetic Stereotaxis System (MSS), as described by D. C. Meeker, E. H. Maslen, R. C. Ritter and F. M. Creighton, Optimal Realization of Arbitrary Forces in a Magnetic Stereotaxis Systems, IEEE Trans. on Magnetics, Vol. 32, No. 2, March 1996, PP. 320–328, the disclosure of which is incorporated by reference. The MSS employs six superconducting coils, with two coils located at the front and the back of the head, two coils on either side of the ears, one coil on top of the head, and one coil below the jaw. The MSS uses low-temperature superconductors and requires liquid helium cooling. In addition, the current ramp rate is limited because of quenching problems associated with low-temperature superconductors.
The shape of the pulsed current is an important factor in controlling the magnetic material motion. In addition to controlling the amplitude of the current pulse, we can control the duration, the rise time, and the shape of the current pulse. In FIG. 3 , the duration of the current pulse is less than 100 mili-seconds (ms). The rise time (the slope of the current profile) is about 100,000 Amperes/second. This is a very fast process. The duration and rise time of the current pulse, if necessary, can be either increased or decreased to satisfy the need of the specific application. The shape of the pulse can also be changed, as is known in the art. For example, instead of the sinusoidal pulse shape shown in FIG. 3 , a square shaped pulse can be generated. Other pulse shapes can easily be employed to meet the requirements of the specific applications. All these factors, the amplitude, the rise time, the duration, and the shape of the current pulse will affect the magnetic field trapped by the superconductor disk or ring. Therefore, these factors will also affect the magnetic forces exerted on the magnetic materials (particles).
While particular embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications and improvements may be made, for example in the processing of the materials or in the electrode and/or cell design without departing from the true spirit and scope of the invention.
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A system and method of controlling movement of magnetic material with at least first and second high temperature superconductors at spaced locations. A plurality of solenoids are associated with the superconductors to induce a persistent currents in preselected high temperature superconductors establishing a plurality of magnetic fields in response to pulsed currents introduced to one or more of the solenoids. Control mechanism in communication with said solenoids and/or said high temperature superconductors are used to demagnetize selected ones of the high temperature superconductors to reduce the magnetic fields substantially to zero. Magnetic material is moved between magnetic fields by establishing the presence thereof and thereafter reducing magnetic fields substantially to zero and establishing magnetic fields in other superconductors arranged in a predetermined configuration.
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BACKGROUND
This invention relates to rotary mechanisms of the trochoidal type for pumps, compressors, fluid motors, and internal combustion engines, and more particularly to a rotor and gear assembly for such mechanisms.
In mechanisms of this type the rotor is mounted for rotation on an eccentric portion of a shaft within a housing, the rotor also performing a planetary motion within the trochoidal housing. An internal ring gear is fixed on one side face of the rotor and engages a stationary spur gear surrounding the shaft to assist in maintaining phasing between the rotor and its trochoidal housing. In early examples of the prior art the ring gear was simply bolted, pinned, or welded to the rotor. However, the materials of the gear and the rotor are different and have different coefficients of thermal expansion, as well as an interface between the two parts across which heat is not readily transferred. Such tight unions between gear and rotor do not allow for differential thermal expansion of the parts, either radially or axially, nor do they allow for cyclically varying stress loads on the gear. Therefore, breakages and distortions occurred, occasional variations in phasing, and faults in concentricity between the rotor and gear.
Various expedients have been tried to correct these conditions, such as flexible bolting and splining, but these arrangements are very expensive to fabricate and assemble. Resilient pins have been tried, as in U.S. Pat. No. 3,297,240, issued Jan. 10, 1967 to Tatsutomi. In that patent a plurality of split tubular pins were circumferentially spaced around the gear, parallel to the rotor axis and fitting tightly in bores in both the gear and the rotor. Under varying loading of the gear or differential expansion between the gear and the rotor, the pins will compress slightly owing to squeezing of the split tubes. However, no provision is made for axial retention of the gear, beyond the frictional fit of the pins, and it is possible for the gear to displace axially so that its entire side face can be in contact with the side wall of the mechanism, causing undue friction and excessive wear of the side wall, since the gear is formed of hardened material. Further, concentricity may not be maintained, since radial expansion of the rotor may be greater in one portion than another, displacing the gear axis transversely from the rotor axis.
The lack of axial retention is corrected by U.S. Pat. No. 3,619,092, issued Nov. 17, 1971 to Kurio. This patent employs the same axially parallel, split tubular pins, but the gear is retained axially by a snap ring fitting into an annular groove in the rotor, with a wedging action pressing the gear tightly against the rotor face. This again increases machining and assembly expense, and since the rotor has a higher coefficient of thermal expansion than the gear and receives more heat, axial expansion can cause the retaining groove for the snap ring to become axially wider, whereupon the ring expands radially outwardly by spring action to fill the groove. Upon cooling, the wedge surface is too flat to allow recompressing the ring radially inwardly when the groove dimension shrinks, so that distortion of the retaining lip of the groove may result. Also, there is still no provision for maintaining concentricity.
In U.S. Pat. No. 3,830,599, issued Aug. 20, 1974 to Poehlman, concentricity in the presence of differential radial expansion is achieved by the use of axially oriented solid pins fitting in radially slotted holes in the gear, which allows radial expansion of a portion of the rotor with respect to the gear, any single pin sliding in its slot without movement of the others and without displacing the gear axis transversely. However, there is again a delicate machining and assembly job to provide axial retention of the gear by means of special standoff bolts, and there is no provision for absorbing momentary circumferential shock loads on the gear caused by cyclic variations in loading.
SUMMARY
The present invention provides a rotor and gear assembly for rotary mechanisms of the trochoidal type, wherein the gear is secured against rotation relative to the rotor and against transverse or axial motion relative thereto, provision is made for differential thermal expansion both radially and axially, concentricity is maintained, circumferential shock loads are cushioned, distortion of parts is obviated, and thermal strain on the attaching means is prevented. These advantages are accomplished by mounting the gear on resilient tubular pins or dowels circumferentially spaced and having a tight fit in both the gear and the rotor, but which are sufficiently resilient to allow for thermal movement and to cushion mechanical shock loading of the gear. The circumferentially spaced pins are disposed at a marked angle to the axis, which provides axial retention and still allows any portion of the rotor to expand radially along the length of the nearest tubular dowel and with slight compression thereof, but without displacing concentricity owing to the restraining effect of the other dowels which have different radial angles.
It is therefore an object of the invention to provide a rotor and internal gear assembly for trochoidal rotary mechanisms allowing differential thermal growth of the parts without strain or distortion.
It is another object to provide such an assembly wherein the gear maintains concentricity with the rotor.
A further object of the invention is to provide such an assembly wherein the gear is retained axially, radially, and circumferentially by the same means.
Other objects and advantages will become apparent on reading the following specification in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the gear and rotor assembly of the invention mounted on the shaft of a rotary mechanism, looking in the axial direction;
FIG. 2 is an elevational cross-section taken generally on line 2--2 of FIG. 1;
FIG. 3 is an enlarged fragmentary view of a portion of FIG. 2, showing the gear detached from the rotor;
FIG. 4 is an enlarged perspective view of one form of resilient tubular pin;
FIG. 5 is a similar view of another form of resilient tubular pin;
FIG. 6 is a modified embodiment of the gear and rotor assembly; and
FIG. 7 is a further embodiment of the gear and rotor assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a rotor 11 of generally triangular profile having three convexly arcuate working faces 12, which is suitable for use in a trochoidal mechanism having a two-lobed trochoidal housing. The invention will be described in terms of such a triangular rotor, but it is to be understood that the rotor and gear assembly of this invention is also applicable to mechanisms of other trochoidal design such as one-lobed, three-lobed, etc., wherein the rotor has a generally polygonal profile differing from that shown. In FIGS. 1 and 2 the rotor 11 is shown rotatably mounted on a bearing 13 surrounding an eccentric portion 14 of a shaft 16.
The main body of the rotor is hollow and comprises a peripheral wall portion 17, a pair of side walls 18 and 19, and a hub portion 21 which is joined to the outer portion 17 by appropriate ribs or webs 22. Each working face 12 may have a recess (not shown) therein, for transfer of working fluid across the cusp of the trochoid when the mechanism is an internal combustion engine. Such recesses may be omitted when the mechanism is a pump or compressor.
Side wall 18 has a central circular aperture 23 therein allowing flow therethrough of lubricating and cooling fluids supplied to the interior of the rotor during operation of the mechanism. The portion 24 of side wall 18 surrounding and defining the aperture 23 projects axially slightly beyond the plane face of wall 18, the projecting portion 24 positioning the rotor axially within its housing and preventing the main body of the rotor from making contact with the housing side wall. Thus, projecting portion 24 serves in effect as a thrust bearing lubricated by the oil flow through the rotor, and as an inner retaining flange for an oil seal.
A groove in the rotor side face 18 surrounds projecting portion 24, with an oil seal 26 (schematically shown) positioned in the groove. Oil seal 26 is resiliently loaded in the axial direction and wipes the housing side wall to prevent leakage of oil along the side face of the rotor.
The other side wall 19 of the rotor also has a central circular aperture 27, of a diameter suitable to accommodate the outer diameter of the oil seal 26. The oil seal of side wall 19 is retained at its inner diameter by the outer diameter 28 of the internal gear 29, which is mounted on the rotor in the manner to be described.
The general structure of rotor 11 is supported on the central hub portion 21 in part by a web 22 in the axial midregion of the rotor and extending from the hub to the peripheral wall 17, generally parallel to the side walls. Web 22 has a plurality of apertures 31 therethrough for transfer of coolant in the axial direction across the interior of the rotor. Additionally, a plurality of webs or ribs 32 radiate from the hub portion toward the peripheral wall and extend to the side walls, ribs 32 being integral portions of the rotor casting and being connected to the hub 21, the central web 22, and the side walls 18 and 19. Ribs 32 therefore divide the interior of the rotor into a plurality of generally radial compartments which intercommunicate from one side of the rotor to the other by the apertures 31 in the central web 22. The ribs 32 not only provide strength and rigidity to the rotor body, but also pump and scavenge coolant from the interior of the rotor and sling it out through the central apertures.
The radiating ribs 32 on the gear side of the rotor and extending from the hub portion to the side wall 19 have their radially inner edges 33 frustoconically machined with respect to the rotor axis, and extending from the hub to wall 19 at the periphery of aperture 27. The angle of the cone on which edges 33 are machined may vary within considerable limits, from an included angle of about 30° to an included angle of about 60°. As shown in FIGS. 2 and 3 the conical angle is 30°, so that the machined faces 33 of ribs 32 present an angle of 15° to the rotor axis. The machined faces 33 comprise surfaces on which mating portions of the internal gear 29 are seated.
The internal gear 29 is provided with a plurality of circumferentially spaced, axially inwardly extending portions or fingers 34 having their radially outer edges machined on a conical angle matching that of the rib faces 33 and dimensioned to seat thereagainst. Generally, there will be the same number of fingers 34 as there are ribs 32, the fingers having the same circumferential thickness as the ribs, so that when the gear is firmly seated the fingers 34 in effect comprise radially inward extensions of the ribs to a diameter slightly larger in the region of side wall 19 than the root diameter of the internal gear teeth. This arrangement not only extends the heat exchange surface of ribs 32, but aids in scavenging and discharging the coolant by bringing it radially inwardly to about the diameter of the gear through which it is discharged. However, in some cases the number of fingers 34 may be fewer than the number of ribs 32, but still of sufficient number and suitable disposition to provide firm seating for the gear.
At least three of the rib members 32 are provided with thickened boss portions 36 midway between the hub and the side wall 19. When only three such ribs are modified in this manner they will usually be those ribs extending from the hub in the apex regions of the rotor. The fingers 34a which seat against the ribs bearing bosses 36 are of greater circumferential width than the other gear fingers 34, matching the dimensions of the bosses. Each finger 34a has a bore 37 therethrough at an angle which is preferably normal to the slope of the circumferential surface of the finger; boss 36 has a blind bore 38 therein which is in register with bore 37 when the gear is seated.
When the gear is pressed firmly into its seat a resilient tubular pin or dowel 39 is passed through bore 37 in the gear finger 34a into bore 38 in boss 36 until it seats against the blind closure of bore 38, leaving approximately half the length of the pin enclosed by each bore. The outer face of gear 29 projects axially beyond the plane face of rotor wall 19 to a distance corresponding to the projection of element 24 on the opposite side, serving the same purpose of acting as a thrust bearing and positioning the rotor axially within its housing. The outer circumference 28 of the body portion of the internal gear 29 has the same diameter as the outer circumference of projecting flange 24 on the opposite side of the rotor, so that an oil seal 26 is positioned surrounding the internal gear and within the circular opening 27 of the rotor side wall 19.
The dimensioning of the axially inward extent of fingers 34 and 34a, and the axial positioning of the adjacent rotor hub face, are such that there is sufficient clearance behind the gear teeth to insert pins 39 into their bores at the selected angle. Although it is preferable that the axes of the pins be normal to the slope of the edges of the ribs which positions them at a corresponding angle to the longitude of the rotor axis, in mechanisms where space is limited the pin bores and the pins may be disposed normal to the rotor axis, whereupon they will be at an angle to the rib edges.
The resilient tubular pins have their diameters compressed for insertion, and expand into tight contact with the walls of their bores so that they will not fall out in the radial direction toward the rotor axis. The blind closures of bores 38 in the ribs prevent the pins from working radially outwardly under the action of centrifugal force.
Since the three pins 39 of FIG. 1 which retain the gear are spaced 60° apart radially there can be no circumferential movement of the gear relative to the rotor, except the minute resilience of the tubular pins which will absorb intermittent circumferential shock loading. The gear cannot move axially from its seat, since the axes of the pins are generally transverse to the rotor axis. As shown in FIGS. 2 and 3 where the cone angle of the gear seat is 30° and the pins are normal thereto, the axes of the pins are disposed at an angle of 75° from the rotor axis with the outer ends of the pins tilted axially inwardly from their inner ends. Even when the gear seat is machined at a conical angle of 60° and the pins are normal to the slope, they will be tilted 60° from the rotor axis, which will not permit axial movement of the gear. When the pins are positioned at a greater angle to the rotor axis, up to 90°, there can of course be no axial movement of the gear.
Likewise, there can be no movement of the gear transversely to the rotor axis, since the retaining pins are disposed radially at angle of 60° to each other, and movement of the gear along the direction of the axis of any pin will be opposed by the others, maintaining concentricity of the gear. However, differential expansion of portions of the parts in the radial direction is possible without imposing strains or distortions, since a slight relative movement of some portion of one or the other parts can occur along the general direction of the axis of any one of the pins, with perhaps some compression of that pin and some slight slippage along it. If the expansion of the rotor is approximately equal in all radial directions, the relation of the parts is the same as if no expansion occurred, the gear is not displaced from concentricity, and no shear load is placed on the pins, as would have been the case with the axially disposed bolts or dowels of the prior art. In the case of axial expansion of a rotor formed of a lightweight alloy having a high coefficient of thermal expansion, the pins in this invention are carried in the axial direction of the rotor with such expansion without imposing strain, as distinguished from the axially disposed bolts of the prior art, which were formed of steel with a lower coefficient of expansion and which would have been placed in tension.
FIG. 4 shows one form of suitable resilient tubular pin 39, comprising a hollow cylinder having its wall split longitudinally with a gap between the edges. Such a split tubular pin is compressible across its diameter. FIG. 5 shows another suitable form of resilient pin 39a, comprising a spirally rolled cylinder of relatively thin metal, would to a plurality of thicknesses and having its outer free edge accommodated in a longitudinal depression in the wall to preserve the generally cylindrical outer surface. Such a pin may also be compressed across its diameter.
FIG. 6 shows a rotor and gear combination 11a on the same principle as in the previous embodiment, but where a sturdier assembly is desired. The difference is that the bosses 36a in the region of the rotor apexes have a greater circumferential dimension than previously, enabling each boss to hold two resilient pins 39 or 39a. The mating fingers 34a of the gear are correspondingly enlarged. The total number of pins for the assembly of FIG. 6 is six, disposed in pairs 120° apart, the rotor ribs 32 and bosses 36a being machined as before on a conical angle of 30° to 60° and seating correspondingly machined gear fingers, with the pins disposed axially behind the gear teeth on axes approximately normal to the seating surfaces.
A third embodiment 11b even more securely assembled is shown in FIG. 7. Three resilient pins 39 or 39a hold the gear in bores in the bosses 36 oriented toward the rotor apexes, as in the embodiment first described. A further plurality of pins is installed in bosses 41 borne by the rotor, bosses 41 being either distributed between rotor ribs 32 as shown, or being enlargements of the ribs themselves, similar to bosses 36. When the additional rotor bosses 41 are positioned between the rotor ribs, additional mating fingers are provided on the gear. FIG. 7 shows a total of nine pins 39 or 39a, distributed in groups of three generally in the apex regions of the rotor. However, other numbers of pins and other distributions are feasible; it is preferred that the number of pins selected be a multiple of the number of rotor apexes, and either equiangularly disposed, or distributed in equiangularly disposed groups.
It is not necessary that bores 37 and 38 in which the pins 39 are installed should be formed with extreme precision, the degree of precision of drill holes being satisfactory. The resilient tubular pins are compressed before being inserted, and expand into contact with the wall of the bore. The shear strength of such pins is very nearly equal to that of solid pins.
An additional advantage of the gear and rotor assembly of this invention is that at the face of the rotor the gear has no greater diameter than is necessary to provide the base for the internal gear teeth, omitting the external flange or lugs needed by gears of the prior art for mounting. This allows more room for the oil seal 26 which surrounds the gear.
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An improved rotor and gear assembly for rotary mechanisms of the trochoidal type, in which a rotor having a central bore is mounted for rotation on a shaft, and an internally toothed ring gear is secured to a side face of the rotor for engagement with a stationary gear to maintain phasing between the rotor and its trochoidal housing during the planetary and rotary motion of the gear within the housing. The ring gear is mounted on the rotor by resilient tubular pins circumferentially disposed, the pins being angularly slanted with respect to the rotor axis in such a manner as to maintain concentricity of the rotor and gear while permitting differences in thermal expansion therebetween, restraining the gear from axial displacement, and providing resilience for intermittent circumferential shock loading of the gear without imposing undue stresses or causing distortion of the gear or the rotor.
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BACKGROUND
[0001] The present invention relates generally to subterranean treatment operations, and more particularly to methods of isolating local areas of interest for subterranean treatment operations.
[0002] In some wells, it may be desirable to individually and selectively create multiple fractures along a well bore at a distance apart from each other. The multiple fractures should have adequate conductivity, so that the greatest possible quantity of hydrocarbons in an oil and gas reservoir can be drained/produced into the well bore. When stimulating a reservoir from a well bore, especially those well bores that are highly deviated or horizontal, it may be difficult to control the creation of multi-zone fractures along the well bore without cementing a liner to the well bore and mechanically isolating the subterranean formation being fractured from previously-fractured formations, or formations that have not yet been fractured.
[0003] One conventional method for fracturing a subterranean formation penetrated by a well bore has involved cementing a solid liner in the lateral section of the well bore, performing a conventional explosive perforating step, and then performing fracturing stages along the well bore. Another conventional method has involved cementing a liner and significantly limiting the number of perforations, often using tightly-grouped sets of perforations, with the number of total perforations intended to create a flow restriction giving a back-pressure of about 100 psi or more; in some instances, the back-pressure may approach about 1000 psi flow resistance. This technology generally is referred to as “limited-entry” perforating technology.
[0004] In one conventional method of fracturing, a first region of a formation is perforated and fractured, and a sand plug then is installed in the well bore at some point above the fracture, e.g., toward the heel. The sand plug may restrict any meaningful flow to the first region of the formation, and thereby may limit the loss of fluid into the formation, while a second, upper portion of a formation is perforated and fracture-stimulated. Coiled tubing may be used to deploy explosive perforating guns to perforate subsequent treatment intervals while maintaining well control and sand-plug integrity. Conventionally, the coiled tubing and perforating guns are removed from the well before subsequent fracturing stages are performed. Each fracturing stage may end with the development of a sand plug across the perforations by increasing the sand concentration and simultaneously reducing pumping rates until a bridge is formed. Increased sand plug integrity may be obtained by performing what is commonly known in the cementing services industry as a “hesitation squeeze” technique. A drawback of this technique, however, is that it requires multiple trips to carry out the various stimulation and isolation steps.
[0005] The pressure required to continue propagation of a fracture present in a subterranean formation may be referred to as the “fracture propagation pressure.” Conventional perforating operations and subsequent fracturing operations undesirably may cause the pressure to which the subterranean formation is exposed to fall below the fracture propagation pressure for a period of time. In certain embodiments of conventional perforating and fracturing operations, the formation may be exposed to pressures that oscillate above and below the fracture propagation pressure. For example, if a hydrajetting operation is halted temporarily, e.g., in order to remove the hydrajetting tool, or to remove formation cuttings from the well bore before continuing to pump the fracturing fluid, then the formation may experience a pressure cycle.
[0006] Pressure cycling may be problematic in sensitive formations. For example, certain subterranean formations may shatter upon exposure to pressure cycling during a fracturing operation, which may result in the creation of numerous undesirable microfractures, rather than one dominant fracture. Still further, certain conventional perforation operations (e.g., perforations performed using wireline tools) often may damage a sensitive formation, shattering it in the area of the perforation so as to reduce the likelihood that subsequent fracturing operations may succeed in establishing a single, dominant fracture.
SUMMARY
[0007] The present invention relates generally to subterranean treatment operations, and more particularly to methods of isolating local areas of interest for subterranean treatment operations.
[0008] In one embodiment, the present invention provides a bottomhole completion assembly comprising: a conduit adapted for installation in a well bore in a subterranean formation; one or more fluid jet forming nozzles disposed about the conduit; and one or more windows formed in the conduit and adapted to selectively allow a flow of a fluid through at least one of the one or more fluid jet forming nozzles.
[0009] In another embodiment, the present invention provides a bottomhole completion assembly comprising: a conduit adapted for installation in a well bore in a subterranean formation; one or more fluid jet forming nozzles disposed about the conduit; a fluid delivery tool disposed within the conduit, wherein the fluid delivery tool is operable to move along the conduit; a straddle assembly operable to substantially isolate the fluid delivery tool from an annulus formed between the fluid delivery tool and the conduit; and wherein the conduit comprises one or more permeable liners.
[0010] In another embodiment, the present invention provides a method of bottomhole completion in a subterranean formation comprising: providing a conduit adapted for installation in a well bore in a subterranean formation; providing one or more fluid jet forming nozzles disposed about the conduit; providing one or more windows adapted to selectively allow a flow of a fluid through the one or more fluid jet forming nozzles; and conducting a well completion operation.
[0011] In another embodiment, the present invention provides a method of bottomhole completion in a subterranean formation comprising: providing a conduit adapted for installation in a well bore in a subterranean formation; providing one or more fluid jet forming nozzles disposed about the conduit; providing a fluid delivery tool disposed within the conduit, wherein the fluid delivery tool is operable to move along the conduit; providing a straddle assembly operable to substantially isolate the fluid delivery tool from an annulus formed between the fluid delivery tool and the conduit, wherein the conduit comprises one or more permeable liners; and conducting a well completion operation.
[0012] The features and advantages of the present invention will be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic cross-sectional view of an illustrative well completion assembly illustrating the perforation of a subterranean formation.
[0014] FIGS. 2A and 2B are schematic cross-sectional views showing an illustrative window casing assembly according to the present invention. FIG. 2A depicts the illustrative window casing in a closed position. FIG. 2B depicts the illustrative window casing in an open position.
[0015] FIGS. 3A-3D are schematic cross-sectional views illustrating various placements of fluid jet forming nozzles in the embodiment illustrated in FIGS. 2A and 2B .
[0016] FIGS. 4A and 4B are schematic cross sectional views of an illustrative well completion assembly constructed in accordance with the embodiment depicted in FIGS. 2A and 2B . FIG. 4A depicts the perforation and fracture of a subterranean formation. FIG. 4B depicts production from a subterranean formation.
[0017] FIG. 5 is a schematic cross-sectional view of an illustrative well completion assembly according to one embodiment of the present invention. Inset 5 A shows an embodiment of the fluid jet forming nozzles described herein.
[0018] FIGS. 5B and 5C illustrate the use of the embodiment illustrated in FIG. 5 in well completion operations. FIG. 5B depicts the perforation and fracture of a subterranean formation. FIG. 5C depicts production from a subterranean formation.
DETAILED DESCRIPTION
[0019] Referring now to FIG. 1 , an illustrative completion assembly 100 includes a well bore 102 coupled to the surface 104 and extending down through a subterranean formation 106 . Well bore 102 may drilled into subterranean formation 106 using conventional (or future) drilling techniques and may extend substantially vertically away from surface 104 or may deviate at any angle from the surface 104 . In some instances, all or portions of well bore 102 may be vertical, deviated, horizontal, and/or curved.
[0020] Conduit 108 may extend through at least a portion of well bore 102 . In some embodiments, conduit 108 may be part of a casing string coupled to the surface 104 . In some embodiments conduit 108 may be a liner that is coupled to a previous casing string. Conduit 108 may or may not be cemented to subterranean formation 106 . When uncemented, conduit 108 may contain one or more permeable liners, or it may be a solid liner. As used herein, the term “permeable liner” includes, but is not limited to, screens, slots and preperforations. Those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether conduit 108 should be cemented or uncemented and whether conduit 108 should be contain one or more permeable liners.
[0021] Conduit 108 includes one or more fluid jet forming nozzles 110 . As used herein, the term “fluid jet forming nozzle” refers to any fixture that may be coupled to an aperture so as to allow the communication of a fluid therethrough such that the fluid velocity exiting the jet is higher than the fluid velocity at the entrance of the jet. In some embodiments, fluid jet forming nozzles 110 may be longitudinally spaced along conduit 108 such that when conduit 108 is inserted into well bore 102 , fluid jet forming nozzles 110 will be adjacent to a local area of interest, e.g., zones 112 in subterranean formation 106 . As used herein, the term “zone” simply refers to a portion of the formation and does not imply a particular geological strata or composition. As will be recognized by those of ordinary skill in the art, with the benefit of this disclosure, conduit 108 may have any number of fluid jet forming nozzles, configured in a variety of combinations along and around conduit 108 .
[0022] Once well bore 102 has been drilled and, if deemed necessary, cased, a fluid 114 may be pumped into conduit 108 and through fluid jet forming nozzles 110 to form fluid jets 116 . In one embodiment, fluid 114 is pumped through fluid jet forming nozzles 110 at a velocity sufficient for fluid jets 116 to form perforation tunnels 118 . In one embodiment, after perforation tunnels 118 are formed, fluid 114 is pumped into conduit 108 and through fluid jet forming nozzles 110 at a pressure sufficient to form cracks or fractures 120 along perforation tunnels 118 .
[0023] As will be recognized by those of ordinary skill in the art, with the benefit of this disclosure, the composition of fluid 114 may be changed to enhance properties desirous for a given function, i.e., the composition of fluid 114 used during fracturing may be different than that used during perforating. In certain embodiments of the present invention, an acidizing fluid may be injected into formation 106 through conduit 108 after perforation tunnels 118 have been created, and shortly before (or during) the initiation of cracks or fractures 120 . The acidizing fluid may etch formation 106 along cracks or fractures 120 , thereby widening them. In certain embodiments, the acidizing fluid may dissolve fines, which further may facilitate flow into cracks or fractures 120 . In another embodiment of the present invention, a proppant may be included in fluid 114 being flowed into cracks or fractures 120 , which proppant may prevent subsequent closure of cracks or fractures 120 .
[0024] For embodiments wherein conduit 108 is not cemented to subterranean formation 106 , annulus 122 may be used in conjunction with conduit 108 to pump fluid 114 into subterranean formation 106 . Annulus 122 may also be used to take returns of fluid 114 during the formation of perforation tunnels 118 . Annulus 122 may also be closed by any suitable means (e.g., by closing a valve, (not shown) at surface 104 ). Furthermore, those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether annulus 122 should be closed.
[0025] Referring now to FIGS. 2A and 2B , an illustrative window casing assembly 200 is shown as adapted for use in the present invention. As used herein, the term “window casing” refers to a section of casing configured to enable selective access to one or more specified zones of an adjacent subterranean formation. As will be recognized by one of ordinary skill in the art, with the benefit of this disclosure, a window casing has a window that may be selectively opened and closed by an operator, for example, movable sleeve member 204 . As will be recognized by one of ordinary skill in the art, with the benefit of this disclosure, window casing assembly 200 can have numerous configurations and can employ a variety of mechanisms to selectively access one or more specified zones of an adjacent subterranean formation. Illustrative window casing 200 includes a substantially cylindrical outer casing 202 that receives a movable sleeve member 204 . Outer casing 202 includes one or more apertures 206 to allow the communication of a fluid from the interior of outer casing 202 into an adjacent subterranean formation (not shown). Apertures 206 are configured such that fluid jet forming nozzles 208 may be coupled thereto. In some embodiments, e.g. illustrative window casing assembly 200 , fluid jet forming nozzles 208 may be threadably inserted into apertures 206 . Fluid jet forming nozzles 208 may be isolated from the annulus 210 (formed between outer casing 202 and movable sleeve member 204 ) by coupling seals or pressure barriers 212 to outer casing 202 .
[0026] Movable sleeve member 204 includes one or more apertures 214 configured such that, as shown in FIG. 2A , apertures 214 may be selectively misaligned with apertures 206 so as to prevent the communication of a fluid from the interior of movable sleeve member 204 into an adjacent subterranean formation (not shown). Movable sleeve member 204 may be shifted axially, rotatably, or by a combination thereof such that, as shown in FIG. 2B , apertures 214 selectively align with apertures 206 so as to allow the communication of a fluid from the interior of movable sleeve member 204 into an adjacent subterranean formation. Movable sleeve member 204 may be shifted via the use of a shifting tool, a hydraulic activated mechanism, or a ball drop mechanism.
[0027] Referring now to FIGS. 3A-3D , a window casing assembly adapted for use in the present invention, e.g., illustrative window casing assembly 200 depicted in FIGS. 2A and 2B , may include fluid jet forming nozzles 300 in a variety of configurations. FIG. 3A shows fluid jet forming nozzles 300 coupled to apertures 302 via the interior surface 304 of outer casing 306 . FIG. 3B shows fluid jet forming nozzles 300 coupled to apertures 302 via the exterior surface 308 of outer casing 306 . FIG. 3C shows fluid jet forming nozzles 300 coupled to apertures 310 via the exterior surface 312 of movable sleeve member 314 . FIG. 3D shows fluid jet forming nozzles 300 coupled to apertures 310 via the interior surface 316 of movable sleeve member 314 .
[0028] Referring now to FIG. 4A , an illustrative well completion assembly 400 includes open window casing 402 and closed window casing 404 formed in conduit 406 . Alternatively, illustrative well completion assembly 400 may be selectively configured such that window casing 404 is open and window casing 402 is closed, such that window casings 402 and 404 are both open, or such that window casings 402 and 404 are both closed.
[0029] A fluid 408 may be pumped down conduit 406 and be communicated through fluid jet forming nozzles 410 of open window casing 402 against the surface of well bore 412 in zone 414 of subterranean formation 416 . Fluid 408 would not be communicated through fluid jet forming nozzles 418 of closed window casing 404 , thereby isolating zone 420 of subterranean formation 416 from any well completion operations being conducted through open window casing 402 involving zone 414 .
[0030] In one embodiment, fluid 408 is pumped through fluid jet forming nozzles 410 at a velocity sufficient for fluid jets 422 to form perforation tunnels 424 . In one embodiment, after perforation tunnels 424 are formed, fluid 408 is pumped into conduit 406 and through fluid jet forming nozzles 410 at a pressure sufficient to form cracks or fractures 426 along perforation tunnels 424 .
[0031] In some embodiments, the fluid jet forming nozzles 410 may be formed of a composition selected to gradually deteriorate during the communication of fluid 408 from conduit 406 into subterranean formation 416 . As used herein, the term “deteriorate” includes any mechanism that causes fluid jet forming nozzles to erode, dissolve, diminish, or otherwise degrade. For example, fluid jet forming nozzles 410 may be composed of a material that will degrade during perforation, fracture, acidizing, or stimulation, thereby allowing production fluid 428 , shown in FIG. 4B , to flow from subterranean formation 416 , through apertures 430 , and up conduit 406 to the surface 432 . By way of example, and not of limitation, some embodiments may utilize abrasive components in fluid 408 to cut the adjacent formation. In such embodiments, fluid jet forming nozzles 410 may be composed of soft materials such as common steel; such that the abrasive components of fluid 408 may erode fluid jet forming nozzles 410 . Some embodiments may incorporate an acid into fluid 408 . In such embodiments, fluid jet forming nozzles 410 may be composed of an acid soluble material such as aluminum. Other suitably acid prone materials may include ceramic materials, such as alumina, depending on the structure and/or binders of the ceramic materials. A person of ordinary skill in the art, with the benefit of this disclosure, will be aware of additional combinations of materials to form fluid jet forming nozzles 410 and compositions of fluid 408 , such that fluid jet forming nozzles 410 will deteriorate when subject to the communication of fluid 408 therethrough. Thus an operator may engage in stimulation and production activities with regard to zones 414 and 420 both selectively and jointly.
[0032] Referring now to FIG. 5 , an illustrative completion assembly 500 includes a well bore 502 coupled to the surface 504 and extending down through a subterranean formation 506 . Well bore 502 may be drilled into subterranean formation 506 using conventional (or future) drilling techniques and may extend substantially vertically away from surface 504 or may deviate at any angle from the surface 504 . In some instances, all or portions of well bore 502 may be vertical, deviated, horizontal, and/or curved.
[0033] Conduit 508 may extend through at least a portion of well bore 502 . In some embodiments, conduit 508 may be part of a casing string coupled to the surface 504 . In some embodiments conduit 508 may be a liner that is coupled to a previous casing string. Conduit 508 may or may not be secured in well bore 502 . When secured, conduit 508 may be secured by casing packers 510 , or it may be cemented to subterranean formation 506 . When cemented, conduit 508 may be secured to subterranean formation 506 using an acid soluble cement. When uncemented, conduit 508 may be a solid liner or it may be a liner that includes one or more permeable liners 512 . Those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether and how conduit 508 should be secured to well bore 502 and whether conduit 508 should include one or more permeable liners.
[0034] Conduit 508 includes one or more fluid jet forming nozzles 514 . In some embodiments, fluid jet forming nozzles 514 may be longitudinally spaced along conduit 508 such that when conduit 508 is inserted into well bore 502 , fluid jet forming nozzles 514 will be adjacent to zones 516 and 518 in subterranean formation 506 . As will be recognized by those of ordinary skill in the art, with the benefit of this disclosure, conduit 508 may have any number of fluid jet forming nozzles, configured in a variety of combinations along and around conduit 508 . Optionally, fluid jet forming nozzles 514 may be coupled to check valves 520 (shown in Inset 5 A) so as to limit the flow of a fluid (not shown) through fluid jet forming nozzles 514 to a single direction. Optionally, conduit 508 may include one or more window casing assemblies, such as for example illustrative window casing assembly 200 (not shown), adapted so as to selectively allow the communication of a fluid through fluid jet forming nozzles 514 .
[0035] Illustrative well completion assembly 500 may include a fluid delivery tool 522 disposed therein. Fluid delivery tool 522 may include injection hole 524 and may be connected to the surface 504 via workstring 526 . Fluid delivery tool 522 may be secured in conduit 508 with a straddle assembly 528 , such that injection hole 524 is isolated from the annulus 530 formed between conduit 508 and workstring 526 . Straddle assembly 528 generally should not prevent fluid delivery tool 520 from moving longitudinally in conduit 508 .
[0036] Referring now to FIG. 5B , illustrative well completion assembly 500 is configured to stimulate zone 516 . Fluid delivery tool 522 is aligned with fluid jet forming nozzles 514 such that a fluid 532 may be pumped down workstring coil 526 , through injection hole 524 , and through fluid jet forming nozzles 514 to form fluid jets 534 . Returns of fluid 532 may be taken through annulus 530 . In one embodiment, fluid 532 is pumped through fluid jet forming nozzles 514 at a velocity sufficient for fluid jets 534 to form perforation tunnels 536 . In one embodiment, after perforation tunnels 536 are formed, fluid 532 is pumped into conduit 508 and through fluid jet forming nozzles 514 at a pressure sufficient to form cracks or fractures 538 along perforation tunnels 536 .
[0037] Optionally, once perforation tunnels 536 have been formed in zone 516 , annulus 530 may be closed by any suitable means (e.g., by closing a valve (not shown) through which returns taken through annulus 530 have been discharged at the surface). Closure of annulus 530 may increase the pressure in well bore 502 , and in subterranean formation 506 , and thereby assist in creating, and extending, cracks or fractures 538 in zone 516 . Closure of annulus 530 after the formation of perforation tunnels 536 , and continuation of flow exiting fluid jet forming nozzles 514 , also may ensure that the well bore pressure will not fall below the fracture closure pressure (e.g., the pressure necessary to maintain the cracks or fractures 538 within subterranean formation 506 in an open position). Generally, upon the initiation of the fracture, the pressure in well bore 502 may decrease briefly (which may signify that a fissure has formed in subterranean formation 506 ), but will not fall below the fracture propagation pressure. Among other things, flowing fluid through both annulus 530 and through fluid delivery tool 522 may provide the largest possible flow path for the fluid, thereby increasing the rate at which the fluid may be forced into subterranean formation 506 .
[0038] In some embodiments, the fluid jet forming nozzles 514 may be formed of a composition selected to gradually deteriorate during the flow of fluid 532 from conduit 508 into subterranean formation 506 . For example, fluid jet forming nozzles 514 may be composed of a material that will degrade during perforation, fracture, acidizing, or stimulation, thereby allowing production fluid 540 , shown in FIG. 5C , to flow from subterranean formation 506 , through apertures 542 , and up conduit 508 to the surface 504 . Production fluid 540 may also enter annulus 530 through permeable liner 512 and be returned to the surface 504 .
[0039] Fluid delivery tool 522 may be moved longitudinally within conduit 508 , such that injection hole 524 aligns with fluid jet forming nozzles adjacent to zone 518 (not shown). Completion operations, including perforation, fracture, stimulation, and production, may thus be carried out in zone 518 in isolation from zone 516 .
[0040] Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.
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Of the many assemblies and methods provided herein, one assembly includes a conduit adapted for installation in a well bore in a subterranean formation; one or more fluid jet forming nozzles disposed about the conduit; and one or more windows formed in the conduit and adapted to selectively allow a flow of a fluid through at least one of the one or more fluid jet forming nozzles. Another assembly provided herein includes a conduit adapted for installation in a well bore in a subterranean formation; one or more fluid jet forming nozzles disposed about the conduit; a fluid delivery tool disposed within the conduit, wherein the fluid delivery tool is operable to move along the conduit; a straddle assembly operable to substantially isolate the fluid delivery tool from an annulus formed between the fluid delivery tool and the conduit; and wherein the conduit comprises one or more permeable liners.
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CROSS REFERENCE TO RELATED APPLICATIONS
This patent application claims the priority and benefit of U.S. provisional patent application 62/030,724, entitled “Automatic Creation of Applique Cutting Data from Machine Embroidery Data”, filed on Jul. 30, 2014 and which herein incorporated by reference in its entirety.
TECHNICAL FIELD
Embodiments are related to sewing, embroidery, embroidery machines, embroidery design software, and automated cutting machines.
BACKGROUND
Applique is often done by labeling the color steps with the words “Applique” and either “Position” or “Material”. The steps always have to be in order. The first sewn section is the Position. This sewing puts an outline on the project being embroidered. This outline is the location of the material applique which that will be applied to a project cloth at this point in time. The next sewing step is the “Material” which can vary in type of stitch, such as single run, double (out and back), or even zigzag. This sewing anchors the material of the applique to the project. The next step a sewer must do is to cut the applique around the outside of the stitches sewn by the “Material” step. They do this by hand using a pair of scissors generally. Once the excess fabric is removed, the sewing is completed to finish the project.
Alternatively, a sewer can run the outline of the design on some other item such as paper. This allows them to place the paper with the outline on the cloth that is to be the applique, allowing the sewer to cut the paper and cloth together. This saves loss of registration by the machine during the sewing process.
Yet another alternate method is to print out a precise template of the applique position color using a normal printer and software that is calibrated for this purpose. All of these methods require the user to hand-cut the applique cloth.
A different process also exists, wherein certain dies have been made to cut cloth. AccuQuilt.com has typical examples. The dies using manual or pneumatic or electrical means can cut the cloth. This means the cloth must be applied using a sewing machine, not with embroidery.
U.S. Pat. No. 6,600,966 titled “SOFTWARE PROGRAM, METHOD AND SYSTEM FOR DIVIDING AN EMBROIDERY MACHINE DESIGN INTO MULTIPLE REGIONAL DESIGNS” issued to Brian D. Bailie on Jul. 29, 2003. U.S. Pat. No. 6,600,966 is herein incorporated by reference in its entirety for its teachings of embroidery techniques, embroidery file formats, embroidery file reading/writing/modification, use of grids, analysis software applied to embroidery, identifying and using embroidery regions, and automated and computerized embroidery.
U.S. Pat. No. 6,633,794 titled “SOFTWARE PROGRAM AND SYSTEM FOR REMOVING UNDERLYING STITCHES IN AN EMBROIDERY MACHINE DESIGN” issued to Brian D. Bailie on Oct. 14, 2003. U.S. Pat. No. 6,633,794 is herein incorporated by reference in its entirety for its teachings of embroidery techniques, embroidery file formats, embroidery file reading/writing/modification, use of grids, analysis software applied to embroidery, identifying and analyzing individual stitches in their context in an embroidery design, and automated and computerized embroidery.
U.S. Pat. No. 6,732,008 titled “SOFTWARE PROGRAM AND SYSTEM FOR EVALUATING THE DENSITY OF AN EMBROIDERY MACHINE DESIGN” issued to Brian D. Bailie on May 4, 2004. U.S. Pat. No. 6,732,008 is herein incorporated by reference in its entirety for its teachings of embroidery techniques, embroidery stitches, embroidery file formats, embroidery file reading/writing/modification, use of grids, analysis software applied to embroidery, identifying and analyzing individual stitches in their context in an embroidery design, and automated and computerized embroidery.
U.S. Pat. No. 6,944,605 titled “EXPERT SYSTEM AND METHOD FOR CREATING AN EMBROIDERED FABRIC” issued to Brian D. Bailie on Sep. 13, 2005. U.S. Pat. No. 6,944,605 is herein incorporated by reference in its entirety for its teachings of embroidery techniques, stitches, fabrics, analysis. Further reasons for incorporating U.S. Pat. No. 6,944,605 in its entirety is its teaching of creating and applying rules in the context of embroidery, its teaching of analysis for offering recommendations to human operators, its approach to embroidery design flow, and its parametric selection teachings.
U.S. Pat. No. 7,457,683 titled “ADJUSTABLE EMBROIDERY DESIGN SYSTEM AND METHOD” issued to Brian D. Bailie on Nov. 25, 2008. U.S. Pat. No. 7,457,683 is herein incorporated by reference in its entirety for its teachings of embroidery techniques, embroidery stitches, embroidery file formats, embroidery file reading/writing/modification, analysis software applied to embroidery, identifying and analyzing individual stitches in their context in an embroidery design, and automated and computerized embroidery.
Prior art references having different authorship are now presented. The references are also incorporated by reference in their entirety for their teachings of certain aspects of embroidery, embroidery techniques, and the automation of aspects of embroidery processes.
U.S. Pat. No. 4,920,902 titled “Automatic pattern sewing machine” issued to Takenoya et al. on May 1, 1990. It is herein incorporated by reference for its teachings of a machine that automatically sews patterns, teaching of applique techniques, teachings of pattern data, and teachings of automatic or assisted modification of the pattern data.
U.S. Pat. No. 1,741,620 titled “Hemstitched applique work and process of making the same” issued to Fixler on Dec. 31, 1929. It is herein incorporated by reference in its entirety for its teachings of stitches, embroidery, and embroidery knowhow.
U.S. Pat. No. 8,557,078 titled “Applique printing process and machine” issued to Marino et al. on Oct. 15, 2013. It is herein incorporated by reference in its entirety for its teachings of automatically producing an applique based on a printing type process, for its teachings of certain embroidery/applique techniques, and for its teaching of cutting cloth/materials for appliques.
U.S. Pat. No. 5,438,520 titled “Method of creating applique data” issued to Satoh et al. on Aug. 1, 1995. It is herein incorporated by reference in its entirety for its teachings of applique techniques, applique data, generation and manipulation of applique data, and for the machinery and equipment (embroidery machine, computer, cutter, etc.) that can be used in association with designing and creating appliques.
U.S. Pat. No. 7,882,645 titled “System and method for making an applique” issued to Boring on Feb. 8, 2011. It is herein incorporated by reference in its entirety for its teachings of applique techniques, applique templates, and applique design.
U.S. Pat. No. 3,226,732 titled “Applique article and method of manufacture” issued to Zerilli on Jan. 4, 1966. It is herein incorporated by reference in its entirety for its teachings of applique techniques, applique layers, and applique design, cutting, stitching and application.
Three related patents are also incorporated herein by reference in their entirety. U.S. Pat. No. 5,430,658 titled “METHOD FOR CREATING SELF-GENERATING EMBROIDERY PATTERN” issued to Davinsky et al. on Jul. 4, 1995. U.S. Pat. No. 5,668,730 titled “METHOD FOR AUTOMATICALLY GENERATING CHAIN STITCHES” issued to Tsonis et al. on Sep. 16, 1997. U.S. Pat. No. 5,771,173 titled “METHOD FOR AUTOMATICALLY GENERATING A CHENILLE FILLED EMBROIDERY STITCH PATTERN” issued to Tsonis et al. on Jun. 23, 1998. These three patents largely have the same inventors and are included by reference herein in their entireties for their teachings of developments and refinements in defining, outlining, and filling embroidery shapes. They are also incorporated by reference for their teachings of automatic or algorithmic generation of chain stitch outlines, of automatic or algorithmic generation and of embroidery patterns, of computer aided design applied to embroidery, of embroidery techniques and processes, and for their detailed teachings of stitch types, properties, and uses.
A document titled “A Survey of Polygon Offseting Strategies” by Fernando Cacciola was incorporated into the filing of U.S. provisional patent application 62/030,724 and is thereby also herein incorporated by reference in its entirety. It is incorporated herein for its teachings of techniques for offsetting polygons and for other transformations and operations.
Applique is a popular technique and embroidery designs for applique exist in abundance. Systems and methods for saving the sewers time by producing properly cut out designs are needed.
BRIEF SUMMARY
The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
Aspects of the embodiments address limitations and flaws in the prior art by analyzing machine embroidery data to automatically produce cutting data that a cutting machine can interpret to cut out the applique. An applique data file specifies an applique design and contains sewing data. The sewing data can include sewing vectors and jump commands. The sewing vectors specify stitches as, for example, movements, stitch points, or needle penetrations. The jump commands split the sewing vectors into subsections. For example, one subsection can be an applique outline while a number of other subsections can be holes or openings in the applique outline. An embroidery machine can read and interpret the applique data file to thereby stitch a pattern onto a piece of cloth. A cutting machine can read the cutting data automatically created by the embodiments disclosed herein and cut the applique out of a piece of cloth.
Aspects of the embodiments can be a non-transitory memory containing program instructions readable by a computer for performing certain operations. Other aspects of the embodiments can be the steps or operations performed in automatically creating the cutting data from the applique data file.
It is, therefore, an aspect of the embodiments to access an applique data file and to create lists of sewing vectors. If there is only one subsection, then there is only one list. If a jump command splits the sewing vectors into two or more subsections, then there can be two more or lists.
It is also an aspect of the embodiments to normalize the lists. Normalizing the lists by discarding certain sewing vectors or data such as tie-off data, double stitches, and other sewing artifacts do not affect the applique outline that is to be cut.
It is a further aspect of the embodiments to close the lists. It is possible for the endpoint on a list to be far enough from the start point that one or more additional sewing vectors are needed to close the list so that it defines a closed outline.
It is a yet further aspect of the embodiments that an outline contains holes. The dosed paths specified by the lists specify at least one outline and may specify a number of holes for applique designs that contain openings. The embodiments can determine that a list is an outline and that another list is a hole. The embodiments can also create objects that include an outline list and one or more hole lists for holes inside the outline.
It is yet another aspect of the embodiments that the outlines are inflated by a positive amount to make them slightly larger and for the holes to be inflated by a negative amount to make them slightly smaller.
It is still yet another aspect of the embodiments to simplify the lists by removing points using certain known algorithms such as the Douglas-Peucker algorithm or any of its readily available derivatives. The outline can then be further simplified by fitting them to Bezier outlines using common fitting technique such as Newton-Raphson least squares fitting techniques or other line and curve fitting algorithms that are known in the arts of graphing or computer graphics.
It is a still yet further aspect of the embodiments to create a preview that can be seen by a person. An image can be produced by copying a first bitmap into the image sections outside of the applique outline and inside any holes in the applique. A second bitmap can be copied into image sections inside the applique outline and outside any holes in the applique.
An alternative embodiment can use the applique design to draw vectors onto a bitmap. The bitmap should be sized such that it is large enough to include all the vectors and also large enough that the shortest vector is at least two pixels long. The bitmap can then be conditioned to produce a better outline. Thinning algorithms and skeletonizing algorithms can condition the bitmap. The applique outline can then be traced by finding a first pixel in the outline and then simply following along the outline. Cutting data can be produced from the applique outline traced in the image. Those familiar with image processing and digital image manipulation are familiar with a number of common thinning an skeletonizing algorithms.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the background of the invention, brief summary of the invention, and detailed description of the invention, serve to explain the principles of the present invention.
FIG. 1 illustrates a high level diagram of a processor executing stored instructions to create a cutting data file from an applique data file in accordance with aspects of the embodiments;
FIG. 2 illustrates a high level block diagram of data transformations and processes to create a cutting data file from an applique data file in accordance with aspects of the embodiments;
FIG. 3 illustrates a high level block diagram of data transformations and processing of a bitmap to create a cutting data file from an applique data file in accordance with aspects of the embodiments;
FIG. 4 illustrates an image with irregular edges in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 5 illustrates an image of needle penetrations in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 6 illustrates the image of FIG. 5 after triad filtering in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 7 illustrates the image of FIG. 6 after simplification of the outline and inflation in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 8 illustrates a tatami fill of the image of FIG. 7 in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 9 illustrates the tatami filled design of FIG. 8 with embroidered letters in association with automated global underlay in accordance with aspects of the embodiments;
FIG. 10 illustrates an echo quilting design with embroidered letters in association with automated echo quilting in accordance with aspects of the embodiments;
FIG. 11 illustrates an automatically generated pattern around embroidered letters in association with automated stippling in accordance with aspects of the embodiments;
FIG. 12 illustrates an automatically generated pattern from a “Drunkard” algorithm in association with automated stippling in accordance with aspects of the embodiments;
FIG. 13 illustrates an automatically generated less randomized version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments;
FIG. 14 illustrates an automatically generated “Leafy” version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments; and
FIG. 15 illustrates an automatically generated “Geometric” version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments.
DETAILED DESCRIPTION OF THE INVENTION
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate embodiments and are not intended to limit the scope thereof.
The embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. The embodiments disclosed herein can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The disclosed embodiments are described in part below with reference to flowchart illustrations and/or block diagrams of methods, systems, and computer program products and data structures according to embodiments of the invention. It will be understood that certain blocks of the illustrations, and combinations of blocks, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the block or blocks.
These computer program instructions may also be stored in a non-transitory computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function/act specified in the block or blocks.
The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the block or blocks.
FIG. 1 illustrates a high level diagram of a processor 104 executing stored instructions 102 to create a cutting data file 107 from an applique data file 105 in accordance with aspects of the embodiments. A non-transitory processor readable medium 101 contains the stored code representing instructions 102 that the processor 104 running in computer 103 accesses. The processor 104 accesses applique data file 105 and processes the sewing data 106 to produce cutting file 107 . A cutter 109 provided with applique cloth 108 can process the cutting data file 107 to thereby cut out an applique 110 . An embroidery machine 112 provided with cloth 111 and applique 110 can process applique data file 105 to thereby sew the applique onto the cloth 113 .
FIG. 2 illustrates a high level block diagram of data transformations and processes to create a cutting data file 107 from an applique data file in accordance with aspects of the embodiments. The applique data file contains sewing data 106 . The sewing data contains sewing vectors 201 and jump commands 202 . There are also sewing artifacts 203 in the sewing data 106 . Examples of sewing artifacts 203 include data for tie-offs, double stitching, and sewing paths that cross in on themselves without stopping.
Two lists 204 , 207 are created from the sewing data 106 because, in this example, the sewing data 106 contains a jump command 202 . The sewing vectors 205 before the jump command can go into list 1 204 while the sewing vectors 208 after the jump command can go into list 2 207 . In practice, more jump commands can result in more lists being created. Furthermore, list 1 204 and list 2 207 do not contain jump commands.
The lists 204 , 207 are normalized to remove sewing artifacts 206 , 209 . Analysis indicates that list 2 defines a closed path, meaning that the first and last points in the list of sewing vectors are closer than a predetermined threshold. Analysis indicates the list 1 204 does not define a closed path. List 1 204 is amended to produce list 1 209 containing sewing vectors 210 wherein the path is closed by adding additional sewing data to the list to thereby close the path. For example, a stitch can be added that connects the first and last points.
List 1 209 and list 2 207 are analyzed and it is determined that the closed path defined by sewing vectors 208 lies inside of the closed path defined by sewing vectors 210 . List 1 209 therefore defines an outline while list 2 207 defines a hole inside the outline. List 1 209 and list 2 207 are combined into object 1 211 because the hole is inside the outline. Object 1 211 can then be inflated by inflating the outline by a positive amount and inflating the hole by a negative amount. In the example, list 1 209 has been inflated by a positive amount into list 1 212 while list 2 207 has been inflated by a negative amount into list 2 213 .
Inflation is a common geometric term which is slightly different than scaling. It is also known as polygon offsetting and is well known in the art. Where there are ‘Holes’ the inflation uses a negative value, thus reducing the size of the hole.
Object 1 can be simplified to include simplified lists such as list 1 214 and list 2 215 . Simplification is the elimination of extra points in the sewing data. There are a number of well-known algorithms such as Douglas-Peucker and its derivatives that eliminate extra points. The outline and hole can also be fitted to Bezier outlines using common fitting techniques such as Newton-Raphson or least squares fitting techniques.
Object 1 can then be transformed into cutting data because the object's data is forward moving, non-repetitive, and possibly spline or cubic Bezier format that is useful to a cutter.
FIG. 3 illustrates a high level block diagram of data transformations and processing of a bitmap 307 to create a cutting data file 107 from an applique data file 105 in accordance with aspects of the embodiments. The applique data file 105 , in an embroidery file format, contains an applique design 301 with sewing data 106 . The sewing data can contain sewing vectors 201 , jump commands 202 , and sewing artifacts 203 . Exemplary sewing vectors 201 include stitches 302 , movements 303 , or needle penetrations 304 .
A bitmap 307 is created that is sized at least as large as the design size 306 and such that the shortest sewing vector 305 is at least two pixels long. The sewing vectors are then drawn onto the bitmap 308 . The bitmap can be conditioned 309 by applying a thinning algorithm or a skeletonizing algorithm. The bitmap can then be traced to find a point on the outline and then the outline traced 310 to produce a list, as discussed above. The list is closed if analysis finds that it is open. The cutting data 107 can then be produced from the list.
The embodiments can consist of the usual apparatus of a computer, a program, and an embroidery machine. The software can look for sections of the design with appropriate labels. It also allows the user to select a section for applique. The software uses the sewing data (stitches) which consist of a series of relative or absolute movements (vectors or stitch points or needle penetrations) to create an outline. That outline is then saved in a format that is useful to a cutting machine. Cutters, similar to the vinyl cutters used by sign shops everywhere, have been adapted to the purpose of cutting fabric recently. Currently, the cutters force the user to draw the outlines for the cut using a manual drawing process—using bezier or point input modes. In some cases, they can scan in a picture and auto-trace an outline. These are separate sets of steps which are prone to terrible inaccuracy when making the outline.
The process for converting is not a simple matter of converting formats of the sewing vectors into cutting vectors. The stitch data for an applique position may contain a set of vectors that handle multiple outlines, including holes in outlines, as well as sewing requirements such as tie-offs which are extra stitches that ensure the thread is working and able to be cut between sections. What's required is forward-moving-only data that forms dosed polygon outlines.
Exemplary descriptions of steps and instructions for performing the process are now provided.
The stitch data may contain both normal sewing vectors and “jump” commands. These jumps are non-sewing movement commands. When the process sees these commands in the data, it can separate the data into subsections, organized as linked lists with each subsection containing the sewing vectors between two jump commands. The end cases, obviously, are the sewing vectors from the stitch data start to the first jump command and the sewing vectors from the last jump command to the end of the stitch data. Note that here linked lists are used in the interests of a simple explanation whereas, in practice, different data structures such as arrays, trees, hash tables, key-value pairs, etc., can be used to similar effect.
The lists, aka subsections, are now processed into normalized data, which removes certain sewing artifacts.
For each list:
Advance a few stitches into the data, looking for a Euclidean distance of travel away from the start point, (2 mm best current) until a new point is found. Once that is reached, the skipped stitch data in between can be discarded. This process is referred to as ‘skipping tie-off data’ and is used throughout. This Euclidean distance and any of the other tolerances or distance discusses below can be user specified parameters having default values or can be constant values. Note, Euclidean distance is specified here as it has proven useful although other distance measures such as Mahalanobis, Manhattan, etc., can be used in appropriate circumstances.
It is entirely possible for the path to continue around its required outline and past the start point, and it frequently does. The process therefore scans the data iteratively and tracks its path. When and if the path comes back within a tolerance, the closing distance, of the start point, the shape is assumed closed at that point, and that section of data is saved for later processing. The closing distance is typically a distance from the current stitch end to the start point. If found, the stitch whose end is within the closing distance is the closing stitch for that particular shape.
If the length of the design, meaning the total length of all vectors is below a threshold, or the number of useable points is too small (a line, not a polygon), then the list is discarded. The data may be double-stitched, wherein the stitches travel to an endpoint, then reverse direction of travel to come back at or near the start point. Therefore the process scans the data looking for double-stitches and removes the double-back section. The process also discards any data beyond the closing stitch.
It is possible that the data at this point does not form a properly closed path and there is no closing stitch. The path is closed in the usual manner of adding a new tail point between the closing stitch and the start point which closes the outline.
It is also possible that a stitch other than a single or double stitch may exist in the stitch data. This can be determined by analyzing the points in the data and seeing how many are repeated within a certain tolerance, usually 0.2 mm. If there is a plurality of these, an alternate method must be used on this data to get a set of points that run in a forward direction. This can be accomplished with an alternate process, such as:
Alternate Method:
Create a 2-color (e.g., black and white) bitmap that will represent the image, using a pixel ratio that is known so that the vectors will have meaningful scale when drawn such as the shortest vector having a length of two or possibly more pixels. Draw the stitches into the bitmap. Apply a thinning algorithm to the bitmap which will provide sensible single-pixel data. Scan the bitmap for a starting pixel and follow the outline, tracing the path. Thinning algorithms are suggested here because they have been used with success. Other well-known image processing algorithms can similarly skeletonize an image or bitmap.
These steps are well known in all areas of computer graphics, but not used in the embroidery art for this purpose. Once a plurality of pixels has been discovered, the results are checked against the same steps as above for length and closure. If it is long enough, but open, then it is closed.
Alternate Method:
The user might use an image of the stitch data and draw on top of it using ordinary computer drawing tools to create an outline from scratch. This is also useful if the user wants to add an applique section to a design that currently does not have one, but is a good candidate (visually) for one.
Sequencing the resultant lists.
Now that we have a plurality of lists containing clean forward-moving-only vector data (cutters don't like a lot of reversals), we can now sort them into outlines and holes.
For each point-list, analyze the remaining point-lists to see if they wholly contain this list. This is achieved using the Winding Number rule, or any similar technique. Lists which are not wholly contained are separated into a group of ‘outline’ lists, and holes are left in the list of point-lists.
Next each hole is analyzed to see which outline contains it, and they are grouped together. This group is an ‘object’. Each object has a single outline and possibly a plurality of holes. There may be several objects.
Optionally:
As applique cloths will need to be attached to the cloth being embroidered, there are always stitches provided to do so in the applique design. These stitches are known as the ‘Material’ stitches. These stitches are either automatically generated or hand-laid by the artist who is creating the design. Often times the automatic creation of these material stitches uses the exact same form and size as the outline of the applique. This process can work if the applique is hand cut by the sewer after the applique has been sewn. However, if the applique is cut in advance, the material stitching may not penetrate the applique cloth, as the applique cloth will be the same size as the stitching. Therefore at the direction of the user, or automatically, the outline of the applique shape may be inflated before cutting. Making this decision can be done as simply as examining the size of the applique and the size of the material stitching, and if they are within a small tolerance (1-2 mm) then the inflation needs to occur.
Inflation is a common geometric term which is slightly different than scaling. It is also known as polygon offsetting and is well known in the art. Where there are ‘Holes’ the inflation uses a negative value, thus reducing the size of the hole.
Optional, depending on the needs of the cutter device:
Now, each point-list within each object is processed by simplification—thus eliminating extra points which can make the cut difficult. The algorithm used is one created by Douglas-Peucker or any readily available derivative. Then the outlines are fitted to Bezier outlines using a common fitting technique such as Newton-Raphson least squares fitting techniques.
Finally each object's data, now in forward-moving, non-repetitive, possibly spline or cubic Bezier format is ready for output to a cutter. The cutters each have a format for their data. A typical example is the HPGL.plt format, which is widely used, although there are many proprietary formats too.
Additionally:
Once a cut outline (cutline) has been created, it is possible to store this cutline alongside the sewing data in the apparatus. This adds a novel benefit of being able to allow the user to select an image, or for the software to create one, simulating fabric of a given or user-chose color, which image is then used in the display to the user for visualization of the applique. The process of display uses the cutline, which is always a closed shape as described, and a pair of bitmaps which will be used to represent the image. The first image is called a bitmap mask and this image is filled with a background color of known value. Then the cutline is drawn on the mask with a different color. The cutline is always at least one pixel smaller on each edge in its representation on the bitmap than the bitmap size.
A loop is run for each pixel in the bitmap and an evaluation is made—if the pixel is background colored data, a determination of that point and whether or not it is inside the actual object is made. Inside is determined true if the point is within the outline, and not within any holes. If it is determined that the point is inside the object shape, then a seeded fill operation is performed, which is a color that fills the inside area, and that color is not background. At the end of the loop the mask bitmap contains a binary image of pixels which are either background or contained in the object.
The next step is to use an image, represented by another bitmap, and placed over the mask bitmap, and a display bitmap. Where the mask bitmap contains drawn pixels, the matching pixel from the image is copied into the display.
In a previous step, the input image may be selected by the user, and certain transforms applied, including brightness, contrast, sepia tone, hue and saturation adjustments for the purpose of matching other colors and even editing may be performed. All of which steps are common to the computer graphics art, and included as a step in the process.
It is not assumed that masked bitmaps are novel. Just the implementation of them in the place is described. There are also transforms that can be applied, too numerous to mention, but by example: rotation, morphing, and alpha channel.
Another Addition:
Prior art (Bailie) has disclosed a method for removing overlapping stitches from a design. This improves the design by removing density which results in damage to equipment, downtime, and even simple production time. The new cutline and masked bitmap allows the process to be extended in such a way that the applique material is now an additional component of the occlusion—causing other stitches which are previously sewn to be unnecessary. Their removal is very useful for the same reasons just mentioned.
An additional item is useful: Tagging the sewing data which are Position and Material runs as NOT to be removed is useful. This stitch data which would be removed during the process normally can now be exempted from the removal. The reason is that Position and Material runs are required where applique materials will be overlapped, according to the designer of the embroidery design. In this case, the stitches that are not part of Position and Material stitches should be removed, and would be, as the subsequent applique would cover them.
Aspects related to automatic global underlay for embroidery designs:
It is often desired to place embroidery on towels or any other items that are composed of a cloth with a texture known as pile. This poses difficulty for the embroiderer as the process of embroidery on that kind of cloth requires a substantial number of stitches to flatten out that cloth before the design is sewn. If the underlying stitches are insufficient, the design will have the texture of the cloth protruding above the embroidery and/or making the texture of the embroidery irregular.
As most designs are not created with this intended purpose, it would be beneficial if there were a way to automatically add such an underlay to any design. This can be accomplished using (the usual apparatus) plus a set of bitmaps, and stitch-creation process.
First a masked bitmap is created. It is filled with no color (black). Then, using a single color, the design is drawn into it. This image when rendered usually has a very irregular edge, one not pleasing to the eye. Due to the nature of stitch data, the bitmap is rendered using LineTo and MoveTo commands, which leave “>” shaped gaps all along the edges of adjacent lines of stitching as can be seen in FIG. 4 .
If a path-following process around the image is used, these “<” or “>” shaped dents are formed. Nonetheless, a set of traces around the drawn design must be the start of the process. However, additional drawing in the form of a different color, only at points of needle penetration can be performed as shown in FIG. 5 .
This allows the outline to have more intelligent data and thus the resultant paths can have the pixels between the penetrated points removed. This makes the outline more regular and pleasing. Further improvement can be made by filtering triads of stitch points which are close together, often the result of embroidery short-stitching, which is commonly used as a method to turn the angle of lines of stitches. FIG. 6 is an image of such a filtered image.
Next a simplification of the outline can be made and conversion into Bezier or other outline form thus made.
As there are likely to be a plurality of outlines, it is important to create objects with outlines and holes, as described previously.
Once those outlines exist, a global underlay can be achieved by first, inflating the size of the shapes to some useful value (best practice is 3 mm) as seen in FIG. 7 .
Then those shapes can be passed to a tatami fill generator which is well defined in the art (best practice for Terry cloth is 3.5 mm stitch length, 1.5 mm line density). The output of the fill generator can then be sequenced as the earliest-sewn data in the design. Thus with a single user action, the process can adapt any design to the desired nappy cloth. Additionally, using the prior art, any stitch data from the original design which is interpreted as underlay may now be removed, as it has been replaced with a superior set of data. FIG. 8 illustrates a tatami fill pattern while FIG. 9 illustrates letters embodied over a tatami filled area.
Aspects related to automatic echo quilting for embroidery designs:
Using a similar process to creating a global underlay, wherein the outline and hole data is created for any embroidery design, we can achieve a different effect. The concept of echo quilting is not new to graphics, but in embroidery such items are manually created by a skilled artist. FIG. 10 illustrates an echo quilting design with embroidered letters.
Outlining stitches with new stitches can be done by taking the objects and handing them to a run stitch generator (or any stitch generator, such as satin, bean stitch, etc.). Further, if we optionally discard any holes, we can then expand the outlines using known polygon inflation techniques to create a single or plurality of outlines which ‘echo’ around the design. This is commonly used by quilters to provide stability to a quilt, using a set of running stitches known as echo quilting. It appears as ripples would in a pond. Further, as each embroidery is constrained by the hoop which will be used to create it, we can cause the echo lines to terminate within the bounds of the hoop, and add tie-off and jump to other echo lines as needed. The user of the software could control the distance and stitch type of the echo lines. Additionally, multiple designs within a hoop could have their outlines inflated together, producing a more visually complex result as the echo patterns interfere with each other, and each echo line can have other stitch actions applied, such as decorative motifs played on the line, etc.
Aspects related to automatic drop shadow embroidery:
Using a similar process to creating a global underlay, wherein the ‘outline’ and ‘hole’ data is created for any embroidery design, we can achieve a different effect. The concept of drop shadow is not new to graphics, but in embroidery such items are manually created by a skilled artist.
In this process, we take a complete set of outlines as proposed above and offset them in a manner described by a user, having little skill and requiring only a visual interest, and offset, inflate with rounding acute corners, monochromatize, and then use a graphical subtraction which created a resulting set of objects that can then have stitches applied. The subtraction includes steps for discovering intersections between the original and copied image, then discarding overlapped regions, however, the drop shadow is compensated such that its shape penetrates the original design by a small amount which is useful in embroidery to prevent gapping in designs, where the background shows through. The user inputs an offset of a vector, containing by definition a distance and an angle. This angle is then used as the angle for a tatami or other patterned fill, well known in the art.
Aspects related to automatic stipple embroidery:
Prior art exists, which has flaws that this overcomes.
1.) Using a similar process to creating a global underlay, wherein the ‘outline’ and ‘hole’ data is created for any embroidery design, we can achieve a different effect. or 2.) Using a user-defined area which typically includes an outer shape, which may be an embroidery hoop area, or some other defined polygon, and optionally an internal area of exclusion such as a design or plurality of designs placed in the hoop area, there is a need to automatically stitch down lines in a pseudo-random order known in the art as stippling. There are several variations on the pattern, but one requirement is near-uniform distance between lines of stitching. And they may not cross.
Prior art has been shown with fractals (Tsonis . . . , Pulse Microsystems, Mississauga, Canada), but that approach has a failure in that the fractal shape does not match the original shape, and thus there are dipped sections causing the stitch to either jump from section to section (undesirable because of time sewing and trimmer [a mechanical device in the machine] wear) or false paths which are too close.
Other prior art—Brother JP—uses a method where the pattern can be trapped and requires an exit to find its way out, which causes the lines of stitching to be closer together than optimal.
These embodiments solve that using maze theory and algorithms, with adaptations for embroidery.
A plurality of tessellated shapes, which may or not be identical in shape, is laid over the desired embroidery region at potentially a user-defined angle, with added spacing between the tessellations, defining graphical cells in a matrix. Each cell has data with it describing its center and the position and state of each edge, along with each edge's availability of an adjacent neighbor. Cells with fewer than two edges that are completely contained in the outline are discarded from the matrix.
As there is a minimal irregularity sometimes desired in stippling, the centers may be randomly offset by some small vector.
Shapes which are partially contained are flagged as such, along with the edges that are available for use in the design (those contained in the shape).
An initial starting point is defined, either randomly or by the user. The software then follows an algorithm (Drunkard's Path example) for selecting and adding cells to the sequence, labeling used cells as it goes, thereby ensuring that a single path can be traced into each and every useable cell in the matrix. Due to the nature of randomization added to the algorithm, the path is always different, although the seed used can be stable or user-altered to change the path. To ensure that the accidental use of continuous forward moves does not occur, the randomizer is presented with a reduced solution set where advancing forward in the same direction as the last move occurred happens. This makes the path turn frequently.
Once the path has been established, there needs to exist a return route in order to achieve the desired effect. For this reason, the actual entry and exit of each cell has its points set at evenly spaced intervals along the edge where travel exists. Thus, the path always forms a closed shape, running twice through each and every cell.
Where the path enters a cell is stable, as that maintains spacing between lines of stitching. Instead of following through the cell, however, the stitches run around the edges of the cell toward the exit edge. This provides additional shape and visual interest to the pattern. This is made possible by the cell spacing, which allows the edges not to touch.
Additional adjustment is made to the points discovered as the path travels through the cells. For each cell where the path enters and then exits, without going through another cell, this cell is flagged for shape adjustments.
The nodes of each entry, exit, and edge travel are set into a list, each given a Bezier handle set (or spline). In the case of Bezier, the handles may be adjusted in length and rotation by small amounts to create imperfect curvature, similar to what a skilled sewer would do by hand. Additional effects can be the lack of curvature and/or the erasure of nodes based on patterns. This produces a random, yet geometrically pleasing image.
Further, the resultant shape can now be taken as an outline and passed to other stitch generating apparatus. In this way motifs (or any other ornamentation) can be added.
A variation of this exists and is known in the industry as “Vermicelli Stitching.” This is similar in that it is random movements of small vector length and those movements are allowed to clip against the actual outlines. In this case we take the original stipple path and allow it to enter any cells that even touch the outline. A similar operation is performed, yet with a simple rule system for internal deformation of each cells travel route. The result is very similar to a manual process that is extremely time-consuming.
FIG. 11 illustrates an automatically generated pattern around embroidered letters in association with automated stippling in accordance with aspects of the embodiments.
FIG. 12 illustrates an automatically generated pattern from a “Drunkard” algorithm in association with automated stippling in accordance with aspects of the embodiments.
FIG. 13 illustrates an automatically generated less randomized version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments.
FIG. 14 illustrates an automatically generated “Leafy” version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments.
FIG. 15 illustrates an automatically generated “Geometric” version of the “Drunkard” pattern of FIG. 12 in association with automated stippling in accordance with aspects of the embodiments.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
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Using an existing embroidery design that has been created for applique, data is automatically created for a cutting machine, which will cut the applique. Currently, the user currently has to cut these by hand—a labor intensive process or use a custom die that can be expensive. The process only requires that the applique steps in the sewing sequence are labeled as such. Generally, the applique steps are so labeled in order for the design creator to be able to let the sewer know what they are doing.
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FIELD OF THE INVENTION
The present invention relates to a system and a method for recovering and increasing the pressure of seal leak gas for recycle or passage to further processing.
BACKGROUND OF THE INVENTION
In many industrial processes it is necessary that gases be compressed. Typically turbine compressors, centrifugal compressors, pumps, screw compressors and the like may be used for this purpose. Such equipment is referred to herein generally as compressors. The compressors typically include seals for the passage of rotary components through sidewalls, ends or the like of the compressors. These seals are typically designed to permit leakage of small amounts of compressed gases through the seal. Many times the passage of the gas is due to wear of the seal but in many instances seals are designed to permit leakage of a selected quantity of gas in normal operation.
The seal leak gas in many instances may be harmful to the environment or constitute a valuable product which is desired to be recovered. In either event, it is typically recovered by positioning covers over the seal areas to sealingly contain the area around the seal with the cover positioned so that the seal leak gas is collected inside the cover. The cover may include a passageway, including a seal, for a rotary component passing through the cover into the compressor. Covers can be of a wide variety of configurations so long as they are effective to sealingly contact the unit containing the seal so that the gas is recovered in the cover. The cover typically has included a line for the passage of the gas into the atmosphere or more frequently to a stack or the like where the gas can be burned or passed to a gas processing system. The seal at the passageway does not present a leakage problem since the gas inside the cover is typically at a low pressure.
Since this seal gas is at relatively low pressures, it typically does not flow readily to further treatment. Usually the seal gas is vented or combusted at atmospheric or near atmospheric pressure. Accordingly, a pump or a fan system is typically required to move the seal leak gas to a treatment area, stack area, or the like if the system is at any level of positive pressure. It is difficult to economically recompress the gas for reuse, if it is a desirable gas. The economics dictate that the gases be sent to a flare for burning or the like even if they are valuable in view of the expense to recover the gases and pass them back for reuse.
Accordingly, a continuing search has been directed to the development of a method and system for economically collecting such gases and increasing their pressure so that they may be either reused or readily passed to further treatment.
SUMMARY OF THE INVENTION
According to the present invention, a system is provided for collecting seal leak gas and increasing the pressure of the seal leak gas, the system comprising: at least one source of seal leak gas having a gas inlet at a first pressure and a pressurized gas outlet at a second pressure and including at least one seal having a gas leak; a cover positioned to collect seal leak gas from at least one gas leak from the source and having a seal leak gas outlet; a venturi having a pressurized gas inlet at a third pressure, a mixed gas outlet at a fourth pressure and a seal leak gas inlet; a first line in fluid communication with the gas outlet and with the pressurized gas inlet; and, a second line in fluid communication with the at least one gas leak and the seal leak gas inlet to produce a mixed gas through the mixed gas outlet at the fourth pressure, the fourth pressure being greater than the first pressure.
The invention further includes a method for collecting seal leak gas from leaks at seals in compression equipment and increasing the pressure of the seal leak gas, the method comprising: compressing an inlet gas stream at a first pressure in the compressor equipment to produce a compressed gas stream at a second pressure; collecting seal leak gas from at least one seal in the compressor equipment; passing a minor amount of the compressed gas stream through a venturi to create a reduced pressure inlet into the venturi; and, passing the seal leak gas to the reduced pressure inlet to produce a mixed gas stream at a third pressure, the third pressure being greater than the first pressure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic diagram of a system for the practice of a method for recovering seal leak gas, recompressing the gas and returning it economically and efficiently to the inlet of a compressor, according to the present invention;
FIG. 2 is a schematic diagram of an alternative embodiment of the present invention wherein a separation zone is used to separate undesirable liquid and/or solid components from a seal leak gas stream; and,
FIG. 3 is a schematic diagram of the use of the method and system of the present invention in conjunction with a natural gas liquefaction process.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the discussion of the Figures, the same numbers will be used throughout to refer to the same or similar components. Many valves, controls and the like which will be necessary in the practice of the present invention have not been shown since the use of these components and the components themselves are well known and do not require further description for the disclosure of the present invention.
The present invention is useful with a compression system which may include compressors, i.e., either axial, positive displacement, centrifugal, screw, and the like or simply pumps, which pump gas from a first pressure to a second higher pressure. In such instances there are seals involved in the equipment which may be designed to leak controlled amounts of seal leak gas through the seal either for purposes of cooling or the like. In other instances the leakage is the result of simple wear. In any event, according to the present invention, the seal leak gases are collected by the use of covers over the seal areas to recover the escaping seal leak gas. The compression system is used to increase the pressure of a gaseous stream. According to the present invention, a small slip stream of the compressed stream is withdrawn and passed through a venturi which enables the suction of the seal leak gas into the venturi for mixture with the higher pressure slip stream. The recovered mixed gas stream is at a significantly higher pressure than the seal leak gas and is readily passed back to the inlet to the compressor so that both the slip stream and the seal leak gas may be recovered.
The invention is shown in FIG. 1 , which shows a compressor 10 having a gas inlet 12 fed by a gas line 14 . A compressed gas outlet 16 is shown and represents a compressed gaseous stream. Seal leak gas escaping the compression system is shown through a plurality of lines 18 , line 23 and a line 20 , having seals 18 ′. Line 20 via covers 19 is connected to venturi 24 which enables the suction of the seal leak gas into the venturi for return to the process as described. In venturi 24 a slip stream from high pressure line 22 is mixed with the seal leak gas from line 20 and passed through a line 26 and a line 28 to line 14 . A line 30 is shown to indicate that the compressed gas may be passed to other treatment, such as flaring and the like. Valves 21 , 25 and 27 regulate flow through lines 22 , 28 and 30 . Particularly in processes, such as processes for the liquefaction of natural gas, the lost gas is a valuable mixed refrigerant. The use of the present invention allows the recovery and return of this mixed refrigerant to the process. The application of the present invention is by no means limited to mixed refrigerants but can be used with any gas pumped through a compression system where it is desirable to recover the seal leak gas.
In FIG. 2 a similar embodiment is shown but line 20 passes the seal leak gas to a separator 32 where liquids and solids can be separated from the seal leak gas with the solids and liquids being recovered through line 36 and the seal leak gases being passed via a line 34 to venturi 24 . Vessel 32 may also be employed as a surge vessel, allowing storage of the seal leak gas for a period of time with no flow passing through lines 22 and 26 . At an appropriate time, flow can be established through lines 22 and 26 to recover the seal leak gas stored in vessel 32 . Seals 18 ′ and covers 19 are positioned on lines 18 and 23 and valves 25 and 27 have been shown in lines 28 and 30 .
Venturi systems are considered to be extremely well known as shown for instances in Chemical Engineer's Handbook, Third Edition , Perry, John H. PhD, Editor, McGraw-Hill Book Company, Inc., 1950 pp. 1285.
In FIG. 3 a schematic diagram of the use of the present invention in combination with a natural gas liquefaction process is shown. A gas liquefaction facility 40 is shown having a natural gas inlet 42 and a liquefied natural gas outlet 44 . In this embodiment inlet gas stream 14 is the spent refrigerant from the gas liquefaction facility 40 with the compressed stream in line 16 comprising the compressed refrigerant for use in the gas liquefaction facility. It is well known to those skilled in the art that such compressed gas typically requires cooling prior to passing it to the gas liquefaction facility or in the gas liquefaction facility so that the compressed, cooled refrigerant may be vaporized to provide cooling in the gas liquefaction facility. Many such processes are known to those skilled in the art and the present invention is considered to be suitable for use with all such processes since it primarily relates to the recovery and repressurization of seal leak gas from the compression system.
The system of the present invention may include a plurality of compression units and the venturi can receive seal leak gas from a plurality of seals. The seals may be contained either in a single unit or a plurality of units. All such embodiments are considered suitable for the recovery of the seal leak gas by means well known to those skilled in the art. In other words, such gas streams have previously been recovered for treatment by either flaring or the like. The same collection system for the gases can be used for the present invention with the difference being the recovery of the gases for passage to the venturi so that the seal leak gases can be recovered at a sufficient pressure for reinjection into the system or passage to other treatment.
According to the present invention, the pressure of the gas stream in line 22 is at or slightly below the pressure in line 16 and flows through venturi 24 , drawing seal leak gas from line 20 into the gas stream from line 22 to produce a mixed gas stream which is recovered through line 26 at a pressure somewhat lower than the pressure in line 22 but greater than the pressure in line 14 . Wide variations in the process pressures are possible so long as the relationship between the pressures is maintained as described above. For instance, in processes for the liquefaction of natural gas the pressure of the refrigerant (line 16 ) may be relatively high (200 to about 1000 psi) and the pressure of the returned, spent refrigerant (line 14 ) may be relatively low (0 to about 200 psi). It is clear that when a slipstream of gas is taken through line 22 in an amount sufficient to produce the desired suction from line 20 , either directly or via separator 32 , that the pressure of the mixed stream will be well above the pressure in line 14 . The flow of high pressure gas through line 22 is desirably regulated by a valve 21 as known to those skilled in the art. The flow through line 22 will typically be limited to only that amount necessary to produce the required suction and the required pressure in line 26 . Since this gas is recovered along with the seal leak gas, there is no net loss of gas to the process. Further there is no requirement for additional compression equipment with the resulting maintenance and power requirements.
While the present invention has been described above primarily with respect to natural gas liquefaction processes, it is equally useful with other processes, such as pumping stations for gaseous products of various kinds. The present invention can generally be used in any process in which a gaseous stream is compressed and which experiences the loss of gas through seals.
While the present invention has been described by reference to certain of its preferred embodiments, it is pointed out that the embodiments described are illustrative rather than limiting in nature and that many variations and modifications are possible within the scope of the present invention. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments.
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A system and a method for recovering and increasing the pressure of seal leak gas for recycle or passage to further processing.
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This application is a CIP of Ser. No. 08/381,349 filed Jan. 31, 1995 now abandoned.
BACKGROUND AND DESCRIPTION OF PRIOR ART
This invention relates to weed and grass trimmers which are mobile and utilize low operator leverage forces to control and manipulate the trimmer. Lawn trimmers have previously been designed for use by persons with average physical abilities and are fairly easy to operate for short periods by these physically able persons. A need for a trimmer that can perform very well and be operated by persons of limited physical abilities, i.e.. elderly and handicapped, has been attempted by several prior art patents. There are benefits associated with some of the prior art but prior art does not singularly and completely eliminate the many problems that result in the use of such devices. The problems encountered are typically: 1) awkward and cumbersome use due to uneven weight distribution and wheel size and location, 2) lack of trim action on both sides and front of device, 3) lack of support of the motor, 4) loss of the automatic feed feature, 5) excessive operator forces required to maneuver the unit and, 6) lack of complete cutting height control.
The present invention eliminates all of the above problems simultaneously in a manner not disclosed in the prior art.
U.S. Pat. No. 5,048,615 to Feldman discloses a three-wheeled trimmer that utilizes a cutting head that is effective only on one side of the apparatus. The effective weight of the motor is substantially forward of the rear axle which requires operator forces during use similar to those needed to manipulate a lawn mower.
U.S. Pat. No. 4,922,694 to Emoto discloses a two-wheeled trimmer support that is adaptable for use with electric trimmers wherein the only weight to support is the cutting head assembly itself. The controllability is limited critically by the point of attachment of the support means and the positioning of the wheels.
U.S. Pat. No. 4,891,931 to Holland discloses a trimmer wheel kit that is adaptable to support a cutting head assembly wherein the weight to be supported is at the lower end.
U.S. Pat. No. 4,531,350 to Hutchmacher discloses a three-wheeled frame support for an electric trimmer which in effect converts it into a lawn mower.
SUMMARY OF PRESENT INVENTION
The present invention will be discussed here as a complete unit, although it should be noted that the components associated with the mobility of the unit can be utilized as a kit by persons possessing basic mechanical skills and tools to convert their existing trimmer to adapt to mounting on the mobility kit.
The drive means in the preferred embodiment utilizes a gasoline powered engine but it should be noted that any suitable drive means can be utilized that includes a rotating shaft as the final drive output means. The present invention is a weed and grass trimmer that solves all problems and concerns with existing trimming devices. Prior art approaches at best, solve a few of the many problems that were eliminated with the present invention. With the present invention, the weight is completely supported and the center of gravity is just forward of the single axle to provide very simple maneuvering which is the foremost desired feature for elderly and handicapped persons. The trimmer has only two wheels, which eliminates cumbersome movement along uneven surfaces. The rotary cutting head is extended forward to allow for a large diameter cut without obstruction being created by the wheels. The bumping action necessary to advance the cutting line is easily accomplished with a quick upward movement of the control handle. Cutting height is easily regulated by the operator since the center of gravity is close to the axle which gives the trimmer well balanced operation. The unit can be made as a whole with the trimming device included or as an inexpensive kit to be added to other trimmers. The trimmer will trim close to any wall or obstruction on either side of the trimmer. Prior art approaches typically have three or four wheels, like small lawn mowers that do not eliminate all problems associated with close easy trimming. The present invention consists of a trimmer unit with all components mounted to the axle and frame assembly, and with the control means being simply one handle. The single axle passes through the rear of the substantially triangular base frame. The cutting head is mounted to the front of the base frame with the motor and drive shaft angled rearward to place the effective weight of the motor slightly forward of the rear axle. The length of the axle can vary but is chosen for best reconciliation of both maneuverability and straight line stability.
The control handle is a tubular shaft with the throttle cable passing through the center. The throttle cable is encased in a flexible tubing extending the distance between the lower end of the handle and the connecting point on the engine. The control handle is attached to the base frame at the rear center where ease of control is best given to the operator for turning, balancing cutting height and maintaining forward movement.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the present invention;
FIG. 2 is a side view of the preferred embodiment of the present invention;
FIG. 3 is a front view of the preferred embodiment of the present invention;
FIG. 4 is a detailed view, in partial cross-section and phantom, of the external housing which contains the clutch assembly and the novel drive connection utilized in the preferred embodiment of the present invention;
FIG. 5 is a detailed view of the operator control handle grip assembly of the preferred embodiment of the present invention;
FIG. 6 is a complete view of the mobility kit showing all associated components of the preferred embodiment of the present invention; and
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The components incorporated in the assembly of the mobile frame portion of the present invention are simple to manufacture and assemble. Referring to FIG. 1 it is shown the overall assembled preferred embodiment with a typical gasoline powered lawn trimmer T adapted to the mobility kit. As shown in FIGS. 1 and 2 the previous mentioned center of gravity can be easily judged to be slightly forward of the rear axle 11, which provides very good stability and ease of cutting height control with low operator forces. FIG. 2 also shows the clearance provided between the cutting line 7 and the wheels 10. This clearance provides the ability to keep an adequate length of trim line extended about the cutting head assembly 5 to allow for close and easy trimming around obstructions. The maximum length of the cutting line 7 is controlled by the line cutter blade 13 mounted to the base frame 2. The front view as shown in FIG. 3 shows the typical gasoline powered lawn trimmer T as mounted on the unit with the drive shaft 4. Also as shown in FIG. 3 it is easy to recognize that the cutting path of the cutting line 7 extends beyond the outer edge of the wheels 10. Referring to FIG. 4, the drive shaft 4 can be seen in more detail with a typical attachment means provided to angle the motor towards the aft area at an angle to move the effective center of gravity to the desired area. The internal drive attachments located within the drive shaft 4 are accessible by removing the two clamps 14, as shown in FIG. 4. The specific internal drive attachments are typically a clutch gear assembly contained within a sleeve to operatively connect the motor drive means to the internal drive shaft components as shown in FIGS. 4 and 7.
The specifics of a preferred approach to the structure of the drive shaft 4 are best shown in the FIG. 7 cross-sectional view. In this view, the housing H surrounding the drive shaft 4 has been cut away to reveal the shaft and its connection to the blade drive. With the housing H cut away, the shaft 4 is shown encased within a pair of bearings 30, and including a toothed gear 40 mounted on the upper end thereof. The toothed gear 40 is positioned to operatively mesh with a second toothed gear 45, mounted on the motor output shaft 50.
The differential relationship between the toothed gears 40 and 45 is such that the ratio between the two is selected and structured to produce a greater cutting head speed, with less output from the motor shaft. In most existing trimmer drives of a non-wheeled design, there is a long, flexible output shaft driven by the motor, and connected to a gear on the end thereof, which gear is connected to the geared drive shaft in the cutting head. Because of the extended length of the output shaft from the motor, there is considerable torque exerted on the drive, causing it to experience damage and resultant weakness, ultimately leading to failure. Additionally, because of this torque and the resulting flexion of the output shaft, the energy output to the trimmer cutting head is substantially reduced. Therefore, the present arrangement, wherein the extended motor output shaft is unnecessary and therefore eliminated, not only increases the life of the equipment, but provides for an increased output efficiency relationship between the motor drive and the trimmer head.
To accomplish this reduction of torque and increased efficiency, it has been realized in the present invention that, due to the inclusion of a relatively short, substantially flat and rectangularly shaped connector 35, positioned between the clutch top head gear 45 in the drive shaft, thereby eliminating the conventional long output shaft, the motor can now be operated at approximately one-half normal speed, with no loss of output power.
Referring to FIG. 6, it illustrates the components that are available in kit form to adapt to an existing lawn trimmer. The base frame 2 is constructed of aluminum with additional aluminum angle 3 that is attached around the edges of the base frame 2 for reinforcement.
The preferred attachment means for the reinforcement is with the use of rivets while the additional components are attached with screws to facilitate removal in the event of needed repairs or replacement of these components. It should be noted that the base frame 2 can be constructed with a single piece of aluminum or other durable material that is formed to accommodate the mounting of the additional components i.e.. axle 11, handle 6 and any cutting head. The reinforced aluminum angle 3 is used for structure to attach the axle 11 to the rear of the frame 2. With reference to FIGS. 4 and 7, these illustrate the novel method of attaching the drive means 4, the cutting head assembly 5 and the handle 6 to the base frame 2. The handle 6 is formed at its lower end to create a flat edge 19 on the top and bottom and is also curved to facilitate the mounting to the base frame 2 at holes 18. The handle 6 has a curve at its upper end to provide the operator a natural grip when in the walking stance and to provide maximum leverage action on the trimmer. The detail in FIG. 5 shows the handle grip assembly 17 with its associated components and features. It illustrates the connection of throttle control 8 to a conventional throttle cable protected in tubing 12 (shown in phantom in FIG. 5). The throttle control lever 8 controls the speed of the rotary cutting head assembly. The trigger action throttle lever 8 is typical of those found on most gasoline lawn trimmers and is implemented on the present invention by utilizing a flexible tubing 12 (FIG. 1), to pass the cable through the tubular handle 6 to the necessary mechanical attachment on the motor 1. The button 9 on the end of the handle grip assembly 17 is an electrical motor stop switch which is activated in a momentary manner to stop the motor which can be either electric or gasoline. The button 9 is a spring loaded device that when pressed makes contact between two wired inner contacts 16 inside the handle grip assembly 17.
The specific electrical operation of the motor stop button 9 is dependent on the requirements of the trimmer adapted for use with the present invention and is readily implemented by those skilled in the art.
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A two-wheeled lawn trimmer, controlled with a handle attached to a frame which receives a conventional gasoline or electric powered rotary lawn trimmer, and provides balanced maneuverability with low operator forces while providing complete trimming access and cutting height control. Additionally the trimmer provides the operator access to vary the rotary cutting head speed as well as the ability to stop the motor device with controls mounted on the handle grip assembly.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to thermal printers and, more particularly, to a media supply for use in thermal ink transfer printers.
2. Description of the Prior Art
The use of electronically controlled thermal printers has increased very rapidly over the last few years. In particular, the market for thermal label printers has shown significant improvement with users focusing on utilizing label printing, especially, bar-code labelling, to improve capital asset management, inventory control or time and attendance reporting--or to meet corporate or industry mandated labelling requirements--such as automotive AIAG, electronic EIA or retail UCC/UPC specifications. Label printers typically incorporate a media supply of "peel away" labels adhered to a coated substrate wound in a rolled configuration. The media with the labels is drawn against a printing head, which, in turn, causes, by localized heating, a transfer of ink from an ink ribbon to a label.
In conventional label printers, the media is positioned or "hung" about a support and is drawn off the media core to be sent through the printing head by a drive motor associated with the printing head or with a take-up roll mechanism. A disadvantage of this prior art arrangement, however, is that the media when passing through the printing head is not under tension, which, undesirably affects registration of the printing head with the media labels. This results in less accuracy or registration of the print, and, consequently a relatively increased number of rejected printed units.
Accordingly, the present invention overcomes the disadvantages of the prior art by providing a media hub supply to be incorporated in a thermal transfer printers, which maintains a defined axis of rotation for the media and a constant drag or tension on the media during the printing process to thereby improve print quality and print registration.
SUMMARY OF THE INVENTION
A media supply for a thermal ink printer, includes a central shaft defining a longitudinal axis, a media hub for supporting a supply of media in a coiled configuration coaxially mounted about the central shaft and adapted for rotational movement thereabout, a hub clamp mounted to the media hub and adapted for axial movement therealong to accommodate media supplies of various lengths, and a torsion spring mounted about the central shaft and operatively engageable with the media hub to rotatably bias the media hub to an initial position corresponding to an unstressed condition of the torsion spring in response to movement of the media hub through a predetermined angular sector of rotation in one rotational direction, to thereby maintain a predetermined level of tension on the media. A locking member may be associated with the hub clamp to selectively secure the hub clamp at a predetermined axial position.
The media hub may include at least one longitudinal rib extending radially from the outer surface of the media hub and being dimensioned to engage the interior surface of the media supply in frictional engagement therewith. Preferably, first and second diametrically opposed longitudinal ribs are provided. The hub clamp may include an inner longitudinal recess dimensioned to accommodate the one longitudinal rib.
A clutch mechanism is associated with the media hub to permit the torsion spring to return to the unstressed condition in response to movement of the media hub beyond the predetermined angular sector of rotation. With this arrangement, a spring support collar is operatively connected to one end portion of the torsion spring wherein the other end portion of the torsion spring is operatively connected to the media hub. The clutch mechanism may further include a compression spring and a clutch plate. The compression spring is in operative engagement with the clutch plate and is dimensioned to bias the clutch plate toward the spring support collar. The clutch plate is in contacting frictional engagement with the spring support collar, wherein movement of the media hub beyond the predetermined angular sector of rotation causes release of the clutch plate from frictional engagement with the spring support collar to permit the spring support collar to move relative to the clutch plate to thereby enable the tension spring to return to an unstressed condition thereof. Preferably, first and second clutch plates are disposed on respective sides of the spring support collar.
In an alternate preferred embodiment, a media supply for a thermal ink printer, includes a central shaft defining a longitudinal axis, a media hub for supporting a spool of media and being coaxially rotatably mounted about the central shaft and having at least one radial rib extending axially along an outer surface of the media hub dimensioned to frictionally engage an interior surface of the spool of media, a torsion spring mounted about the central shaft and operatively engageable with the media hub to rotatably bias the media hub to an initial position corresponding to an unstressed condition of the torsion spring in response to movement of the media hub through first and second predetermined angular sectors of rotation in respective first and second rotational directions, to thereby maintain a predetermined level of tension on the media and clutch means associated with the media hub to permit the torsion spring to return to the unstressed condition in response to movement of the ribbon hub beyond either the first and second predetermined angular sectors of rotation.
Preferably, the media hub includes first and second diametrically opposed axial ribs. A hub clamp may also be mounted to the media hub and adapted for reciprocal axial movement therealong to accommodate media spools of various lengths. A locking member is associated with the hub clamp to selectively secure the hub clamp at a predetermined axial position.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described hereinbelow with reference to the drawing herein:
FIG. 1 is a schematic view of a printing section of a thermal label printer which may incorporate the media supply hub of the present invention;
FIG. 2 is a perspective view of the media supply hub;
FIG. 3 is a perspective view with parts separated of the media supply hub further detailing the components thereof; and
FIG. 4 is a cross-sectional view of the media supply hub taken along the lines 4--4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail wherein like reference numerals identify similar or like reference numerals throughout the several views, FIG. 1 illustrates in schematic view, a representative printing section of a thermal printer which may utilize the ink ribbon supply of the present invention. This printing section is similar to the printing section disclosed in commonly assigned U.S. Pat. No. 5,326,182, the contents of which are incorporated herein by reference. Printing section 10 generally includes frame 12, media supply section 14, printing head section 16, ink ribbon supply section 18 and ink take-up section 20. Media supply section 14 includes media hub 22 which supports media supply roll 24. Media hub 22 will be discussed in greater detail hereinbelow in connection with the discussion of FIGS. 2-4. Media supply roll 24 includes core 26 of sleeve-like configuration and media web 28, consisting of blank labels provided on a coated paper substrate, wound into a roll about the core 26. Media web 28 is directed to printing head section 16 through guide 30 by rotation of pinch roller 32. The rotation of pinch roller 32 is under the direction of a motor of a control system (not shown). After the print is applied to the media web 28, the web is directed to a take-up location (not shown).
Printing head section 16 includes support structure 34 and thermal head section 36 mounted to the support structure 34. Thermal head section 36 applies ink to media web 28 to provide the desired print pattern. Ink ribbon supply section 18 includes ribbon supply assembly 38 and a supply of ink ribbon 40 would into a coiled configuration about a ribbon core. Ink ribbon 40 is directed about roller 42 mounted to support structure 34 and through printing thermal head section 36. Ink ribbon 40, after emerging from between pinch roller 32 and thermal head section 36, passes over plate 44 and roller 46, both of which are mounted in support structure 34, to ink take-up section 20.
Ink take-up section 20 includes drive shaft 48, drive support hub 50 and ink take-up roll 52 which accumulates the used ink ribbon 40 in a rolled configuration. Drive shaft 48 and drive support hub 50 are typically driven by an electric motor to advance the ink ribbon 40 from ink ribbon supply 38.
The above-described printing section 10 is representative of only one type of printing section of a thermal ink printer, which may incorporate the media supply section 14 22 of the present invention. It is to be appreciated that other printing arrangements may be adapted to utilize the media supply section 14.
Referring now to FIGS. 2-4, the media supply assembly 22 in accordance with the principles of the present disclosure will be discussed in detail. Media supply assembly 22 includes media supply support or hub 100 about which the media supply roll 24 is positioned. Media hub 100 may be fabricated from a suitable metal including stainless steel or aluminum. Preferably, media hub 100 is formed of a plastic material and manufactured using molding techniques.
Media hub 100 is generally circular in cross-section to correspond to the circular core 26 of media supply roll 24. Media hub 100 includes first and second diametrically opposed longitudinal ribs 102 extending along the entire length of media hub 100. Longitudinal ribs 102 project radially outwardly and are advantageously dimensioned to form a frictional engagement with the interior surface of the core or spool 26 of media supply roll 24 in a manner whereby rotational movement of the media supply roll 24 causes corresponding rotational movement of the media hub 100. Longitudinal ribs 102 are each disposed on cantilevered portions 104 which are normally outwardly biased to the position shown in the Figures, but, are capable of inward flexing movement. Accordingly, upon positioning of the media spool 26 on media hub 100, cantilevered portions 104 may flex inwardly through engagement of longitudinal ribs 102 with the interior of the media spool 26 whereby the outward bias of the cantilevered portions 104 ensures a desired frictional engagement of longitudinal ribs 102 with the interior of the media spool.
Media hub 100 has an end flange 106 integrally formed at one end thereof which functions as a stop for one end of the media spool 26 positioned on media hub 100. A locking hub clamp or flange 108 is slidably mounted on media hub 100 to engage the other end of the media spool 26. Hub clamp 108 is selectively movable on media hub 100 to accommodate various length media spools. In a preferred arrangement, hub clamp 108 includes first and second longitudinal recesses 110 formed in the interior surface thereof. Recesses 110 accommodate longitudinal ribs 102 of media hub 100 and are dimensioned to permit hub clamp 108 to slide along media hub 100 without interference of the longitudinal ribs 102.
Hub clamp 108 further includes locking fastener 111, and locking nut 112 securely mounted within a correspondingly dimensioned mount 114 formed in hub clamp 108. Mount 114 is slidably received within correspondingly dimensioned longitudinal rail 116 defined in media hub 100. Locking fastener 111 has a threaded portion 118 which extends through and threadably engages the internal threaded aperture of locking nut 112 thereby permitting translation of the locking fastener 111 through the locking nut 112 through manual rotation of the fastener 111. Locking fastener 111 is movable to engage media hub 100 and thereby selectively secure the hub clamp 110 at a desired axial position to secure the media spool 24 between flange 108 and the hub clamp 108.
Referring still to FIGS. 2-4, media supply assembly 22 further includes stationary central shaft 120 about which media hub 100 rotates. In particular, central shaft 120 is received within central axial bore 100a extending through media hub 100. Central shaft 120 defines longitudinal axis 120a and possessing proximal shaft section 122, main shaft section 124 and distal shaft section 126. Proximal shaft section 122 defines a non-circular or eccentric cross-section while main and distal shaft sections 124, 126 each define circular cross-sections with the diameter of the distal shaft section 126 being reduced as shown. Distal shaft section 126 further includes internal threaded bore 128. Threaded bore 128 receives threaded fastener 130 and washer 132 to mount the media hub 100 to the central shaft 120.
A circular mounting flange 134 is affixed to proximal shaft section 122 of central shaft 120. Mounting flange 134 is directly mountable to frame 12 and includes three spaced apertures 136 which receive corresponding mounting fasteners (not shown) of frame 10 to mount the mounting flange 134 and thus mounting hub 100 to the frame 12.
Media supply 22 further includes a torsion spring mechanism which maintains a predetermined level of drag or tension on the media web 28 during rotation of media hub 100 through a predetermined angular sector of rotation. Torsion spring mechanism includes torsion spring 138 and spring support collar each being mounted in coaxial arrangement about central shaft 120. Torsion spring 138 is anchored at one end to spring support collar 140 by reception of proximal longitudinal portion 138a of the torsion spring 138 within a correspondingly dimensioned aperture 142 formed in support collar 140. The other end (e.g., distal) of torsion spring 138 is anchored in media hub 100 by reception of distal longitudinal portion 138b within a corresponding longitudinal bore 144 in media hub 100. Torsion spring 138 is dimensioned to rotatably bias media hub 100 to an initial rest position upon movement of media hub 100 in either rotational direction about longitudinal axis 102a. In the preferred embodiment, torsion spring has a spring contact ranging from about 20 to 90 ##EQU1##
Support collar 140 includes circular aperture 146 which is positioned about proximal shaft portion 122 of central shaft 120 in the assembled condition of the media supply. Aperture 146 defines a diameter greater than the cross-sectional dimension of eccentric proximal shaft section 122 such that spring support collar 146 is capable of rotating about the shaft section 122, the significance of which will be discussed in greater detail below.
A clutch mechanism including compression spring 148 and clutch plates 150, 152 are mounted about proximal shaft section 122 adjacent torsion spring 138 and spring support collar 140. Clutch plates 150, 152 are disposed on respective sides 140a, 140b of support collar 140 as shown. Clutch plates 150, 152 each define eccentric apertures 154 corresponding in dimension to the cross-sectional dimension of proximal shaft section 122. In this manner, clutch plates 150, 152 are rotatably fixed on central shaft, 102. A locking clasp 156 is mounted on proximal shaft section 104 adjacent clutch plate 152. Locking clasp 156 includes locking structure 158 adapted to be received within circumferential groove 160 formed in proximal shaft section 122 to secure the locking clasp 156 at a fixed axial position on central shaft 102.
Compression spring 148 is dimensioned to engage clutch plate 150 to normally bias the clutch plate 150 against spring support collar 136. Due to the fixed axial positioning of locking clasp 156, the biasing force of compression spring 148 establishes frictional relationships between the adjacent surfaces of clutch plate 150 and spring support collar 140 and the adjacent surfaces of clutch plate 152 and the support collar 140, thus establishing a slip clutch arrangement or mechanism. Generally, the slip clutch arrangement permits support collar 140 to move when the torque or torsional forces of torsion spring overcome the frictional relation between clutch plates 150, 152 and the support collar 140 thereby enabling the torsion spring 138 to return to an unstressed condition.
The clutch mechanism may further include a spacer 162 mounted about central shaft 102 interposed between mounting flange 134 and compression spring 148. Spacer 162 is intended to increase the degree of compressive forces exerted by compression spring 148 on clutch plate 150 to increase the torque level of the clutch. It is envisioned that spacer 162 may be removed to decrease the torque level. Similarly, a second spacer may be utilized as well to provide an increased torque level as well.
Further details of media supply of the present invention will be better appreciated by the following description of same in use to feed media web and labels to printing head section 16 with the printing section disclosed in FIG. 1. The media supply of the present invention may be utilized to feed media web 28 in either rotational direction of media hub 100. In particular, media hub 100 may rotate in the direction indicated by directional arrow "a" (FIG. 2) to feed the media to printing head section 16, or the media hub may rotate in the direction indicated by the directional arrow "b" to feed the media. The particular rotation or use of media hub will depend on the manner in which the media and labels are coiled on the supply spool.
In use of supply assembly 100 in the rotational direction "a" of media hub 100, the spool of media is positioned on the media hub 100 and the motor associated with pinch roller 32 is actuated to pull the media with labels off the media hub 100. As indicated above, media hub 100 is provided with longitudinal ribs 102 to frictionally engage the inner surface of the media spool 26 such that rotation of the spool 26 causes corresponding rotation of the media hub 100. Cantilevered portions 104 also assist in ensuring the desired frictional engagement as well. As media hub 100 rotates in the direction of directional arrow "a", spring support collar 140 remains stationary due to the frictional engagement of stationary clutch plates 150, 152 with the support collar 140. Such rotation causes torsion spring 138 to be tensioned, i.e., the rotation of media hub causes the distal end 138b of torsion spring 138 to rotate about the central axis 102a while the proximal spring end 138a remains stationary, thereby tensioning the torsion spring 138. As appreciated, the torsion spring 138 continually rotatably biases media hub 100 in the direction of arrow "b" corresponding to an unstressed condition of the torsion spring 138, thus maintaining a sufficient level of tension on the media during feeding and the printing step.
Media hub 100 is continually rotated in direction "a" to feed the media labels. Once the torsional force or torque of torsion spring 138 overcomes the frictional forces between the adjacent surfaces (as provided by compression spring 148) of clutch plates 150,152 and spring support collar 140, the clutch releases thereby permitting the support collar 140 to slip or move relative to the clutch plates 150,152 under the influence of torsion spring 138 to cause the support collar 140 to move (e.g., rotate in direction "b") relative to central shaft 102 to an initial position which corresponds to an unstressed condition of torsion spring 138. At this point, torsion spring 138 is reset and media hub 100 may be rotated in a similar manner (in direction "a") to feed media web 28 to printing head section 16.
Media hub 100 may also operate to feed media web 28 by rotating in the feed direction of directional arrow "b". During movement of media hub 100 in this direction, torsion spring 138 is caused to move in a direction corresponding to a stressed condition to cause the spring 138 to "unwind". The torsional characteristics of torsion spring 138 (i.e., the tendency of torsion spring 138 to return to its initial unstressed condition) continuously biases media hub 100 in direction "a" thereby maintaining a level of tension on the media web 28 during feeding and printing. Media hub 100 is rotated in direction "b" through a predetermined angular sector of rotation. When the torsional force of torsion spring 138 overcomes the forces (friction) between the adjacent surfaces of clutch plates 150, 152 and support collar 140, the slip clutch releases thereby permitting support collar 140 to rotate about proximal shaft section 122 in direction "a" to permit torsion spring 138 to assume its initial at-rest position. Thus, torsion spring 138 is reset to permit continued feeding media web 28 in direction "b".
Thus, the media supply assembly of the present invention maintains a sufficient level of tension on the media web 28 regardless of the rotational direction of media hub 100. Torsion spring 138 maintains a level of tension on the media web 28 during printing thereby improving print registration and quality. In addition, the uniform tension maintained on media web 28 via torsion spring 138 and clutch plates 150, 155 reduces dynamic loads caused by the acceleration of the media as the system (feed motor) accelerates. Another advantageous feature of torsion spring 138 is that it provides a predictable rotatable response of media hub 100 during starting and stopping. In particular, torsion spring 138 has a quantifiable or given angular natural frequency. Based on this natural frequency, the acceleration rates at which the printer operates (e.g. speed of the motor) may be pre-programmed or controlled to reduce the effect of the spring's angular frequency thereby minimizing undesired speed changes of the media web 28 during start-up and stopping. Thus, an internal self-contained control of undesirable acceleration loads is provided. This obviates the need as in conventional thermal printers for a separate spring loaded damper or buffer positioned between the media supply support and the printing head.
While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the disclosure, but merely as exemplifications of preferred embodiments thereof. For example, it is envisioned that other types of slip clutch arrangements are envisioned as well including powered or driven shafts through the same arrangement. Those skilled in the art will envision many other possible variations that are within the scope and spirit of the disclosure as defined by the claims appended hereto.
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A media supply for a thermal ink printer, includes a central shaft defining a longitudinal axis, a media hub for supporting a supply of media in a coiled configuration coaxially mounted about the central shaft and adapted for rotational movement thereabout, a hub clamp mounted to the media hub and adapted for axial movement therealong to accommodate media supplies of various lengths and a torsion spring mounted about the central shaft and operatively engageable with the media hub to rotatably bias the media hub to an initial position corresponding to an unstressed condition of the torsion spring in response to movement of the media hub through a predetermined angular sector of rotation in one rotational direction, to thereby maintain a predetermined level of tension on the media. A locking member may be associated with the hub clamp to selectively secure the hub clamp at a predetermined axial position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic pipe gridding method allowing implementation of codes for modelling fluids carried by these pipes.
2. Description of the Prior Art
The modes of flow of multiphase fluids in pipes are extremely varied and complex. Two-phase flows, for example, can be stratified, the liquid phase flowing in the lower part of the pipe, or intermittent with a succession of liquid and gaseous plugs, or dispersed, the liquid being carried along as fine droplets. The flow modes vary notably with the inclination of the pipes in relation to the horizontal and it depends on the flow rate of the gas phase, on the temperature, etc. Slippage between the phases, which varies according to whether the ascending or the descending pipe sections are considered, leads to pressure variations without there being necessarily any compensation. The characteristics of the flow network (dimensions, pressure, gas flow rate, etc.) must be carefully determined.
The TACITE simulation code takes into account a certain number of parameters that directly influence the physics of the problem which is considered. Examples of these parameters are the properties of the fluids and of the flow modes, the topographic variations (length, inclination, diameter variations, etc.), the possible roughness of the pipes, their thermal properties (number of insulating layers and their nature), or the arrangement of equipments along the pipe (pumps, injectors, separators, etc.) that lead to physical flow changes.
Gridding of a physical domain is an essential stage within the scope of numerical simulation. The validity of the results and the calculating times depend on the quality thereof. It is therefore fundamental to provide the code with a correct grid prior to starting simulation. The quality of a grid is generally judged from its capacity to properly describe physical phenomena without simulation taking up too much time, so that there always is an optimum grid for each problem studied. An unsuitable grid can lead, during implementation of the numerical pattern that governs the simulation, to errors that are difficult to detect, at least initially, and can even make calculation impossible and stop the execution of the code if it is excessively aberrant. Code users are not necessarily experienced enough in numerical analysis to produce a correct grid likely to really take into account the physical phenomena to be studied.
The topography of a cylindrical pipe can be compared to a succession of segments of lines connecting successive points. In cartesian coordinates, two successive points of the pipe on the vertical (ascending or descending) portions thereof can have the same abscissa (curve A in FIG. 1 ). It is therefore preferable to represent the elevation of each point as a function of its curvilinear abscissa along the pipe. With this mode of representation, successive points of the pipe of different elevations necessarily have two distinct curvilinear abscissas and the slope of the pipe sections is at most 45° to the horizontal (case of absolutely vertical ascending or descending sections, the curve in FIG. 1 ). One ordinate and only one always corresponds to an abscissa.
With some physical sense, certain gridding errors can be prevented. A finer grid pattern can be imposed in places of the pipe likely to undergo great physical parameter variations if they can be foreseen. Less calculations are thus carried out in each time interval while keeping the desired fineness in the important places. However, going from a fine cell to a coarser cell must be continuous with a view to obtaining a continuous solution.
FIG. 2 a shows for example a 2-km long W-shaped pipe section comprising four 500-m long section. If such a pipe is discretized with cells having a constant 40-m interval from beginning to end, the important points of the route at 500 m and 1500 m are left out. The simulation will not allow correctly showing the accumulation of liquid at these lower points of the topography. More important yet, the calculation is distorted by the fact that the angles of the W are replaced by horizontal segments of lines ( FIG. 2 b ). The physical phenomena observed are thus not the phenomena that are sought.
The method according to the invention allows obtaining automatic gridding or discretization of a pipe taking into account, in the best possible way, the topography and the physical parameters that affect the flow physics, subjected to the following constraints:
1—Ensure calculation convergence; 2—Best represent large accumulations of liquid at the lower points of the pipe; 3—Place the equipments on a cell edge; 4—Impose the same order of length on two consecutive cells; 5—Respect the total length of the pipe; 6—Limit the number of cells to the possible minimum by respecting the previous constraints so as not to penalize simulation with the calculating time.
Respecting the previous six constraints is not easy, but it is essential in order not to grid the pipe studied homogeneously, without having to care about the physics of the problem, like most automatic gridders do.
In order to limit the number of cells, one has to try to simplify, if possible, the topography in order to keep only the zones of the pipe where the significant profile variations likely to significantly influence the physical phenomena are present.
SUMMARY OF THE INVENTION
The method according to the invention allows automatic 1D gridding of a pipe exhibiting any topography or profile over the total length thereof, in order to facilitate implementation of flow modelling codes. The grid obtained with the method has a distribution of cells of variable dimensions, suitable to best take into account the flow physics.
The method according to the invention finds applications in many spheres. It can notably be used in the sphere of hydrocarbon production for implementation of codes allowing simulation of multiphase flows in oil pipes from production sites to destination sites.
The grid obtained by means of the method can notably be used for implementing the TACITE modelling code (registered trademark) intended to simulate steady or transient hydrocarbon flows in pipes. Various algorithms allowing to carry out flow simulation according to the TACITE code from the subject of U.S. Pat. No. 5,550,761 and French Patent 2,756,044 and FR-2,756,045 (U.S. Pat. No. 5,960,187).
The method is characterized in that, after defining a minimum and a maximum grid cell size, the pipe is subdivided into sections delimited by bends, a cell of minimum size is positioned on either side of each bend, large cells whose size is at most equal to the maximum size are positioned in the central portion of each section, and cells of increasing or decreasing sizes are distributed on the intermediate portions of each section between each minimum-size cell and the central portion.
The distribution of the cells of increasing or decreasing sizes on the portions of each intermediate section between each minimum-size cell and the central portion is for example obtained by determining the points of intersection, with each pipe section, of a pencil of lines concurrent at one point and forming a constant angle with one another.
The position of the vertex of the pencil of lines is for example determined on an axis passing through a bend of the pipe and perpendicular to each section, at a distance therefrom that depends on the size of the extreme cells of each intermediate portion and on the distance between them.
Automatic positioning of the cells with smaller cells in the neighbourhood of the ends of each section allows exercising great care in modelling of the phenomena in the pipe portions exhibiting changes of direction (inflection or bend).
The method according to the invention preferably comprises previous simplification of the pipe topography so that the total number of cells of the pipe grid allows realistic modelling of the phenomena physics within a fixed time interval.
According to a first implementation mode, the method comprises representing the pipe in form of a graph connecting the curvilinear abscissa and the level variation, and simplifying the number of sections a) by assigning to each point between two successive sections a weight taking into account the length of the sections and the respective slopes thereof, b) by selecting, from among the points arranged in increasing or decreasing order of weight, those whose weight is the greatest, the simplified topography being that of the graph passing through the points selected.
Selection of the points of the pipe whose weight is the greatest is obtained for example by locating, in the arrangement of points, a weight discontinuity that is above a certain fixed threshold.
According to another implementation mode, the method comprises representing the pipe in form of a graph connecting the curvilinear abscissa and the level variation, and simplifying the number of sections a) by forming the frequency spectrum of the curve representative of the pipe topography, b) by attenuating the highest frequencies of the spectrum showing the slightest topography variations, and c) by reconstructing a simplified topography corresponding to the rectified frequency spectrum.
Selection is made for example a) by sampling the curve representative of the pipe topography with a sampling interval that is so selected that the smallest section of the pipe contains at least two sampling intervals, b) by determining the frequency spectrum of the curve sampled by application, c) by correcting the spectrum by low-pass filtering whose cutoff frequency is selected according to a fixed maximum number of cells for subdividing the pipe, and d) by determining the topography corresponding to the rectified frequency spectrum.
The two automatic simplification modes described above can be applied independently of one another or successively, the second mode being preferably applied when the first mode does not allow obtaining a notable simplification of the topography.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the method according to the invention will be clear from reading the description hereafter of non limitative examples, with reference to the accompanying drawings wherein:
FIG. 1 shows two diagrammatic representations of the variation of elevation (E) of a pipe as a function of abscissa (A), according to whether the abscissa is a cartesian abscissa (ca) or a curvilinear abscissa (cu);
FIGS. 2 a , 2 b respectively show the diagrammatic topography of a W-shaped pipe in curvilinear coordinates, and an enlarged part of this topography, discretized with a suitable grid pattern;
FIG. 3 shows a mode of assigning a weight (P) to points of the topography of a pipe;
FIG. 4 shows an example of dimensionless weight spectrum (PA) as a function of length (L);
FIG. 5 shows an example of arrangement of points in decreasing weight plateaus; allowing to locate the position of a threshold and to simplify the topography of the pipe,
FIG. 6 shows an example of topography of a sea line (variation of elevation E as a function of curvilinear abscissa ca) comprising a riser at its ends;
FIG. 7 shows the simplified topography of the same line, obtained by selection of the weights;
FIG. 8 shows that, without the terminal risers, the general shape of the same line is more difficult to show;
FIG. 9 shows a typical frequency spectrum of a pipe;
FIG. 10 shows an example of a pipe section with a distribution of cells of various sizes, the smallest ones M 1 being positioned at the bends, the largest ones M 2 being placed in the central third, the intermediate cells M 3 being interposed and resulting from an interpolation I between the others;
FIG. 11 shows a mode of forming cells of increasing size;
FIG. 12 illustrates the mode of angular division of an intermediate portion on a pipe section; and
FIG. 13 shows the grid pattern obtained by implementing the method, on a 90-km long subsea line.
DETAILED DESCRIPTION OF THE INVENTION
I) Simplification of the Topography of a Pipe
The global shape of any profile is generally not difficult to bring out at first sight. The method according to the invention allows, by means of purely mathematical criteria, automatic determination of the configuration of a pipe based on a spectral analysis of the curve representative of the profile variations. Among all the spectra that can be associated with a given topography, a spectrum allowing distinguishing the portions of the profile to be simplified and the important profile portions is sought.
I-1) First Simplification Mode
In a topography, the only criteria according to which a point can be simplified in relation to another can only be the lengths of the sections surrounding it and the angular difference between them (FIG. 3 ). When the two (Section indices)−(Section lengths) and (Curvilinear abscissa of the points)−(Angular difference of the incoming and outgoing sections) “spectra” are constructed, it appears that they exhibit notable differences in their orders of magnitude, and also that these two spectra are independent so that, while simplifying negligible points in one, important points may have been suppressed in the other.
In order to group these two spectra into a single spectrum, each topographic point is assigned a weight that takes into account the section lengths and the angular differences that separate them. The following weighting is used for example:
Weight = L 1 · L 2 L 1 + L 2 ( P 2 - P 1 ) 2
wherein L 1 and L 2 are the lengths of the sections, and
P 1 = y 1 x 1 and P 2 = y 2 x 2
are the slopes. Thus, for the same lengths, the sections separated by the smallest slope difference will be simplified. And, for the same angles, the shortest lengths will be simplified.
Construction of the Spectrum
In most cases, the (Curvilinear abscissa−Weight) spectrum comprises a succession of peaks of all sizes. These spectra, such as the spectrum shown in FIG. 4 , cannot be directly analyzed generally. Under such conditions, the technique used here consists in classifying weights (P) in increasing or decreasing order and in assigning thereto the corresponding index of classification (CI) by weight from 1 to N. A (Log Weight−Index) representation is preferably used, which better shows the orders of magnitude because a jump by n on such a spectrum means a 10 a ratio on the weights. All the weights with the same order of magnitude are arranged on more or less horizontal plateaus. Two weights of different orders of magnitude are separated by a vertical segment of a line. A cascade spectrum is obtained, which allows readily reading the various orders of magnitude present in the topography. In the example of FIG. 5 for instance, the logarithmic spectrum Log P contains two distinct plateaus separated by a vertical segment.
The first triplet of consecutive points of the spectrum, defined for example by a threshold ΔP set on the logarithmic scale (ΔP=1 for example) between the second and the third, which follows a jump that is less than ΔP between the first and the second, is sought. The first two points are of the same order of magnitude. All the following points are of a negligible order of magnitude in relation to the first two points. One thus makes sure that all the weights on the right of the triplet in question will be at least 10 times smaller than the weight of the second one and therefore negligible in relation to the upstream points. The points of curvilinear abscissa corresponding to the greatest weights selected are selected in the correspondence table (weight index-curvilinear abscissa). The simplified topography will be the line passing through these points.
Three distinct parts can be seen in the topography example of FIG. 6 . It starts with a 3-km long riser, followed by a 20-km long sawtoothed horizontal part and ending with a 200-m long riser, also sawtoothed. Its spectrum is the spectrum of FIG. 5 . The first triplet, which meets the thresholding criterion, consists of points 4 , 5 and 6 . The simplification threshold is the point of index 6 . A jump greater than 2 in the logarithmic scale separates the horizontal plateaus on either side of points 5 and 6 . It is thus possible to check that the points on the left of index 5 have weights that are at least 100 times greater than those on the right of index 6 .
In this example, the topography is simplified by keeping only the points of the curvilinear abscissa corresponding to the weights that are greater than or equal to the weight of point 6 . The simplified topography of FIG. 7 is obtained. The global shape is kept. All the slight sawtoothed variations on the 20-km long horizontal part have been suppressed. The number of points has changed from 43 initially ( FIG. 6 ) to 6, that is, reduction by a factor of 7. This case is particularly well suited for thresholding since the various orders of magnitude are visible on the initial topography.
The first simplification mode that has been described is easy to implement and based on relatively simple algorithms that can be quickly executed. It is suited to topographies having several orders of magnitude, such as the previous topography that has been considerably simplified because it contained points with weights that were negligible in relation to one another.
The problem is quite different if only the central part of this topography is taken into account, the terminal risers being removed, because in this case, as can be seen in FIG. 8 , the general shape of the pipe is more difficult to show. Simplification of this topography by a line connecting the starting point and the end point is not possible. The spectrum is exactly the same as the spectrum of the initial topography, apart from the fact that it starts at point 6 . No threshold is present in this part of the spectrum, the points all have the same order of magnitude. And even if the greatest weight is more than 100 times greater than the smallest, one goes from one to the other continuously.
I-2) Second Simplification Mode
For topographies with points having the same order of magnitude, that cannot be processed with the previous thresholding method, spectral filtering is carried out. The slight pipe profile variations lead to high frequencies in the Fourier spectrum of the function representative of the topography. The topography can be simplified by cutting or by attenuating the highest frequencies of the frequency spectrum thereof.
The topographic function is therefore sampled and its spectrum is determined by means of the FFT (Fast Fourier Transform) method. The sampling interval must be small enough to show all the frequency ranges while avoiding aliasing. The number of sampling points is therefore so selected that the smallest pipe section contains at least two subdivisions to ensure that the Fourier transform will act upon all the parts of the pipe, even the most insignificant ones. Attenuation of the high frequencies must of course be done judiciously and it must be adjusted so that the topographic function obtained remains representative of the initial function.
The simplest filtering method consists for example in applying a threshold, all the Fourier coefficients (FC) whose amplitude A(FC) is below this threshold being eliminated (coefficients below 40 for instance in the example of FIG. 9 ). Only the information contained in the frequencies below this threshold is kept. The corresponding simplified topography is reconstructed by inverse transform.
The maximum number of oscillations of the reconstructed signal is thus set by fixing a cutoff frequency. If only the first ten frequencies are kept, the reconstructed function will follow the general shape of the pipe, with a maximum of twenty extrema.
II) Selection of the Cell Sizes on Each Pipe Section
Principle
The gridding principle grids independently the pipe sections between two imposed edges. Since the advantage of a correct gridding is to allow correct observation of the liquid accumulations in the bends, gridding is preferably refined down at the points of the topography where liquid or gas is likely to accumulate. A short cell is therefore preferably placed before and after each bend, larger ones being positioned between the bends. On the other hand, fine gridding of the intermediate parts of the sections between the bends is unnecessary.
The topography of the pipe having been previously simplified (when necessary) and reduced to a certain number of sections, a minimum size and a maximum size are fixed for the cells. The edges of each one (inlet, outlet) are first isolated by small cells, then cell edges are inserted on the central part thereof, which is longer. It is generally not necessary to refine down the grid pattern at the inlet and at the outlet outside the portions at the ends of each section, and edges can therefore be inserted over a large part of the length of each section (⅔ of the length for example) of the maximum size that has been set.
The distribution can be so selected that, for example, the size of the cells after that following a bend gradually increases over a third of the length of the section, remains constant over the following third and eventually decreases over the last third before the final short cell as shown in FIG. 10 .
Definition of the Minimum and Maximum Cell Lengths
Two cell lengths are defined, a minimum length for isolating the cell edges imposed by small cells, and a maximum length for gridding the middle of the sections contained between two short cells.
All the cells that are inserted after these two stages are deduced from the initial cells by interpolation between a short cell and a long cell. They therefore have intermediate sizes. This property is interesting. It shows that the total number of cells will necessarily range between the number that would have been obtained by homogeneously gridding with the minimum length and the number obtained in the same way but with the maximum length. The total number of cells can thus be controlled from the minimum and maximum sizes.
One of the constraints of automatic gridding lies in the total number of cells. It must generate the shortest possible simulation time, while allowing good display of the physical phenomena. Experience shows, on the one hand, that a discretization of less than 40 cells does not allow good physical description of the problems. On the other hand, grid patterns with more than 150 cells generate simulations which are too long. Default gridding must therefore be flexible enough and comprise 40 to 100 cells.
Such a small number of cells is not always suitable. The ideal number of cells for a precise case depends on several factors taken into account in the numerical pattern. For the same topography for example, a case comprising a large number of section changes requires a finer grid. The method according to the invention allows the user considerable latitude to select the suitable total number of cells.
From this number N, the code calculates the minimum Min and maximum Max lengths as follows:
Min = L N + P
Max = L N - P
Parameter P allows reduction of the difference between the minimum and maximum lengths so as to make the grid progressively homogeneous for the large number of cells.
This parameter is for example defined as follows. For a number of cells selected less than or equal to 60 for example, it is set at 60 for example. It is the default grid. The value of the parameter is 40. The value of the smallest cell will be L/100 and the value of the largest cell, L/20. The total number of cells will range between 20 and 100.
A number of cells greater than or equal to 150 means that the modelling process to be dealt with is certainly more delicate. A homogeneous grid therefore has to be constructed. The minimum and maximum sizes must then be close to one another. The parameter is therefore set at 10. The total number of cells will then range between
L N + 10 and L N - 10 .
Above 150, the desired number of cells is obtained to within 20 cells.
For the grid to become progressively homogeneous between 60 and 150 cells, the parameter is calculated by linear interpolation between the two domains, which is expressed as follows:
P=40 if N<60
P = - 1 3 N + 60 if 60 < N < 150
P=10 if N>150.
This parameter being determined, it is possible to isolate the edges imposed by short cells and to discretize the middle of the sections by long cells.
It only remains to find a means for gradually going from a short cell to a long cell. The lengths of the three cells are known, and cell edges are to be inserted on the central part. The sizes of the cells thus created must range between the sizes of the extreme cells. Starting from the smallest one, the next cell must always be longer than the previous one, but shorter than the next.
In the general case, there is no pair (ƒ,n)∈(R,N) such that:
the size of a cell is deduced from that of the previous one by multiplying it by a factor f, the sum of the n lengths thus created is equal to (L1+L2), the size of the last cell can be expressed as follows: ƒ n+1 ,L 1 f.
This is also the case for a possible linear interpolation between the two cells. Knowing the three lengths imposes an overabundance of data in relation to the unknowns. It is then impossible to meet all the constraints.
In order to overcome this difficulty, a geometric type method is proposed, using the property according to which segments L1, L2, L3, L4 formed on an axis by the lines of a regular pencil (with a constant angular space α in relation to one another), whose vertex is outside this axis, vary progressively (FIG. 11 ).
A pipe section ( FIG. 12 ) is considered starting with a small cell (0, x1) of length L1 and ended by a cell (x2, x3) of length L3>L1. It can be shown that there is a point on a perpendicular to the pipe section at abscissa 0 such that the cells of lengths L1 and L3 are seen from this point under the same angle α. The ordinate y of this vertex is given by the relation:
y = L 1 ( L 1 + L 2 ) ( L 1 + L 2 + L 3 ) ( L 3 - L 1 )
wherein L2 is the length of segment (x1, x2).
Angle β then has to be divided into N equal parts, N being equal to the entire division of β by α, i.e.
N = E ( β α ) .
Each of the N angles dividing β is always greater than or equal to α.
The principle used for inserting the cell edges is both simple and reliable. It allows, by means of a single parameter, to create either a uniform grid, or a heterogeneous grid fined down at the important points.
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An automatic pipe gridding method allowing implementation of codes for modelling fluids carried by pipes is disclosed which has for example an application for oil pipes. The method comprises, considering a minimum and a maximum grid cell size, subdividing the pipe into sections including bends, positioning cells of minimum size on either side of each bend, positioning large cells whose size is at most equal to the maximum size in the central portion of each section, and distributing cells of increasing or decreasing size on the intermediate portions of each section between each minimum-size cell and the central portion. The method preferably comprises a prior stage of simplification of the pipe topography by means of weight or frequency spectrum analysis, so as to reduce the total number of cells without affecting the representativeness of the flow model obtained with the grid pattern.
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FIELD OF THE INVENTION
This invention relates to a seat. It particularly relates to a seat of an orthopedic nature. It further relates to a seat that may be easily transported and that is adapted for use under a variety of conditions.
BACKGROUND OF THE INVENTION
Orthopedic seats may be generally characterized as seats that are contoured so as to provide proper support for the skeletal structure, whereby they promote good posture, thereby permitting the relaxation of the muscles of the body.
Seats of this nature are described in U.S. Pat. Nos. 3,288,525 (CERF); 3,740,096 (BRIDGER) and 3,177,036 (HALTER).
The seats described in these patents are each of a solid one-piece construction. They are moreover, permanently combined with a backrest portion, often the seat and backrest being unitarily molded. Such seats are not suited for easy transportation, for example into stadiums or other public spectator facilities, where the seating provided is often marginal comfort, even for able bodied persons.
Considerable effort has been expended in the past to provide comfortable seating for wheelchairs, for users may be confined for extended periods of time. Moreover, the compressive loading on the gluteus, and on the bony protuberances comprising the ischea and the coccyx may be higher in the case of persons confined to a wheelchair than is otherwise the case, as the reactive forces generated by work effort of the upper body portions will in the main be expended by reactive forces transmitted through the seated areas, whereas a non-confined person may well choose not to be seated at times of higher loadings on the upper body portions.
The seats as envisioned herein are generally for use in conjunction with existing seat units such as chairs, whether wheeled or otherwise. The seat portions of chairs do not conform to any standard, and the front to back distance of such seat portions may vary considerably. Thus, the front to back measurement of the seat portion of a compact wheelchair or a typical secretarial chair is about 35 cms, whereas the seat portion of full size chairs will commonly measure about 45 cms from front to back. The prior art seats are not readily utilizable with a wide variety of different seating units.
As indicated above, orthopedic seats are generally combined into a single unit with an orthopedic backrest. In my U.S. patent, I describe a backrest which is easily portable. It is desirable to provide an orthopedic seat which is also easily portable and which may be readily linked with the backrest, without the use of tools, to form a combination unit.
It is then an object of this invention to provide a readily transportable seat.
It is another object of the invention to provide orthopedic seats that are easily transportable.
It is a further object of the invention to provide orthopedic seats that may be readily adapted for use with different seating units that are already existing.
It is a still further object of the invention to provide a portable seat that may be adapted for use with a variety of seat units without requiring tools or the like.
It is yet another object of the invention to provide a transportable orthopedic seat that may be combined with a suitable backrest to form an orthopedic seating unit.
SUMMARY OF THE INVENTION
In accordance with one aspect of my invention, a seat comprises a rear portion having a forwardly facing transversely disposed bounding edge, a front portion having a rearwardly facing transversely disposed bounding edge, and a mid portion having transversely disposed bounding edges facing the respective bounding edges of the front and rear portions, and hinge means which connects the mid portion to the front and rear portions whereby the portions may be rotated generally about these bounding edges, so that the portions may lie one on the other for convenient transportation.
Preferably the portions are upholstered, and the upholstering material may suitably form a flexible hinge along the whole or substantial part of the length of the facing, transverse edges of at least two of the portions.
Suitably, the front portion attaches to the mid portion by a detachable fastener such as a zipper or loop and pile fastener, whereby it may be detached to shorten the front to back measurement of the seat.
Desirably, the front portion hinge line connecting to the mid portion locates rearwardly of the forward transverse edge of the mid portion, whereby medial portions of the upper surface of the front portion may be approximately in vertical alignment with the forward edge of the mid portion when the front portion is hinged downwardly.
The portions of the seat comprise a support layer and an overlaying foam layer. The support layer will normally be shaped and contoured so as to position the body correctly in relation to the seat, and so as to provide a suitable delocalized support for the skeletal structure, in particular to relieve the pressure on the bony protuberances comprising the tuberous ischea of the pelvis and the coccyx.
These aspects, and other objects and aspects of the invention will become more apparent from the following consideration of a preferred embodiment of the invention, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an orthopedic seat in accordance with the invention in upper, front right perspective view;
FIG. 2 is a perspective view from a similar position to FIG. 1, but shows the shell frame structure only of the seat;
FIG. 3 is a cross section along 3--3 of FIG. 2, and shows additionally a foam layer of which the seat is comprised overlaying the shell frame;
FIG. 4 is a fragmentary cross section along 4--4 of FIG. 2, on enlarged scale, showing in addition foam material and an upholstery cover and the coupling of the seat portions together;
FIG. 5 shows the seat in perspective view folded for carrying;
FIG. 6 shows the seat in perspective view with the front portion partially detached, and
FIG. 7 shows the seat in side elevation with the front portion hanging down over a narrow seat platform, and further shows the manner of coupling the seat to a backrest.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, an orthopedic seat in accordance with the invention is identified therein by the numeral 10. Seat 10 comprises a front portion 12, a mid portion 13 and a rear portion 14.
With particular reference to FIGS. 2 and 3, the seat 10 comprises a support layer 20 and a foam layer 30 overlaying the support layer. The individual portions of the support layer are also numbered from front to rear as 22, 23 and 24 and the portions of the foam layer similarly as 32, 33 and 34. Support layer 20 is resiliently movable under the weight of a user, but is formed of a relatively high tensile strength material so as to resist localized deformation forces such as may be encounted if the seat 10 is employed with a seat platform having an uneven surface. Conveniently support layer 20 amy be cold molded from fibreglass reinforced polyester resin, or injection molded from a so called engineering thermoplastic resin, for example a polycarbonate resin. Expediently support layer 20 may be formed as a single unit, and cut transversely to provide individual portions 22, 23, and 24.
Support layer 20 has an axially aligned central ridge 25, sometimes referred to as the gluteal ridge, for supporting the gluteal muscles. Ridge 25 increases in height from the back to front of the seat 10. The effect of this is to forwardly, upwardly incline the femur, thereby tending to raise the knee joint of a seated person, which has the effect of reducing pressure on the sciatic nerve. The lateral edges 26 and the rear edge 27 of the support layer 20 are gently upswept from adjacent the margins thereof, the transverse cross section of the support layer having a smoothly curved, shallow W shape. The rear edge 27 has a camel back plan profile defining a V shaped cut out 28. Support layer 20 is symmetrical about the central axis thereof. The central ridges 25 and the upswept lateral edges cooperate to assist in positioning the body of a seated user symmetrically in the seat, whereby the coccyx of the user is positioned slightly rearwardly of cutout 28, thereby relieving the pressure thereon, and also on the spine.
Foam layer 30 has a plan form similar to the plan form of support layer 20, but extends beyond the bounding edges of each of the portions 22, 23 and 24. The foam layer 30 is desirably adhered to the support layer 20 for location purposes.
Seat portions 12, 13 and 14 include an upholstering cover 50 which completely envelopes the support layer 20 and overlaying foam layer 30. Conveniently, rear portion 14 and mid portion 13 are contained within a common envelope, the portions being separated by a connecting link 51 of upholstery material, thereby providing a hinge about which the two portions may relatively rotate. The upholstery cover material 50 forming connecting link 51 is stitched together at 52, so as to flatten the link. Preferably, the upholstery material from which the cover 50 is formed is a stretch material, and it is stretched about the foam layer 30 and support layer 20 so as to compress the foam layer 30 somewhat. The extension of the foam layer 30 beyond the bounding edges of support layer portions 22, 23, and 24 acts to increase the radius of curvature adopted by the cover material about the edges of the support layer, so reducing the stress and wear on the material in this area. The extension further serves to provide an axial separation of adjacent portions 12, 13 and 14 of the seat, so as to reduce the risk of flesh being trapped or nipped between the facing transverse edges of these portions. Connecting link 51 also serves somewhat to separate portions 13 and 14.
Front portion 12 of seat 10 is upholstered separately from portions 13 and 14 by a cover 53. Cover 53 is sewn so as to provide a rearwardly, downwardly facing transverse tail 54 along the rearward transverse edge of the front portion. A detachable zip fastener 55 has one selvage sewn to tail 54, the other to the underside of mid portion 13 somewhat rearwardly of the forwardly facing transverse edge thereof at 56. Effectively, the fastener 55 is overlain by the portions 12 and 13 of the seat 10, whereby it is unlikely to snag on the clothing of a user.
A buckled strap 60 secured to cover 50 at the axial mid point of the rear edge 27 of the seat. A tongue 62 also secures to cover 50 at this point, but above strap 60. Tongue 62 is provided at the distal end with a loop pad 63 on one side thereof, and on the opposed side a pile pad 64. A second pile pad 65 locates on the same side as the loop pad 63, but adjacent the proximal end of the tongue.
Having described the salient constructional features of the seat 10, the manner of use thereof will now be briefly referred to . With reference to FIG. 1, seat 10 will be used in conjunction with a seating platform (not shown) having a front to back dimension at least approximately equal to the front to back dimension of seat 10. When seat 10 is used in conjunction with a smaller seat platform such as may be provided by the seat S of a secretarial chair (FIG. 6) front portion 12 may be conveniently removed, as suggested by this Figure. Alternately, when used in conjunction with rudimentary seating platforms as suggested by the platform P in FIG. 7, which may well have a rough forwardly facing surface against which the calves of a seated person bear. In this instance, forward portion 12 may be suspended downwardly and it will hinge on stitch line 56 and reside generally rearwardly of the forward edge of mid portion 13.
In use separate from a backrest, tongue 62 is folded over, whereby the loop and pile pads 63 and 65 provided on the same side of the tongue engage together. When it is desired to combine the seat 10 together with a backrest B as suggested in FIG. 7, tongue 62 is unfolded to expose the loop pad 63. This pad may simply be engaged with the fabric cover of backrest B. Preferably, however, where the backrest has a cover C with a loop and pile closure L, tongue 62 is adapted whereby its loop and pile structure at the distal end thereof may be inserted between the loop and pile closure elements L, in the direction of the arrow 66, to engage therewith. A backrest of suitable construction is described in U.S. Pat. No. 4,556,254, commonly assigned herewith.
For transportation of the seat 10, the hinge structure provided by link 51 and fastener 55 permits the three portions 12, 13 and 14 thereof to be folded in concertina fashion, and secured closed by buckled strap 60, as shown in FIG. 5.
The foregoing embodiment is illustrative only of the invention, and it is not to be taken as being limitative of at least the broad aspects of the invention, as many variations thereof may be made, and such variations are intended to fall within the scope of the claims appended hereto.
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An orthopedic seat comprises three portions that are linked together to permit the seat to be folded into a compact package for carrying. The linkage permits the forward portion of the seat to be detached so as to adapt the seat for use with chairs having a small back to front dimension.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 11/514,930, filed Sep. 5, 2006 now U.S. Pat. No. 7,181,751, which is a continuation of U.S. application Ser. No. 10/714,944, filed Nov. 18, 2003 now U.S. Pat. No. 7,107,602, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an objective-lens driving apparatus for use in an optical disk apparatus for recording information on the recording surface of an optical disk or for reading the information recorded thereon.
In an optical disk apparatus for recording information on a disk-shaped recording medium or for reading and reproducing the information recorded thereon, an objective-lens driving apparatus is an apparatus for driving an objective lens in the focusing direction (i.e., the direction in which the objective lens comes closer to/goes away from the recording surface of the optical disk) and in the tracking direction (i.e., the radial direction of the disk). Here, the objective lens light-converges light on the optical-disk recording surface. Generally, the objective-lens driving apparatus incorporates a movable unit with the objective lens, a supporting member for supporting this movable unit, and a magnetic circuit with a yoke and a permanent magnet. A focusing coil and a tracking coil are mounted onto the movable unit. Applying a driving current to the focusing coil drives the movable unit in the focusing direction by an electromagnetic force generated by the interaction with a magnetic flux from the permanent magnet. Similarly, applying the driving current to the tracking coil drives the movable unit in the tracking direction by an electromagnetic force generated by the interaction with the magnetic flux from the permanent magnet.
In the objective-lens driving apparatus like this, if the objective lens has been inclined, an optical aberration occurs, thereby enlarging a light-converged spot. This makes it impossible to correctly record the information on the disk, or results in a degradation in the reproduced signal.
Conventionally, there has been known the optical pick-up unit which was devised in order to suppress this inclination of the objective lens (e.g., JP-A-2001-101687). This optical pick-up unit incorporates the tracking coil, the focusing coil, the objective lens, a lens holder, a damper base for supporting the lens holder in a movable manner via plural suspension wires, the yoke, and the permanent magnet. Moreover, in the optical pick-up unit, the configuration size of the permanent magnet is set so that electromagnetic forces, which exert themselves on the tracking coil and/or the focusing coil thereby to cause the optical axis of the objective lens to be inclined from its reference axis, will substantially cancel out each other.
In the above-described related art, the configuration size of the permanent magnet is set at a certain value. This setting has canceled out moments generated at the focusing coil and the tracking coil when the objective lens is displaced, thereby suppressing the inclination of the objective lens. This setting, however, imposes the restrictions on the sizes of the permanent magnet, the focusing coil, and the tracking coil. As a consequence, the design's degree-of-freedom has been limited, and there has been acquired only effect that is not necessarily sufficient in an aspect of the apparatus's downsizing.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide an objective-lens driving apparatus and an optical disk apparatus where, even when the objective lens is displaced, the inclination of the objective lens become small, and the dependency on the size of magnetic circuit become low.
In order to accomplish the above-described object, in the present invention, there is provided an objective-lens driving apparatus that incorporates the following configuration components: an objective lens for light-converging light on the recording surface of an optical disk, a lens holder for holding the objective lens, a focusing coil and a tracking coil mounted onto the lens holder, plural supporting members for supporting a movable unit, which incorporates the lens holder, in a movable manner in the focusing direction and the tracking direction with respect to a fixed unit, a yoke member having a magnetic substance, and plural permanent magnets located in parallel to the tracking direction and on both ends of the movable unit. Moreover, in the objective-lens driving apparatus, on one side of the movable unit parallel to the tracking direction, the permanent magnets are located on both ends of the movable unit. Simultaneously, on the other side of the movable unit parallel to the tracking direction, the permanent magnets is located at a position closer to the center of the movable unit.
With the permanent magnets, the focusing coil and the tracking coil arranged as described above, this configuration makes it possible to reduce each moment generated at each of the focusing coil and the tracking coil when the objective lens is displaced. Accordingly, it becomes possible to implement the objective-lens driving apparatus and, eventually, the optical disk apparatus where the inclination of the objective lens becomes small.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a diagram for illustrating an embodiment of the objective-lens driving apparatus according to the present invention;
FIG. 2 is a top view for illustrating a major portion in FIG. 1 ;
FIG. 3 is a top view for illustrating a magnetic-flux density distribution in the embodiment in FIG. 1 ;
FIG. 4 is a side view for illustrating the magnetic-flux density distribution in the embodiment in FIG. 1 ;
FIG. 5 is a diagram for explaining a force that exerts itself on a focusing coil in the embodiment in FIG. 1 ;
FIG. 6A and FIG. 6B are diagrams for explaining a force that exerts itself on a tracking coil in the embodiment in FIG. 1 ;
FIG. 7 is a diagram for illustrating another embodiment of the objective-lens driving apparatus according to the present invention;
FIG. 8 is a top view for illustrating a magnetic-flux density distribution in the embodiment in FIG. 7 ; and
FIG. 9 is a diagram for illustrating still another embodiment of the objective-lens driving apparatus according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, the explanation will be given below concerning embodiments of the present invention. The optical disk apparatus according to the present invention drives the objective lens by the objective-lens driving apparatus so as to light-converge light on the recording surface of the optical disk, thereby performing the reproduction of information.
FIG. 1 is an exploded perspective view for illustrating the configuration of an embodiment of the objective-lens driving apparatus. In FIG. 1 , the x-axis direction is the tangent direction of a not-illustrated disk. The y-axis direction is the tracking direction, i.e., the radial direction of the disk. The z-axis direction is the focusing direction, i.e., the optical-axis direction of an objective lens 1 .
A focusing coil 3 , i.e., a driving coil, is wound around a lens holder 2 for holding the objective lens 1 . Also, four tracking coils 4 a , 4 b , 4 c and 4 d are mounted onto the lens holder 2 . One ends of wire-like supporting members 6 having electrical conductivity are fixed to a fixed unit 7 , and the other ends thereof are fixed to the side of the lens holder 2 .
Here, the objective lens 1 , the lens holder 2 , the focusing coil 3 and the tracking coils 4 a to 4 d turn out to become a movable unit.
Permanent magnets 11 a , 11 b , and 11 c whose magnetization directions become identical to the x-axis direction in the drawing are mounted onto and fixed to outer yokes 9 , i.e., yoke members including a magnetic substance, on both ends of the movable unit parallel to the tracking direction.
From bottom surfaces of the outer yokes 9 , inner yokes 10 , i.e., yoke members including a magnetic substance similarly, are located such that the inner yokes 10 are positioned at the inner side of the focusing coil 3 . This configuration forms a magnetic circuit where magnetic fluxes from the permanent magnets 11 a to 11 c pass through to the inner yokes 10 and the outer yokes 9 .
Here, on one side of the movable unit parallel to the tracking direction which is the y-axis direction in the drawing, the permanent magnets 11 a and 11 b are arranged apart on both ends of the movable unit. Simultaneously, on the other side of the movable unit parallel to the tracking direction, the permanent magnet 11 c is arranged at the center of the movable unit.
FIG. 2 is a top view of the objective-lens driving apparatus illustrated in FIG. 1 . Here, in order to make the drawing easy to see, there are illustrated only the focusing coil 3 , the tracking coils 4 a to 4 d , the permanent magnets 11 a to 11 c , the outer yokes 9 and the inner yokes 10 . As illustrated in FIG. 2 , the tracking coils 4 a and 4 b are located at positions closer to the center of the movable unit with respect to the permanent magnets 11 a and 11 b arranged apart in the tracking direction. The tracking coils 4 c and 4 d are arranged at the outer side of the movable unit with respect to the permanent magnet 11 c . Namely, the permanent magnets 11 a and 11 b confront the coil-wound portions positioned at the outer sides of the tracking coils 4 a and 4 b , and the permanent magnet 11 c confronts the coil-wound portion positioned at the inner side of the tracking coils 4 c and 4 d.
In the objective-lens driving apparatus configured as described above, the magnetic-flux density distribution turns out to become one as illustrated in a top view in FIG. 3 and a side view in FIG. 4 . Each magnetic-flux density is the largest at the central portion of each permanent magnet, and becomes smaller and smaller at a more peripheral portion of each permanent magnet. Accordingly, as illustrated in FIG. 3 , the distribution turns out to be as follows: on the side of the permanent magnets 11 a and 11 b , the magnetic-flux density is large on both ends of the focusing coil 3 . On the side of the permanent magnet 11 c , the magnetic-flux density is large at the center of the focusing coil 3 .
Concerning the polarities of the permanent magnets 11 a to 11 c , the polarities on the closer sides to the focusing coil 3 are set to be the N poles, and the polarities on the sides of the outer yokes 9 are set to be the S poles. Then, as illustrated in FIG. 5 , causing an electric current 51 to flow through the focusing coil 3 generates a z-direction force at the focusing coil 3 , thereby driving the movable unit in the z-axis direction which is the focusing direction. Also, as illustrated in FIG. 6A and FIG. 6B , causing an electric current 52 to flow through the tracking coils 4 a to 4 d generates y-direction forces at the tracking coils 4 a to 4 d , thereby driving the movable unit in the y-axis direction which is the tracking direction.
Here, assuming that the displacement amount in the tracking direction is equal to Δy, and that the displacement amount in the focusing direction is equal to Δz. Then, as illustrated in FIG. 5 , the side of the focusing coil 3 confronting the permanent magnets 11 a and 11 b goes away from the permanent magnet 11 a , and confronts the permanent magnet 11 b entirely. As a result, a force 61 generated at the portion confronting the permanent magnet 11 a becomes smaller, and a force 62 generated at the portion confronting the permanent magnet 11 b becomes larger. This generates a moment 91 by the center of the movable unit around the x axis. Meanwhile, on the side of the focusing coil 3 confronting the permanent magnet 11 c , the magnetic-flux density distribution from the permanent magnet 11 c does not change, and the center of the movable unit is displaced by Δy. This, based on a force 63 in the focusing direction and the distance Δy with the center of the movable unit, generates a moment 92 by the center of the movable unit around the x axis. At this time, the moment 91 and the moment 92 become opposite to each other in their directions. This condition reduces a resultant moment that exerts itself on the focusing coil 3 as a whole. Namely, it becomes possible to reduce the force that causes the movable unit to be inclined.
Also, in the tracking coils 4 a to 4 d , as illustrated in FIG. 6A and FIG. 6B , in addition to the driving forces 71 , 74 , 77 , and 80 in the tracking direction, forces 72 , 75 , 78 , and 81 are generated at the upper-side portions of the tracking coils 4 a to 4 d , and forces 73 , 76 , 79 , and 82 are generated at the lower-side portions thereof. At this time, the movable unit is displaced by Δz in the focusing direction. As a result of this, the forces generated at the lower-side portions of the tracking coils 4 a to 4 d become larger than the forces generated at the upper-side portions thereof. This generates a moment 101 and a moment 102 by the center of the movable unit around the x axis. Here, however, the portions confronting the permanent magnets 11 a and 11 b differ from the portion confronting the permanent magnet 11 c in that the portions are positioned at the outer sides of the tracking coils 4 a and 4 b and the portion is positioned at the inner side of the tracking coils 4 c and 4 d . This makes the generated forces opposite to each other in their directions. Accordingly, the moment 101 generated at the tracking coils 4 a and 4 b and the moment 102 generated at the tracking coils 4 c and 4 d become opposite to each other in their directions. This condition reduces a resultant moment that exerts itself on the tracking coils 4 a to 4 d as a whole. Namely, it becomes possible to reduce the forces that cause the movable unit to be inclined.
As having been described so far, in the present embodiment, on one side of the movable unit parallel to the tracking direction, the permanent magnets 11 a and 11 b are arranged apart on both ends of the movable unit. Simultaneously, on the other side of the movable unit parallel to the tracking direction, the permanent magnet 11 c is arranged at the center of the movable unit. This configuration makes it possible not only to reduce the moments generated at the focusing coil 3 , but also to reduce the moments generated at the tracking coils 4 a to 4 d . Consequently, it becomes possible to implement the objective-lens driving apparatus and, eventually, the optical disk apparatus where the inclination of the objective lens is found to be small.
Next, referring to FIG. 7 and FIG. 8 , the explanation will be given below concerning another embodiment of the present invention. FIG. 7 is an exploded perspective view for illustrating the configuration of the objective-lens driving apparatus in the present embodiment. FIG. 8 is a top view for illustrating its major portion and its magnetic-flux density distribution.
Two focusing coils 33 a and 33 b , i.e., driving coils, and four tracking coils 34 a , 34 b , 34 c and 34 d are mounted onto a lens holder 32 for holding an objective lens 31 . One ends of wire-like supporting members 36 having electrical conductivity are fixed to a fixed unit 37 , and the other ends thereof are fixed to the side of the lens holder 32 .
Permanent magnets 41 a , 41 b , 41 c and 41 d whose magnetization directions become identical to the x-axis direction in the drawing are mounted onto and fixed to outer yokes 39 , i.e., yoke members including a magnetic substance, on both ends of the movable unit parallel to the tracking direction.
From bottom surfaces of the outer yokes 39 , inner yokes 40 , i.e., yoke members including a magnetic substance similarly, are arranged such that the inner yokes 40 are positioned at the inner side of the focusing coils 33 a and 33 b.
Here, on one side of the movable unit parallel to the tracking direction which is the y-axis direction in the drawing, the permanent magnets 41 a and 41 b are arranged apart on both ends of the movable unit. Simultaneously, on the other side of the movable unit parallel to the tracking direction, the permanent magnets 41 c and 41 d are arranged at positions closer to the center of the movable unit.
As illustrated in FIG. 8 , the tracking coils 34 a and 34 b are arranged at positions closer to the center of the movable unit with respect to the permanent magnets 41 a and 41 b arranged apart on both ends of the movable unit. The tracking coils 34 c and 34 d are arranged at the outer side of the movable unit with respect to the permanent magnets 41 c and 41 d . Namely, the permanent magnets 41 a and 41 b confront the coil-wound portions positioned at the outer sides of the tracking coils 34 a and 34 b , and the permanent magnets 41 c and 41 d confront the coil-wound portions positioned at the inner sides of the tracking coils 34 c and 34 d.
The magnetic-flux density distribution turns out to be as follows: on the side of the permanent magnets 41 a and 41 b , the magnetic-flux density is large on both ends of the movable unit. On the side of the permanent magnets 41 c and 41 d , the magnetic-flux density exhibits two peaks at positions closer to the center of the movable unit.
The present embodiment differs from the first embodiment in that the focusing coil is divided into the two units, and that there are provided the four permanent magnets. However, on one side of the movable unit parallel to the tracking direction, the permanent magnets 41 a and 41 b are arranged apart on both ends of the movable unit. Simultaneously, on the other side of the movable unit parallel to the tracking direction, the permanent magnets 41 c and 41 d are arranged at the positions closer to the center of the movable unit than both ends thereof. This configuration allows the implementation of basically the same effect concerning a reduction in moments generated at the focusing coils 33 a and 33 b when the objective lens is displaced, and a reduction in moments generated at the tracking coils 34 a to 34 d at that time.
Moreover, the two focusing coils 33 a and 33 b are arranged in a manner of being apart from each other. This configuration allows the creation of a space within the side surface of the movable unit, thereby making it possible to permit light to pass through the movable unit. Accordingly, it becomes possible to implement the fabrication of a thin-type driving apparatus.
Also, the two permanent magnets are each arranged on both ends of the movable unit. This configuration makes it possible to make the size of the permanent magnets 41 a and 41 b identical or substantially identical to the size of the permanent magnets 41 c and 41 d . This, further, allows an effect of facilitating the maintenance of a balance among the driving forces.
Next, referring to FIG. 9 , the explanation will be given below concerning still another embodiment of the present invention. FIG. 9 is a top view for illustrating a major portion of the objective-lens driving apparatus in the present embodiment.
In the present embodiment, each of permanent magnets 111 a , 111 b , 111 c and 111 d is formed as a double-pole-magnetized permanent magnet. In addition, each of tracking coils 121 a , 121 b , 121 c and 121 d is located in a manner of confronting each of boundary portions of the double magnetic poles. The other configuration is the same as the one in FIG. 7 and FIG. 8 , and thus the explanation thereof will be omitted here.
The employment of this configuration allows a characteristic that, in each of the tracking coils 121 a , 121 b , 121 c and 121 d , the portion generating a driving force in the tracking direction includes two sides. This characteristic makes it possible to increase the driving force in the tracking direction, thereby allowing the fabrication of the objective-lens driving apparatus having a high driving efficiency, i.e., a small power consumption.
According to the present invention, it becomes possible to provide the objective-lens driving apparatus and the optical disk apparatus where, even when the objective lens is displaced, the inclination of the objective lens is small.
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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An optical disk apparatus includes an objective-lens for converging light on a recording surface of an optical disk, and an objective-lens driving device for driving the objective-lens in a focusing direction and a tracking direction. The objective-lens driving device includes a focusing coil having four edges to enclose the objective-lens, and two pairs of permanent magnets. The two pairs of permanent magnets are arranged so that polarities thereof become identical to sides of focusing coil, wherein one pair of the permanent magnets is arranged opposed to an edge of the focusing coil, and an other pair of the permanent magnets is arranged opposed to an edge opposite to the edge of the focusing coil. An interval between two magnets constituting the one pair of permanent magnets is narrower than an interval between two magnets constituting the other pair of permanent magnets.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a memory device, and more specifically, to a hybrid switch cell embodied as a cross-point cell using a nonvolatile ferroelectric capacitor and a hybrid switch, and a nonvolatile memory device using the hybrid switch cell to improve the whole size.
2. Description of the Prior Art
Generally, a ferroelectric random access memory (hereinafter, referred to as ‘FeRAM’) has attracted considerable attention as next generation memory device because it has a data processing speed as fast as a Dynamic Random Access Memory DRAM and conserves data even after the power is turned off.
The FeRAM having structures similar to the DRAM includes the capacitors made of a ferroelectric substance, so that it utilizes the characteristic of a high residual polarization of the ferroelectric substance in which data is not deleted even after an electric field is eliminated.
The technical contents on the above FeRAM are disclosed in the Korean Patent Application No. 2001-57275 by the same inventor of the present invention. Therefore, the basic structure and the operation on the FeRAM are not described herein.
The conventional FeRAM device comprises a switching device which is switched depending on a voltage of a word line and connects a nonvolatile ferroelectric capacitor to a sub bit line. The nonvolatile ferroelectric capacitor is connected to a terminal of the switching device and a plate line.
Meanwhile, in the conventional FeRAM, a NMOS transistor whose switching operation is controlled by a gate control signal is used as the switching device.
However, the above-described NMOS transistor requires an additional area for gate control when a cell array is embodied with a switching device, which results in increase of the whole chip size.
SUMMARY OF THE INVENTION
Accordingly, it is a first object of the present invention to reduce the whole size of a nonvolatile memory device by embodying a cross-point cell with a nonvolatile ferroelectric capacitor and a hybrid switch.
It is a second object of the present invention to improve operation characteristics of a memory cell by effectively driving read/write operations in a cell array using the hybrid switch.
In an embodiment, a hybrid switch cell comprises a nonvolatile ferroelectric capacitor and a hybrid switch. The nonvolatile ferroelectric capacitor, connected to a word line, stores a logic data value. The hybrid switch is connected between the nonvolatile ferroelectric capacitor and a bit line, and selectively switched depending on voltages applied to the word line and the bit line.
Preferably, the hybrid switch has a sequentially deposited structure of the bit line, the hybrid switch, the nonvolatile ferroelectric capacitor and the word line, and the nonvolatile ferroelectric capacitor and the hybrid switch are formed where the word line and the bit line are crossed.
In an embodiment, a memory device using a hybrid switch cell comprises a plurality of hybrid switch cell arrays, a plurality of word line driving units and a plurality of sense amplifiers. Each of the plurality of hybrid switch cell arrays comprises a plurality of hybrid switch cells each located where a word line and a bit line are crossed. The plurality of word line driving units selectively drive the word line. The plurality of sense amplifiers sense and amplify data transmitted through the bit line. The memory device further comprises a data bus, a main amplifier, a data buffer and an input/output port. The data bus is shared by the plurality of sense amplifiers. The main amplifier amplifies data of the data bus. The data buffer buffers data inputted/outputted in the main amplifier. The input/output port, connected to the data buffer, inputs/outputs data.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a circuit diagram of a hybrid switch cell according to an embodiment of the present invention;
FIG. 2 is a cross-sectional diagram of a hybrid switch of FIG. 1 ;
FIG. 3 is a cross-sectional diagram of the hybrid switch cell of FIG. 1 ;
FIG. 4 is a graph illustrating the operation of the hybrid switch of FIG. 1 ;
FIGS. 5 a to 5 c are a circuit diagram and graphs illustrating the word line/bit line voltage dependency of the hybrid switch cell according to an embodiment of the present invention;
FIG. 6 is a block diagram of a memory device using a hybrid switch cell according to an embodiment of the present invention;
FIG. 7 is a layout diagram of a hybrid switch cell array of FIG. 6 ;
FIG. 8 is a circuit diagram of a hybrid switch cell array of FIG. 6 ;
FIG. 9 is a circuit diagram of a sense amplifier of FIG. 8 ;
FIG. 10 is a circuit diagram illustrating another example of the hybrid switch cell array of FIG. 6 ;
FIG. 11 is a circuit diagram of the sense amplifier of FIG. 10 ;
FIG. 12 is a timing diagram illustrating the read mode of the nonvolatile memory device using a hybrid switch cell according to an embodiment of the present invention; and
FIG. 13 is a timing diagram illustrating the write mode of the nonvolatile memory device using a hybrid switch cell according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a circuit diagram of a hybrid switch cell according to an embodiment of the present invention.
A hybrid switch cell comprises a nonvolatile ferroelectric capacitor FC and a hybrid switch HSW which are connected serially. Here, the hybrid switch HSW is connected between one electrode of the nonvolatile ferroelectric capacitor FC and a bit line BL. The other electrode of the nonvolatile ferroelectric capacitor FC is connected to a word line WL.
FIG. 2 is a cross-sectional diagram of the hybrid switch HSW of FIG. 1 .
The hybrid switch HSW comprises a PN diode switch 1 and a PNPN diode switch 2 which are connected in parallel between the nonvolatile ferroelectric capacitor FC and the bit line BL.
In the PN diode switch 1 , a P-type region is deposited on a N-type region. The P-type region of the PN diode switch 1 is connected to one electrode of the nonvolatile ferroelectric capacitor FC, and the N-type region of the PN diode switch 1 is connected to one electrode of the bit line BL.
In the PNPN diode switch 2 , a P-type region, a N-type region, a P-type region and a N-type region are sequentially deposited. The upper N-type region of the PNPN diode switch 2 is connected to one electrode of the nonvolatile ferroelectric capacitor FC, and the lower P-type region of the PNPN diode switch 2 is connected to the bit line BL.
The above-described hybrid switch HSW is represented by a symbol as shown in FIG. 1 .
FIG. 3 is a cross-sectional diagram of the hybrid switch cell of FIG. 1 .
The hybrid switch HSW is deposited on the bit line BL of the hybrid switch cell. The nonvolatile ferroelectric capacitor FC is deposited on the hybrid switch HSW. Also, the word line WL is connected to the upper portion of the nonvolatile ferroelectric capacitor FC.
Here, the nonvolatile ferroelectric capacitor FC comprises a top electrode 3 , a ferroelectric film 4 and a bottom electrode 5 . The top electrode 3 is connected to the word line WL, and the bottom electrode 5 is connected to the P-type region of the PN diode switch 1 and the upper N-type region of the PNPN diode switch 2 .
The bit line BL is connected to the N-type region of the PN diode switch 1 and the lower P-type region of the PNPN diode switch 2 .
FIG. 4 is a graph illustrating the operation of the hybrid switch HSW of FIG. 1 .
Although a voltage applied to the nonvolatile ferroelectric capacitor FC increases toward a positive direction on the basis of the bit line BL and reaches a power voltage Vo, the hybrid switch HSW is kept off. As a result, current does not flow.
Thereafter, if the voltage applied to the bit line BL more increases and reaches a threshold voltage Vc, the PNPN diode switch 2 is turned on depending on the forward operation characteristic of the diode. As a result, as the hybrid switch HSW is turned on, the amount of current remarkably increases. Here, when the voltage applied to the bit line BL is over the threshold voltage Vc, a value of current I is affected by resistance (not shown) connected to the bit line BL to serve as load.
After the PNPN diode switch 2 is turned on, the large amount of current can flow although a small voltage Vs is applied to the bit line BL. Here, the PN diode switch 1 is kept off by the reverse operation characteristic.
On the other hand, if a predetermined voltage is applied to the nonvolatile ferroelectric capacitor FC increases toward a negative direction on the basis of the bit line BL, that is, a predetermined voltage is applied to the word line WL, the hybrid switch HSW is turned on by the forward operation characteristic of the PN diode switch 1 . Then, current flows at a random operation voltage state. Here, the PNPN diode switch 1 is kept off by the reverse operation characteristic.
FIGS. 5 a to 5 c are a circuit diagram and graphs illustrating the word line/bit line voltage dependency of the hybrid switch cell according to an embodiment of the present invention.
Referring to FIG. 5 a , Vfc refers to a voltage flowing the nonvolatile ferroelectric capacitor FC connected between the word line WL and a node SN, and Vsw refers to a voltage flowing in the hybrid switch HSW connected between the node SN and the bit line BL.
FIG. 5 b is a diagram illustrating the word line WL voltage dependency of the hybrid switch cell according to an embodiment of the present invention.
If a voltage of the word line WL increases while a voltage of the bit line BL is fixed at a ground voltage level, the voltage of the word line WL is distributed to the nonvolatile ferroelectric capacitor FC and the hybrid switch HSW.
In other words, if the voltage of the word line WL increases while the voltage of the bit line BL is at the ground level, the PN diode switch 1 of the hybrid switch HSW is turned on at a small voltage. As a result, current flows.
Here, the small voltage Vsw is distributed by the forward operation characteristic of the PN diode switch 1 in the hybrid switch HSW. On the other hand, the voltage of the word line WL is distributed as the large voltage Vfc to the nonvolatile ferroelectric capacitor FC. Therefore, the operation characteristics by the voltage of the word line WL are improved.
FIG. 5 c is a diagram illustrating the bit line BL voltage dependency of the hybrid switch cell according to an embodiment of the present invention.
If a voltage of the bit line BL increases while a voltage of the word line WL is fixed at a ground voltage level, the voltage of the bit line BL is distributed to the nonvolatile ferroelectric capacitor FC and the hybrid switch HSW.
In other words, if the voltage of the bit line BL increases while the voltage of the word line WL is fixed at the ground voltage level, the PNPN diode switch 2 of the hybrid switch HSW is kept off until the voltage of the bit line BL reaches a threshold voltage Vc. The PN diode switch 1 of the hybrid switch HSW is kept off by the reverse operation characteristic of the PN diode switch 1 . As a result, most voltage of the bit line BL is distributed as the large voltage Vsw to the hybrid switch HSW.
On the other hand, when the hybrid switch HSW is turned off, the voltage of the bit line BL is distributed as the small voltage Vfc to the nonvolatile ferroelectric capacitor FC. As a result, data stored in the nonvolatile ferroelectric capacitor FC are not changed.
Thereafter, when the voltage of the bit line BL rises to reach over the threshold voltage Vc, the PNPN diode switch 2 of the hybrid switch HSW is turned on, and most voltage of the bit line BL is distributed to the nonvolatile ferroelectric capacitor FC, and the voltage Vfc increases. As a result, new data are written in the nonvolatile ferroelectric capacitor FC of the hybrid switch cell.
FIG. 6 is a block diagram of a memory device using a hybrid switch cell according to an embodiment of the present invention.
In an embodiment, the memory device comprises a plurality of hybrid switch cell arrays 10 , a plurality of word line driving units 20 , a plurality of sense amplifiers 30 , a data bus 40 , a main amplifier 50 , a data buffer 60 and an input/output port 70 .
Each hybrid switch cell array 10 comprises a plurality of hybrid switch cells arranged in row and column directions as described in FIG. 1 . A plurality of word lines WL arranged in the row direction are connected to the word line driving unit 20 . A plurality of bit lines BL arranged in the column direction are connected to the sense amplifier 30 .
Here, one hybrid switch cell array 10 is correspondingly connected to one word line driving unit 20 and one sense amplifier 30 .
The plurality of sense amplifiers 30 share one data bus 40 . The data bus 40 is connected to the main amplifier 50 which amplifies data applied to the data bus 40 .
The data buffer 60 buffers the amplified data applied to the main amplifier 50 . The input/output port 70 outputs output data applied from the data buffer 60 to the outside or applies input data applied from the outside to the data buffer 60 .
FIG. 7 is a layout diagram of the hybrid switch cell array 10 of FIG. 6 .
The hybrid switch cell array 10 comprises a plurality of word lines WL arranged in the row direction and a plurality of bit lines BL arranged in the column direction. A unit cell C is located only where the word line WL and the bit line BL are crossed. That is, a cross-point cell is embodied. Since it is unnecessary to form devices in other regions, a cell can be formed in a space necessary to form the word line WL and the bit line BL without requiring an additional area.
Here, the cross-point cell refers to a hybrid switch cell using the hybrid switch HSW comprising a nonvolatile ferroelectric capacitor FC located where a bit line BL and a word line WL are crossed. The hybrid switch cell does not comprise a NMOS transistor using an additional word line WL or gate control signal but comprises two connection electrode node.
FIG. 8 is a circuit diagram of the hybrid switch cell array 10 of FIG. 6 .
The hybrid switch cell array 10 comprises a plurality of word lines WL< 0 >˜WL<n> arranged in the row direction and a plurality of bit lines BL< 0 >˜BL<m> arranged in the column direction. A unit cell C is located only where the word line WL and the bit line BL are crossed. Here, the unit cell C comprises one nonvolatile ferroelectric capacitor FC and one hybrid switch HSW.
The plurality of sense amplifiers 30 are connected one by one to the bit lines BL. Each sense amplifier 30 compares a voltage applied from the bit line BL with a reference voltage REF previously set when a sense amplifier enable signal SEN is activated, and amplifies the comparison result.
A bit line pull-down device N 1 is connected to the bit line BL< 0 >, and a bit line pull-down device N 2 is connected to the bit line BL<m>. When a bit line pull-down signal SBPD is activated, a ground voltage is applied to the bit line BL and pull down the bit line BL to a ground level.
The above-described hybrid switch cell array 10 is operated so that each nonvolatile ferroelectric capacitor FC may store one data.
FIG. 9 is a circuit diagram of the sense amplifier 30 of FIG. 8 .
The sense amplifier 30 comprises an amplifying unit 31 and a column selecting switching unit 32 .
Here, the amplification unit 31 comprises PMOS transistors P 1 ˜P 3 and NMOS transistors N 1 ˜N 3 . The PMOS transistor P 1 , connected between a power voltage terminal and a common source terminal of the PMOS transistors P 2 and P 3 , has a gate to receive a sense amplifier enable signal SEP. The cross-coupled PMOS transistors P 2 and P 3 latch a power voltage applied through the PMOS transistor P 1 .
A NMOS transistor N 3 , connected between a ground voltage terminal and a common source terminal of NMOS transistors N 1 and N 2 , has a gate to receive a sense amplifier enable signal SEN. The cross-coupled NMOS transistors N 1 and N 2 latch a ground voltage applied through the NMOS transistor N 3 .
Here, the sense amplifier enable signal SEN has a phase opposite to that of the sense amplifier enable signal SEP. When the sense amplifier enable signal SEN is activated, the amplification unit 31 is operated. One output terminal of the amplification unit 31 is connected to the bit line BL<m>, and the other output terminal of the amplification unit 31 is connected to a terminal to receive a reference voltage REF.
The column selecting switching unit 32 comprises NMOS transistors N 4 and N 5 . The NMOS transistor N 4 , connected between the bit line BL<m> and the data bus 40 , has a gate to receive a column selecting signal CS<n>, thereby controlling input/output of the data /D. The NMOS transistor N 5 , connected to the terminal to receive the reference voltage REF and the data bus 40 , has a gate to receive the column selecting signal CS<n>, thereby controlling input/output of the data D.
FIG. 10 is a circuit diagram illustrating another example of the hybrid switch cell array 10 of FIG. 6 .
The hybrid switch cell array 10 comprises a plurality of word lines WL< 0 >˜WL<n> arranged in the row direction and a plurality of paired bit lines BL and /BL arranged in the column direction. A unit cell C is located only where the paired bit lines BL and /BL are crossed. The unit cell C comprises one nonvolatile ferroelectric capacitor FC and one hybrid switch HSW.
One sense amplifier 30 is connected one by one to the paired bit lines BL and /BL. When a sense amplifier enable signal SEN is activated, each sense amplifier 30 is simultaneously operated to amplify data applied from the paired bit lines BL and /BL.
A bit line pull-down device N 6 is connected to the bit line /BL< 0 >, and a bit line pull-down device N 7 is connected to the bit line BL< 0 >. As a result, when a bit line pull-down signal SBPD is activated, the bit line pull-down devices N 6 and N 7 apply a ground voltage to the paired bit lines BL and /BL, and pull down the paired bit lines BL and /BL to a ground voltage level.
The above-described hybrid switch cell array 10 is operated so that two nonvolatile ferroelectric capacitors FC may store one data.
FIG. 11 is a circuit diagram of the sense amplifier 30 of FIG. 10 .
The sense amplifier 30 comprises an amplifying unit 33 and a column selecting switching unit 34 .
Here, the amplification unit 33 comprises PMOS transistors P 4 ˜P 6 and NMOS transistors N 8 ˜N 10 . The PMOS transistor P 4 , connected between a power voltage terminal and a common source terminal of the PMOS transistors P 5 and P 6 , has a gate to receive a sense amplifier enable signal SEP. The cross-coupled PMOS transistors P 5 and P 6 latch a power voltage applied through the PMOS transistor P 4 .
A NMOS transistor N 10 , connected between a ground voltage terminal and a common source terminal of NMOS transistors N 8 and N 9 , has a gate to receive a sense amplifier enable signal SEN. The cross-coupled NMOS transistors N 8 and N 9 latch a ground voltage applied through the NMOS transistor N 10 .
Here, the sense amplifier enable signal SEN has a phase opposite to that of the sense amplifier enable signal SEP. When the sense amplifier enable signal SEN is activated, the amplification unit 33 is operated. One output terminal of the amplification unit 33 is connected to the bit line BL<m>, and the other output terminal of the amplification unit 33 is connected to a terminal to receive a reference voltage REF.
The column selecting switching unit 34 comprises NMOS transistors N 11 and N 12 . The NMOS transistor N 11 , connected between the bit line BL<m> and the data bus 40 , has a gate to receive a column selecting signal CS<n>, thereby controlling input/output of the data /D. The NMOS transistor N 12 , connected to the terminal to receive the reference voltage REF and the data bus 40 , has a gate to receive the column selecting signal CS<n>, thereby controlling input/output of the data D.
FIG. 12 is a timing diagram illustrating the read mode of the nonvolatile memory device using a hybrid switch cell according to an embodiment of the present invention.
In an interval t 0 , the bit line pull-down signal SBPD is activated, and the ground voltage is applied to the paired bit lines BL. As a result, the bit line BL is precharged to the ground level.
When an interval t 1 starts, if the word line WL transits to ‘high’ and a predetermined voltage is applied to the word line WL, the PN diode 1 of the hybrid switch HSW is turned on. As a result, data of the hybrid switch cell are transmitted to the bit line BL. Here, the bit line pull-down signal SBPD transits to ‘low’.
Next, in an interval t 2 , if the sense amplifier enable signal transits to ‘high’, the sense amplifier 30 amplifies data applied from the bit line BL. If the voltage of the bit line BL is amplified to the low level while the voltage of the word line WL is ‘high’, data “0” is restored in the hybrid switch cell C.
Thereafter, in an interval t 3 , the voltage of the word line WL transits to a negative voltage which is less than the threshold voltage Vc. That is, a difference between the low voltage level of the bit line BL and the negative voltage level of the word line WL does not reach the level of the threshold voltage Vc to turn on the PNPN diode switch 2 of the hybrid switch HSW.
However, a voltage higher than the threshold voltage Vc is applied to turn on the PNPN diode switch 2 depending on the difference between the low voltage level of the bit line BL and the negative voltage level of the word line WL. As a result, the PNPN diode switch 2 is turned on, and data “1” are restored in the hybrid switch cell.
After the PNPN diode switch 2 is turned on, a large amount of current can flow although the small voltage Vs is applied to the bit line BL. As a result, the sufficient amount of current can flow although the voltage of the word line WL rises from the negative voltage to the low level in the interval t 3 .
In the interval t 3 , if the column selecting signal transits to ‘high’, the NMOS transistors N 11 and N 12 of the column selecting switching unit 34 are turned on, and the data D and /D in the bit line BL are outputted to the data bus 40 . As a result, data stored in the hybrid switch cell C can be read.
FIG. 13 is a timing diagram illustrating the write mode of the nonvolatile memory device using a hybrid switch cell according to an embodiment of the present invention.
In an interval t 0 , the bit line pull-down signal SBPD is activated, and the ground voltage is applied to the paired bit lines BL. As a result, the bit line BL is pulled down to the ground level.
Thereafter, when an interval t 1 starts, if the voltage of the word line WL transits to ‘high’, data of the hybrid switch cell are transmitted to the bit line BL. Here, the bit line pull-down signal SBPD transits to ‘low’. Then, new data D and /D to be written through the data bus 40 are inputted to the bit line BL.
Next, in an interval t 2 , the sense amplifier enable signal SEN is activated, and the sense amplifier 30 amplifies data in the bit line BL. If the voltage of the bit line BL is amplified to the low level while the voltage of the word line is ‘high’, data “0” are written in the hybrid switch cell C.
Here, if the column selecting signal CS transits to ‘high’, the NMOS transistors N 11 and N 12 of the column selecting switching unit 34 are turned on. As a result, the data D and /D inputted through the data bus 40 are applied to the bit line BL.
Thereafter, in an interval t 3 , the voltage of the word line WL transits to the negative voltage. That is, a difference between the low voltage level of the bit line BL and the negative voltage level of the word line WL does not read the level of the threshold voltage Vc to turn on the PNPN diode switch 2 of the hybrid switch HSW.
However, a voltage higher than the threshold voltage Vc to turn on the PNPN diode switch 2 is applied depending on the high level voltage of the bit line BL and the negative voltage level of the word line WL. As a result, the PNPN diode switch 2 is turned on, and data “1” are written in the hybrid switch cell.
Although a nonvolatile ferroelectric memory device is described as an example of a memory device to store data herein, the present invention is not limited to the particular form disclosed. Rather, the memory device according to an embodiment of the present invention can include a DRAM device or a flash device.
As discussed earlier, a memory device using a hybrid switch cell according to an embodiment of the present invention provides the following effects: to embody a cross-point cell with a nonvolatile ferroelectric capacitor and a hybrid switch, thereby reducing the whole size of the memory; and to effectively drive read/write operations in a cell array using the hybrid switch, thereby improving operating characteristics of the memory cell.
While the invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and described in detail herein. However, it should be understood that the invention is not limited to the particular forms disclosed. Rather, the invention covers all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined in the appended claims.
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A nonvolatile memory device features a hybrid switch cell as a cross-point cell using a nonvolatile ferroelectric capacitor and a hybrid switch. The hybrid switch cell comprises a ferroelectric capacitor and a hybrid switch. The ferroelectric capacitor, located where a word line and a bit line are crossed, stores values of logic data. The hybrid switch is connected between the ferroelectric capacitor and the bit line and selectively switched depending on voltages applied to the word line. The nonvolatile memory device using a hybrid switch cell comprises a plurality of hybrid switch cell arrays, a plurality of word line driving units and a plurality of sense amplifiers. Each of the plurality of hybrid switch cell arrays each includes a single hybrid switch cell where a word line and a bit line are crossed. The plurality of word line driving units selectively drive the word line. The plurality of sense amplifiers sense and amplify data transmitted through the bit line.
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BACKGROUND
Subsurface safety valves, such as a tubing retrievable safety valves, deploy on production tubing in a producing well. The safety valves can selectively seal fluid flow through the production tubing if a failure or hazardous condition occurs at the well surface. In this way, safety valves can minimize the loss of reservoir resources or production equipment resulting from catastrophic subsurface events.
A conventional safety valve uses a flapper to close off flow through the valve. The flapper, which is normally closed, can be opened when hydraulic pressure applied to a hydraulic piston move a flow tube against the bias of a spring in the valve. When the flow tube moves, it pivots the flapper valve open, allowing flow through the safety valve.
From the surface, a control line supplies the hydraulic pressure to operate the valve. The control line extends from a surface controlled emergency closure system, through the wellhead, and to the safety valve. As long as hydraulic pressure P C is applied through the control line, the valve can remain in the opened position, but removal of control line pressure returns the valve to its normally closed position. The hydrostatic or “head” pressures P H from the column of fluid in the control line can directly limit the setting depth and operational characteristics of the safety valve in such a system.
Historically, additional load from stronger power springs has been used to offset the hydrostatic pressure of the control line. However, safety valves have limited space available to accommodate a larger spring. In fact, the active control line hydrostatic pressure P H can be so significant in some applications that a spring may not be able to overcome the hydrostatic pressure and the valve's flapper cannot close, assuming the wellbore pressure is zero.
To compensate for the control line's hydrostatic pressure P H , a gas (nitrogen) charge can be stored in the safety valve to counteract the hydrostatic pressure. Unfortunately, using a gas charge in the valve presents problems with leakage of the gas, which can cause the valve to fail in the open position. In addition, once the charge is spent in a fail-safe operation, operators must do a substantial amount of work to replace the valve.
In contrast to a gas charge, safety valves have been developed that use a magnetically driven device on the valve. The magnetic device allows the hydraulics to reside outside the wellbore and may use annulus pressure to offset the hydrostatic pressure of the control line so that the safety valve can be set at greater depths. Unfortunately, using such an arrangement may be undesirable in some applications.
In yet another solution, a second “balance” control line has been used with a deep-set safety valve to negate the effect of hydrostatic pressure P H from the active control line. In these existing balance line valves, the second balance line acts on the valve's piston against the pressure from the active control line to balance the hydrostatic pressure P H from the active control line Therefore, because the underside of the piston is in fluid communication with the balance line, the piston is no longer in fluid communication with the tubing. Accordingly, any beneficial effect produced by the tubing pressure P T in operating this type of deep-set safety valve is not utilized.
A different type of balance line arrangement shown in FIG. 1 is disclosed in U.S. Pat. No. 7,392,849, which is assigned to the Assignee of the present disclosure and is incorporated herein in its entirety. Production tubing 20 has a deep-set safety valve 50 for controlling the flow of fluid in the production tubing 20 . In this example, the wellbore 10 has been lined with casing 12 with perforations 16 for communicating with the surrounding formation 18 . The production tubing 20 with the safety valve 50 deploys in the wellbore 10 to a predetermined depth. Produced fluid flows into the production tubing 20 through a sliding sleeve or other type of device. Traveling up the tubing 20 , the produced fluid flows up through the safety valve 50 , through a surface valve 25 , and into a flow line 22 .
As is known, the flow of the produced fluid can be stopped at any time during production by switching the safety valve 50 from an open condition to a closed condition. To that end, a hydraulic system having a pump 30 draws hydraulic fluid from a reservoir 35 and communicates with the safety valve 50 via a first control line 40 A. When actuated, the pump 30 exerts a control pressure P C through the control line 40 A to the safety valve 50 .
Due to vertical height of the control line 40 A, a hydrostatic pressure P H also exerts on the valve 50 through the control line 40 A. For this reason, a balance line 40 B also extends to the valve 50 and provides fluid communication between the reservoir 35 and the valve 50 . Because the balance line 40 B has the same column of fluid as the control line 40 A, the outlet of the balance line 40 B connected to the valve 50 has the same hydrostatic pressure P H as the control line 40 A.
Internally, components of the safety valve 50 are exposed to control pressure P C from the control line 40 A and the offsetting hydrostatic pressure P H from the balance line 40 B. Yet, the components are also exposed to tubing pressure P T in the well during operation, which can be beneficial. As briefly illustrated in FIGS. 2A-2B , the deep-set safety valve 50 uses the hydraulic pressures from the two control lines ( 40 A-B) so the valve 50 can be set at greater depths downhole. The valve 50 as illustrated in FIGS. 2A and 2B has first and second actuators 60 A-B. The first actuator 60 A has an active piston 62 A coupled to a flow tube 54 . Control pressure from the primary control line ( 40 A) moves the control piston 62 A and the flow tube 54 against the bias of a spring 56 to open the valve's flapper (not shown). The second actuator 60 B has a balance piston 62 B that can intermittently engage the flow tube 54 during operation.
In FIG. 2A , the valve 50 is in a closed condition where the balance piston 62 B is idle in which case the tubing pressure P T is greater than the hydrostatic pressure P H . By contrast, the valve 50 is in an opened condition in FIG. 2B . As shown in FIG. 2A , if the tubing pressure P T is substantial, then force from this tubing pressure P T and from the spring 56 exerts on the control piston 62 A and tends to close the valve 50 . Since the tubing pressure P T is greater than P H in FIG. 2A , however, the balance piston 52 B is idle as it exerts no force on the flow tube 54 because a net downward force exerted by the tubing pressure P T keeps the balance piston 62 B resting on a shoulder 57 .
As shown in FIG. 2B , if the hydrostatic pressure P H is substantial, a force exerts on the control piston 62 A and tends to open the valve 50 . Likewise, control pressure P C from the control line ( 40 A) exerts on the control piston 62 A and tends to open the valve 50 . Yet, the hydrostatic pressure P H exerts an opposing force on the balance piston 62 B, thereby tending to close the valve 50 . Additionally, the tubing pressure P T exerts an opposing force on the balance piston 62 B; however, this force does not tend to open the valve 50 because the balance piston 62 B is structurally isolated from the flow tube 54 (and the spring 56 ) by interaction of a block 55 with the shoulder 57 of the chamber housing. Thus, if the control pressure P C is reduced in FIG. 2B , the valve 50 will revert to the closed condition shown in FIG. 2A .
Although existing safety valves for deep-set applications may be effective, operators are continually seeking improved hydraulic control systems for deep-set applications that can avoid failures and mitigate other problems. The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
SUMMARY
A hydraulic control system for a sub-surface safety valve has first and second control lines in hydraulic communication with the sub-surface safety valve. The first control line communicates first hydraulic pressure to actuate the sub-surface safety valve. The second control line communicates second hydraulic pressure to compensate for hydrostatic pressure associated with the first control line. A regulator regulates hydraulic communication between the first and second control lines. The regulator can affix to production tubing and can be plumbed between the two control lines downhole. Alternatively, the regulator can be installed on or incorporated into the safety valve itself or some other tubing component downhole.
In general, as long as the second hydraulic pressure compensates for the hydrostatic pressure in the first control line, the safety valve can operate appropriately. In this case, the regulator prevents fluid communication from the first control line to the second control line. However, when the second hydraulic pressure falls below a particular level related to the hydrostatic pressures associated with the first control line, the safety valve can fail in the open position depending on the pressure in the well. In this case, the regulator permits hydraulic communication from the first control line to the second control line. As hydraulic pressure bleeds from the first line to the second line, the hydraulic pressure from the first line may fall below a particular level. Assisted by the spring (and potentially by tubing pressure as well), the safety valve can then fail in the closed condition instead of remaining open. Eventually, the hydraulic pressure bled from the first control line may charge the second control line if the second line's integrity is regained. In this way, the safety valve can then be reset.
The first control line extends from the sub-surface safety valve uphole through a wellhead, where the first control line couples to a hydraulic system, having a pump and reservoir. The second control line can also extend from the sub-surface safety valve up through the wellhead and can couple to a pump or a reservoir of the hydraulic system. Alternatively, the second control line extends from the sub-surface safety valve, but it terminates at some point downhole from the wellhead. In this case, the second control line can have a cap. When the production tubing with the safety valve and control lines is deployed downhole, the second control line may be evacuated of hydraulic fluid. Once deployed, hydraulic pressure can be bled from the first control line to the second control line through the regulator to an appropriate pressure for the deep-set operation of the safety valve. Any trapped gas in the second control line can then be used as a compressible buffer for the line, which may be advantageous for its operation.
The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a wellbore having a string of production tubing and a deep-set safety valve in accordance with the prior art.
FIGS. 2A-2B illustrate details of the deep-set safety valve of the prior art.
FIGS. 3A-3C illustrate configurations of a control system in accordance with the present disclosure for a deep-set safety valve.
FIGS. 4A-4B illustrate configurations for affixing the control system on production tubing having a deep-set safety valve.
FIGS. 5A-5B illustrate cross-sections of a regulator in closed and opened conditions for the disclosed control system.
DETAILED DESCRIPTION
A dual line control system 100 in FIGS. 3A-3C operates with a deep-set safety valve 50 . As described previously, the safety valve 50 installs on production tubing (not shown) disposed in a wellbore, and the safety valve 50 controls the uphole flow of production fluid through the production tubing. In use, the safety valve 50 closes flow through the tubing in the event of a sudden and unexpected pressure loss or drop in the produced fluid, which coincides with a corresponding increase in flow rate within the production tubing. Such a condition could be due to the loss of flow control (i.e., a blowout) of the production fluid. During such a condition, the safety valve 50 automatically actuates and shuts off the uphole flow of production fluid through the tubing. When control is regained, the safety valve 50 can be remotely reopened to reestablish the flow of production fluid.
The control system 100 includes a well control panel or manifold of a hydraulic system 110 , which can have one or more pumps 112 , reservoirs 114 , and other necessary components for a high-pressure hydraulic system used in wells. In FIG. 3A , two control lines 120 A-B extend from the hydraulic system 110 through the wellhead 115 and down the well to the deep-set safety valve 50 . One of the control lines 120 A couples to the pump 112 of the hydraulic system 110 , while the other control line 120 B couples to the reservoir 114 of the hydraulic system 110 in a manner similar to that described in U.S. Pat. No. 7,392,849, which has been incorporated herein by reference in it its entirety.
In FIG. 3B , two control lines 120 A-B extend from the hydraulic system 110 through the wellhead 115 and down the well to the deep-set safety valve 50 . In this configuration, however, both control lines 120 A-B couple to the one or more pumps 112 of the hydraulic system 110 and are separately operable. Using this configuration, operators can open and close the deep-set safety valve 50 in both directions with hydraulic fluid from the control lines 120 A-B being separately operated with the hydraulic system 110 . Either way, the balance control line 120 B in FIGS. 3A-3B can offset the hydrostatic pressure in the primary control line 120 A, allowing the safety valve 50 to be set at greater depths.
Passing control lines through the components of the wellhead 115 can be complicated. As another alternative, the configuration of the control system 100 in FIG. 3C has the balance control line 120 B terminated or capped off below the wellhead 115 . Thus, only the primary control line 120 A runs to the surface and the hydraulic system 110 , while the balance control line 120 B for offsetting the hydrostatic pressure terminates below the wellhead 115 with a cap 130 . In this way, the configuration of FIG. 3C eliminates the need for passing two control lines through the wellhead 115 .
For its part, the safety valve 50 in FIGS. 3A-3C can include any of the deep-set valves known and used in the art. In one implementation, the deep-set safety valve 50 can have features such as disclosed in incorporated U.S. Pat. No. 7,392,849. In general, the deep-set safety valve 50 uses hydraulic pressures from the two control lines 120 A-B to actuate a closure 65 of the valve 50 so the valve 50 can be set at greater depths downhole. As best shown in FIG. 3A , for example, the primary or active control line 120 A can operate a primary actuator 60 A in the valve 50 , while the second or balance control line 120 B can operate a second actuator 60 B. As shown, the closure 65 can include a flapper 52 , a flow tube 54 , and a spring 56 . The primary actuator 60 A can include a rod piston assembly known in the art for moving the flow tube 54 . The balance actuator 60 B can also include a rod piston assembly known in the art for moving the flow tube 54 .
Alternatively, the balance actuator 60 B can include the balance control line 120 B communicating with a chamber for the spring 56 so second hydraulic pressure in the balance control line 120 B can act in conjunction with the spring 56 against the flow tube 54 . Moreover, the balance control line 120 B can communicate with an opposing side of the piston assembly of the first actuator 60 A to balance the hydrostatic pressure in the first control line 120 A. Alternatively, the control lines 120 A-B can couple to actuators in the safety valve 50 in accordance with the arrangement disclosed in incorporated U.S. Pat. No. 7,392,849, which allows tubing pressure to be utilized. These and other actuators 60 A-B and closures 65 can be used in the safety valve 50 for the disclosed control system 100 .
Either way, with the primary control line 120 A charged with hydraulic pressure, the primary actuator 60 A opens the closure 65 . For example, the piston of the actuator 60 A moves the flow tube 54 down, which opens the flapper 52 of the safety valve 50 . For its part, the hydraulic pressure from the balance control line 120 B offsets the hydrostatic pressure in the primary control line 120 A by acting against the balance actuator 60 B. For example, the balance actuator 60 B having the balance piston assembly acts upward on the flow tube 54 and offsets the hydrostatic pressure from the primary control line 120 A. Therefore, this offsetting negates effects of the hydrostatic pressure in the primary control line 120 A and enables the valve 50 to operate at greater setting depths.
If the balance control line 120 B loses integrity and insufficient annular pressure is present to offset the primary control line's hydrostatic pressure, then the valve 50 can fail in the open position, which is unacceptable. The control line 120 B, which may be %-inch diameter tubing, can fail due to various reasons. For example, the control line 120 B can leak, or it can become contaminated or blocked over time due to debris in the control fluid. Typical debris, contamination, or particles that can develop and become suspended in the control fluid can come from reservoirs, physical wear of system components, chemical degradation, and other sources.
To overcome unacceptable failure, the control system 100 includes a fail-safe device or regulator 150 disposed at some point down the well. The regulator 150 interconnects the two control lines 120 A-B to one another and acts as a one-way valve between the two lines 120 A-B. Under certain circumstances discussed later, the regulator 150 bleeds pressure from the primary control line 120 A to the balance control line 120 B to facilitate operation of the safety valve 50 .
Briefly, FIG. 4A shows an arrangement for affixing the control lines 120 A-B to production tubing 20 having the deep-set safety valve 50 . The control lines 120 A-B can use straps or bandings 24 typically used to attach control lines to tubing. The regulator 150 can be an independent component coupled by flow tees or other necessary components to the control lines 120 A-B and can also affix to the tubing 20 with bandings 24 . Alternatively, as shown in FIG. 4B , the regulator 150 can be installed on or incorporated into the housing of the safety valve 50 or some other tubing component downhole, while the control lines 120 A-B affix with bandings 24 or the like. The banding and other arrangements can be used to install the control system 100 on the tubing 20 .
As noted previously, the configurations in FIGS. 3A-3B have the control lines 120 A-B pass through the wellhead 115 using known techniques. For the configuration in FIG. 3C , however, the balance control line 120 B is terminated downhole with a cap 130 using capping techniques known in the art. The depth at which the balance control line 120 B is capped can vary depending on the implementation. In practice, the balance control line 120 B is intended to provide an offset of the hydrostatic pressure in the primary control line 120 A.
When deploying the control system 100 of FIG. 3C downhole, the balance control line 120 B is preferably evacuated of hydraulic fluid. As the lines 120 A-B are lowered with the tubing 20 , the primary control line 120 A bleeds hydraulic pressure into the balance control line 120 B through the regulator 150 , which allows pressure flow from the line 120 A to 120 B (but not from 120 B to 120 A). As hydraulic pressure builds in the balance line 120 B, an amount of trapped gas forms in the line 120 B, which is beneficial for the operation of the control system 100 . For example, this trapped gas acts as a compressible buffer and can help avoid vapor lock in the system 100 .
In any of the configurations of FIGS. 3A-3C , if the balance control line 120 B line is ever lost, the regulator 150 can bleed hydraulic pressure from the primary line 120 A to the balance control line 120 B to achieve any of the various purposes disclosed herein. Details of the regulator 150 for the control system 100 are shown in FIGS. 5A-5B .
The regulator 150 is shown in a closed condition in FIG. 5A and is shown in an opened condition in FIG. 5B . As shown, the regulator 150 has a housing 160 defining an internal passage therein so that this arrangement represents the regulator 150 designed as a separate component from the safety valve ( 50 ). However, as noted previously, it will be appreciated that the regulator 150 can be part of the safety valve ( 50 ) and the regulator's housing 160 can actually be components of the safety valve ( 50 ) itself. Moreover, the housing 160 can be constructed in ways known in the art for facilitating its assembly, which may not be depicted in the drawings.
The housing 160 has a primary port 162 with a hydraulic fitting 163 for connecting to the primary control line 120 A with a flow tee or the like. The primary port 162 communicates with an intermediate barrel chamber 166 through a choke passage 164 . A sleeve 170 installs in the intermediate barrel chamber 166 and has a hydraulic fitting 173 for connecting to the balance control line 120 B with a flow tee or the like.
A dart 190 for flow control resides in the primary port 162 and can move therein to seal against a seal or seat 165 around the choke passage 164 . A piston 180 resides in the open end 174 of the sleeve 170 . A spring 185 resides in an atmospheric or low pressure chamber of the sleeve 170 behind the piston 180 and biases the piston 180 outward. Depending on the hydraulic pressure acting against the piston's front end 182 and the bias of the spring 185 , the piston 180 can move relative to the dart 190 and can push the dart 190 relative to the choke passage 164 .
As noted previously, hydraulic pressure applied to the primary control line 120 A (communicating with port 162 ) opens the safety valve ( 50 ) coupled to the lines 120 A-B. Hydraulic pressure from control line 120 A applied to the balance control line 120 B until the balance line reaches its designed hydrostatic pressure. At that pressure, the communication between line 120 A to line 120 B will cease. The stored hydrostatic pressure in line 120 B acts to offset the hydrostatic pressure from the primary control line 120 A for the purposes of controlling the safety valve ( 50 ) as disclosed herein.
In the closed condition of FIG. 5A , the hydraulic pressure of the primary control line 120 A pushes against the dart 190 so that it seals on the seat 165 inside the choke passage 164 . On the other end of the regulator 150 , hydraulic pressure from the balance control line 120 B pushes the piston 180 against the bias of spring 185 so that the piston 180 does not engage the dart 190 . In particular, pressure from the balance control line 120 B communicates through the fitting 173 and passes out the sleeve's cross-ports 172 to communicate in the annulus around the sleeve 170 in the barrel chamber 166 .
The pressure communicates to the end 174 of the sleeve 170 and enters the space between the dart 190 and the piston 180 . Here, the hydraulic pressure acts against the piston's end 182 having a cup seal 184 , and the pressure tends to force the piston 180 against the bias of the spring 185 . The cup seal 184 can use non-elastomeric, metal-to-metal sealing systems known in the art, although any suitable sealing system could be used.
At normal conditions, the primary pressure in port 162 acting against the dart 190 is greater to or equal to the second pressure in chamber 166 acting against the dart 190 so that the dart 190 seals off flow through the regulator 150 . In other words, the differential between the first and second hydraulic pressures bias the piston 182 to the released position as shown in FIG. 5A , thus allowing the dart 190 to be in the closed condition. If the balance control line 120 B loses integrity and insufficient annular pressure is present to offset the primary control line's hydrostatic pressure, then the safety valve ( 50 ) as described previously can fail in the open position, which is unacceptable.
Weakening of the pressure integrity of the balance control line 120 B is shown in FIG. 5B . Reduced pressure acting against the piston 180 has allowed the spring 185 to bias the piston 180 so that it now engages the end of the dart 190 . If the weakening is great enough, then the piston 180 pushes the dart 190 through the choke passage 164 and away from the seal 165 as shown. (Preferably, the cup seal 184 on the piston's end 182 is not allowed to pass the edge 174 of the sleeve 170 because this could damage the seal 184 and cause it to extrude.)
Having the dart 190 moved away from the seal 165 allows pressure from the primary control line 120 A to pass by the dart 190 and through choke passage 164 . This action bleeds pressure from the primary control line 120 A to the balance control line 120 B. In this way, the regulator 150 helps the control system 100 to overcome failure of the safety valve ( 50 ) in the opened condition.
By opening as in FIG. 5B , for example, the regulator 150 ensures that the primary control line 120 A at port 162 bleeds into balance line 120 B, thus equalizing the hydrostatics to the safety valve ( 50 ). As hydraulic pressure bleeds through the regulator 150 , the hydraulic pressure supplied by the primary line 120 A to the safety valve ( 50 ) may fall below a level that allows the safety valve ( 50 ) to remain open. For instance, the force from the internal spring ( 56 ) in the valve ( 50 ), any remaining pressure in the balance control line 120 B, and possibly tubing pressure, if applicable, can act to close the valve ( 50 ) as described previously. When this happens, the safety valve ( 50 ) closes and fails in the closed condition rather than staying open.
If integrity in the balance control line 120 B is regained, then the hydraulic pressure in the balance line 120 B can eventually move the piston 180 against the spring 185 and allow the dart 190 to seat in the closed position of FIG. 5A . Once this is done, the primary control line 120 A can again be used to operate the valve ( 50 ) while the balance control line 120 B provides the hydrostatic offset for deep-set operation.
For ease of explanation, the disclosed control system has been described generally in relation to a cased vertical wellbore. However, the disclosed control system can be employed in any type of well, such as an open wellbore, a horizontal wellbore, or a diverging wellbore, without departing from principles of the present disclosure. Furthermore, a land well is shown for the purpose of illustration; however, it is understood that the disclosed control system can also be employed in offshore wells.
Spring forces, hydraulic surface areas, volumes, and other details for the components disclosed herein can be suited for a particular implementation and can vary based on expected operating pressures and other considerations. Therefore, the disclosed regulator and control system can be configured to operate in response to a set and determined pressure differential for a particular implementation. With that said, the disclosed regulator and control system are intended to permit hydraulic pressure to flow from a primary control line to a balance line in response to pressure in the balance line falling below some set pressure level. In general, this set pressure level is related to the hydrostatic pressure associated with the column of hydraulic fluid in the primary control line, although the actual values of the level may be different than the precise hydrostatic pressure.
Although use of one regulator 150 between control lines 120 A-B has been shown and described herein, it will be appreciated that multiple regulators 150 can be used between the control lines 120 A-B. These multiple regulators 150 can be similarly configured to provide redundancy should one fail to operate. Alternatively, the various regulators 150 can be configured to operate differently in response to different hydraulic pressures in the control lines 120 A-B, which in turn can have direct bearing on the safety valve's operation and the pressures it is exposed to.
Again, although the disclosed regulator 150 of FIGS. 5A-5B is shown as a separate component with its own housing 160 , it will be appreciated that the regulator 150 can be incorporated into the housing of the safety valve 50 as shown in FIG. 4B or incorporated into some other downhole tubing component. For example, the control lines 120 A-B can communicate with internal channels or ports that connect to an internal chamber in the safety valve's housing. Components of the regulator 150 , such as sleeve 170 , piston 180 , spring 185 , and dart 190 can install in the valve's internal chamber to regulate hydraulic pressure between the ports for the control lines 120 A-B according to the purposes disclosed herein.
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.
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A hydraulic control system for a sub-surface safety valve has control lines in hydraulic communication with the valve. A first control line communicates hydraulic pressure to actuate the valve, while the other control line communicates hydraulic pressure to compensate for hydrostatic pressure associated with the first control line. A regulator regulates hydraulic communication between the two control lines. The regulator prevents fluid communication from the first to the balance control line as long as integrity of the second line is maintained. When the second line fails, the safety valve can fail in the open position. In this case, the regulator permits hydraulic pressure to bleed from the first line to the second line. This allows the safety valve to then fail in a closed condition and allows the second line to potentially be recharged if its integrity is regained.
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RELATED APPLICATIONS
[0001] The present application relates to co-pending U.S. patent application Ser. No. 12/978,154, filed on Dec. 23, 2010, and assigned Attorney Docket No. 10-SIN-058, and U.S. patent application Ser. No. ______, filed concurrently, and assigned Attorney Docket No. 10-SIN-1148.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention generally relates to an apparatus and method for local video detection for mixed cadence sequence, and more particularly to a pixel-based Local Video Detection (LVD) method and system used as part of the Local Film Mode Detector (LFMD), or part of the de-interlacer, or part of the picture quality enhancement in TV and Set-Top-Box products.
[0004] 2. Relevant Background.
[0005] Interlaced video was used for cathode ray tube (CRT) displays and is found throughout a number of broadcasting formats. Modern video displays, e.g., liquid crystal displays (LCD) and plasma displays, do not operate in interlaced mode. Therefore, de-interlacing circuitry is needed in set-top-box (STB)/TV to de-interlace video into progressive video that can be played on modern video displays.
[0006] Currently, there are a number of different source formats. Video formats usually display at 50 or 60 frames per second; film formats are commonly captured at 24 or 25 frames per second. Because of the difference is frame rate, telecine is applied to a film source video in order to properly display the film source video on a video display. Reverse telecine may be applied to the telecined film source video to recover a higher quality non-interlaced video to display on a compatible device, such as a modern video display.
[0007] U.S. patent application Ser. No. 12/978,154, “Apparatus and Method for Exotic Cadence Detection,” discusses an apparatus and method for exotic cadence detection. Cadence detection finds the source format of a sequence of video fields or detects the absence of motion between frames (still pictures) and determines whether a video is originally from a video or film source that had interlacing or telecine applied. After that, de-interlacing or inverse telecine can be appropriately applied to the video.
[0008] Cadence detection systems in the related art have limited applicability to broadcasted videos. Broadcasted videos commonly consist of mixed video and film sources, for example, graphics overlay on a video source, or scrolling text on a film source. Applying either de-interlacing or inverse telecine to mixed cadence sources is suboptimal because de-interlacing compromises vertical resolution on the telecined parts and inverse telecine leaves unhandled feathering or combing artifacts on the interlaced parts.
[0009] U.S. Patent Publication No. 2007/0291169, “Region-Based Cadence Detector,” discusses blocked based film/video decision and switching. A frame is segmented into a pre-set number of regions (or clusters of blocks) for cadence and phase tracking. Region-based cadence detection suffers in picture quality and robustness due to artifacts from the switching.
[0010] Accordingly, there is a need in the art for an accurate, robust, and efficient mixed film/video mode cadence detection system.
SUMMARY OF THE INVENTION
[0011] Accordingly, the invention is directed to an apparatus and method for local film/video mode processing system that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0012] An advantage of the invention is to provide an apparatus and method to increase detection accuracy and to prevent feathering/comb artifacts on moving video object areas.
[0013] Another advantage of the invention is to increase the robustness of local film mode detection to improve picture quality of mixed cadence sources.
[0014] Yet another advantage of the invention is to avoid global, block, or region-of-block based decisions on mixed film and video sequences to prevent switch artifacts.
[0015] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0016] To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described, an apparatus for local video detection is provided. The apparatus includes a contour and contrast adjusted comb detector, a false motion excluded motion detector, and a video fader value estimator.
[0017] In one embodiment of the invention, the contour and contrast adjusted comb detector includes a field to frame coupling unit, a directional support pixel extraction unit, a comb detection unit, a comb post-processing unit, a comb value estimation unit, and a contrast adjustment unit. The false motion excluded motion detector includes an inter-frame motion detection unit, an inter-field motion detection unit, a false motion exclusion unit, and a motion post-processing unit. The video fader value estimator includes a pixel classification unit, a video value calculator, and a video value post-processing unit.
[0018] Another aspect of the invention is directed towards a mixed film/video mode detection apparatus. The mixed film/video mode detection apparatus includes a film mode detector, a local video detector, a film mode processing unit, and a video mode processing unit and a fader.
[0019] Yet another aspect of the invention is directed towards a method for local film/video mode processing. The method includes the steps of detecting a cadence and phase information from an input video, calculating pixel-based video confidence values of the input video based on the cadence and phase information, performing film mode processing on the input video, performing video mode processing on the input video, and fading between the film mode and video mode processing according to the pixel-based video confidence values.
[0020] 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. In addition, various aspects of the invention may be generated with software or hardware as known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates an exemplary diagram of a video processing system that makes use of a local video detector for optimally displaying a mixed cadence video sequence according to an embodiment of the invention;
[0022] FIG. 2 is an exemplary diagram of a local video detector according to an embodiment of the invention;
[0023] FIG. 3 is an exemplary diagram of a contour and contrast adjusted comb detector according to an embodiment of the invention;
[0024] FIG. 4 is a diagram illustrating examples of contour adjusted support pixel extraction;
[0025] FIG. 5 is a diagram illustrating a pixel window used by a comb detection unit, a comb value estimation unit, and a contrast adjustment unit;
[0026] FIG. 6 is a diagram of an example processing window of a comb post-processing unit;
[0027] FIG. 7 is an exemplary diagram of a false motion excluded motion detector according to an embodiment of the invention;
[0028] FIG. 8 is an exemplary diagram of an inter-frame motion detector according to an embodiment of the invention;
[0029] FIG. 9 is an exemplary diagram of an inter-field motion detector according to an embodiment of the invention;
[0030] FIG. 10 is an exemplary diagram of a false motion exclusion unit according to an embodiment of the invention;
[0031] FIG. 11 is a diagram of an example processing window of a motion post-processing unit;
[0032] FIG. 12 is an exemplary diagram of a video fader value estimator according to an embodiment of the invention;
[0033] FIG. 13 is a diagram of an example processing window of a video value post-processing unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Embodiments of the present invention are hereafter described in detail with reference to the accompanying figures. Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention.
[0035] The following description with reference to the accompanying figures is provided to assist in a comprehensive understanding of exemplary embodiments of the present invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. Also, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0036] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for purposes of illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
[0037] Reference will now be made in detail to an embodiment of the present invention, an example of which is illustrated in the accompanying drawings.
[0038] FIG. 1 illustrates a video processing system that makes use of a local video detector for optimally displaying a mixed cadence video sequence according to an embodiment of the invention.
[0039] The video processing system receives an input video signal 10 , which could contain film or video source, or a mix of both, and outputs the processed video 90 for displaying on modern LCD/LED TVs. The video processing system comprises a film mode detector 20 , a local video detector 50 , a film mode processing unit 30 , also known as “inverse telecine”, a video mode processing unit 40 , also referred to as “de-interlacer”, and a fader unit 60 .
[0040] The film mode detector 20 , such as one disclosed U.S. patent application Ser. No. 12/978,154, detects the cadence and the phase of the film source, if there is any, and provides such cadence and phase information 70 to the local video detector 50 and the film mode processing unit 30 . The local video detector 50 receives the input video signal 10 , the cadence and phase information 70 , and provides a pixel-based video fader value 80 to the fader 60 . The film mode processing unit 30 receives the input video signal 10 , interweaves the coupling of two fields according to the cadence and phase information 70 from the film mode detector 20 , and outputs the merged video frame 35 to the fader 60 . The video mode processing unit 40 receives the input video signal 10 , interpolates it spatially and/or temporally, and outputs an interpolated frame 45 to the fader 60 . Finally, the fader 60 receives the outputs from the film mode processing unit 30 and the video mode processing unit 40 , then fades between them based on the video fader value 80 estimated by the local video detector 50 , and outputs the final video output 90 for display.
[0041] Referring now to FIG. 2 , there is illustrated in diagram an embodiment of a local video detector 200 according to an embodiment of the invention.
[0042] The local video detector receives the input video signal 10 and the cadence and phase information 70 , and outputs the video fader value 80 . The local video detector apparatus comprises a contour and contrast adjusted comb detector 100 , a false motion excluded motion detector 200 , and a video fader value estimator 300 .
[0043] Referring now to FIG. 3 , there is illustrated in diagram an embodiment of a contour and contrast adjusted comb detector 100 .
[0044] Contour and contrast adjusted comb detector 100 receives the input video signal 10 , the cadence and phase information 70 , a contour angle α 101 from an external contour detector, and a recursive motion m 102 from an external motion detector, and provides the detected comb signals 180 and a comb value 190 . Contour and contrast adjusted comb detector 100 further comprises a field to frame coupling unit 110 , a directional support pixel extraction unit 120 , a comb detection unit 130 , an optional post-processing unit 140 , a comb value estimation unit 150 , and an optional contrast adjustment unit 160 .
[0045] The field to frame coupling unit 110 receives three fields of the input video signal 10 at times t−1, t, and t+1, and merges two fields belonging to the same frame (either t−1 & t, or t & t+1) according to the cadence and phase information received from an external film mode detector to generate a complete frame.
[0046] The directional support pixel extraction unit 120 , receives a complete frame from the field to frame coupling unit 110 and a contour angle signal 101 estimated on the field at time t from an external contour detector, which could be part of a video mode processing unit in many cases, and provides a seven-pixel window 125 . An example of the external contour detector providing contour angle α 101 is disclosed in U.S. Pat. No. 7,773,151. As combing artifacts appear along the contours of a moving object, a directional support pixel extraction unit could greatly improve the accuracy of a comb detector, as can be appreciated by the skilled addressee. Some examples of the directional support pixel extraction based on the estimated contour angle α 101 are shown in FIG. 4 .
[0047] The comb detection unit 130 then receives the seven-pixel window 125 as shown in FIG. 5 , including even-numbered pixels from the current field and odd-numbered pixels from the coupling field. It also receives the recursive motion m 102 from an external motion detector, and provides a moving comb signal 135 . An example of the external motion detector providing recursive motion m 102 is disclosed in U.S. Pat. No. 7,193,655.
[0048] An example method of moving comb detection processed by comb detection unit 130 is illustrated with reference to Equation 1, 2, and 3.
[0000]
vfreq
k
=
{
freq
k
,
1
-
freq
k
,
2
fielddiff
k
≥
MonotoneTh
0
otherwise
k
=
0
,
1
,
2
Eqn
1
(
a
)
where
freq
k
,
1
=
∑
i
=
0
3
(
(
y
k
+
i
-
mean
k
)
·
(
y
k
+
i
+
1
-
mean
k
)
<
0
)
Eqn
1
(
b
)
freq
k
,
2
=
∑
i
=
0
2
(
(
y
k
+
i
-
mean
k
)
·
(
y
k
+
i
+
2
-
mean
k
)
<
0
)
Eqn
1
(
c
)
mean
k
=
(
(
y
k
+
y
k
+
2
+
y
k
+
4
)
×
2
+
(
y
k
+
1
+
y
k
+
3
)
×
3
+
6
)
/
12
Eqn
1
(
d
)
and
fielddiff
k
=
(
y
k
+
y
k
+
2
+
y
k
+
4
)
×
2
-
(
y
k
+
1
+
y
k
+
3
)
×
3
/
12
Eqn
1
(
e
)
[0049] In Equation 1, comb pixels are detected by evaluating the local vertical frequency. One should note that ‘vertical frequency’ referenced here actually means ‘directional frequency’ as a directional support pixel extraction unit has been used previously. The vertical frequency, represented by vfreq k , is calculated by the vertical frequency of consecutive pixels in a frame (freq k,1 ), subtracted by the vertical frequency of pixels in a field (freq k,2 ). To calculate the vertical frequency freq k,1 and freq k,2 , the number of pixels having different signs when they are subtracted by the local mean value would be summed, as in Equation 1(b) and (c). The local mean value mean k , calculated as in Equation 1(d), represents the mean value of two coupling fields at the center pixel. One of ordinary skill in the art would understand that by subtracting the vertical frequency of pixels in a field from the vertical frequency of pixels in a frame, the comb effect could be detected with less interference from high frequency details of the picture content. Finally, for immunity to noise at monotone area, the vertical frequency vfreq k is set to zero if the average difference of two fields fielddiff k calculated in Equation 1(e) is lower than a monotone threshold MonotoneTh, as in Equation 1(a).
[0000]
C
=
{
max
(
vfreq
0
,
vfreq
1
)
topfield
max
(
vfreq
1
,
vfreq
2
)
bottomfield
Eqn
2
C
′
=
{
C
m
≥
MotionTh
0
otherwise
Eqn
3
where
m
is
the
recursive
motion
[0050] Equation 2 is optional to take the comb pixels of the neighboring field into account. Equation 3 is to exclude the stationary ‘comb’ pixels from the final moving comb signal C′ to improve the comb detection accuracy, since stationary ‘comb’ pixels could only be false alarms.
[0051] The optional comb detection post-processing unit 140 is configured to receive a plurality of the detected comb signals C′ from comb detection unit 130 , and provides a post-processed comb signal 180 to the video fader value estimator 300 for more robust comb detection. An example embodiment of the comb detection post-processing is illustrated in Equation 4 (a) to (f) with its local processing window shown in FIG. 6 .
[0000]
c_mid1
=
(
∑
i
=
-
1
1
l
i
≥
DirCombCntThM
)
&
(
∑
i
=
-
1
1
(
h
i
>
0
)
≥
DirCombCntInRowTh
)
Eqn
4
(
a
)
c_mid2
=
(
min
(
C
i
-
1
,
j
′
C
i
,
j
′
C
i
+
1
,
j
′
)
≥
DirCombThH
)
Eqn
4
(
b
)
c_mid
=
c_mid1
|
c_mid2
Eqn
4
(
c
)
c_low
=
(
∑
i
=
-
1
1
l
i
≥
DirCombCntThL
)
Eqn
4
(
d
)
where
h
i
=
∑
j
=
-
4
4
(
C
i
,
j
′
>
DirCombThH
)
i
∈
[
-
1
,
1
]
Eqn
4
(
e
)
l
i
=
∑
j
=
-
4
4
(
C
i
,
j
′
>
DirCombThL
)
i
∈
[
-
1
,
1
]
Eqn
4
(
f
)
[0052] According to the embodiment, comb detection post-processing 140 selects a bigger window within the locale of a target comb pixel to determine how densely combing pixels are located near the target comb pixel. As a result, comb detection accuracy is further improved as the target comb pixel can be confirmed and higher confidence is obtained. Comb detection post-processing according to the embodiment calculates and outputs c_mid and c_low as the detected comb signals 180 .
[0053] The comb value estimation unit 150 is configured to receive the seven-pixel window 125 as in FIG. 5 , and provides the calculated comb value 155 . An example comb value estimation method is illustrated in Equation 5 (a) to (c), and Equation 6 is optional to take the comb values of the neighboring field into account.
[0000]
f
k
=
(
3
×
a
k
,
1
-
4
×
a
k
,
2
)
/
12
k
∈
[
0
,
2
]
Eqn
5
(
a
)
where
a
k
,
1
=
∑
i
=
k
k
+
3
y
i
-
y
i
+
1
Eqn
5
(
b
)
a
k
,
2
=
∑
i
=
k
k
+
2
y
i
-
y
i
+
2
Eqn
5
(
c
)
f
=
max
(
f
0
,
f
1
,
f
2
)
Eqn
6
[0054] Equation 5(a) calculates f k , the detail compensated comb value, where the comb value in frame is α k,1 in Equation 5(b) and the details in field is α k,2 in Equation 5(c). Equation 6 further takes into account the maximum comb value of the two fields at three vertically adjacent center positions as the actual comb value.
[0055] The optional contrast adjustment unit 160 then receives the same seven-pixel window 125 and the calculated comb value 155 , and provides a contrast adjusted comb value 190 for the low contrasted but highly confident comb pixels. Contrast adjustment is needed to enhance certain low contrast pixels for better result. An example contrast adjustment method is illustrated in Equation 7 (a) to (c).
[0000]
F
=
{
max
(
MinContras
t
,
f
)
max
(
b
0
,
b
1
,
b
2
)
≥
4
f
otherwise
Eqn
7
(
a
)
where
b
k
=
∑
i
=
k
k
+
3
sign
(
y
i
,
y
i
+
1
,
DTh
)
k
∈
[
0
,
2
]
Eqn
7
(
b
)
and
sign
(
y
i
,
y
i
+
1
,
DTh
)
=
{
1
y
odd
>
y
even
+
DTh
-
1
y
even
>
y
odd
+
DTh
0
otherwise
Eqn
7
(
c
)
[0056] Equation 7(a) enhances a low-contrasted comb value if the confidence of combing is high. Equation 7(b) and (c) calculates the confidence that a pixel is combing.
[0057] Referring now to FIG. 7 , there is illustrated in diagram an embodiment of a false motion excluded motion detector 200 .
[0058] The false motion excluded motion detector 200 receives three fields of the input video signal 10 at time t−1, t, and t+1, the cadence and phase information 70 , and provides detected motion signals 285 and a motion value 275 . The false motion excluded motion detector 200 further comprises optional pre-filters 210 , 220 , and 230 applied on the three input fields respectively, a multiplexer 240 , an inter-frame motion detector 250 , an inter-field motion detector 260 , a false motion exclusion unit 270 , and an optional motion post-processing unit 280 .
[0059] Each of the optional pre-filters 210 , 220 , and 230 is configured to receive an input video field with its respective top/bottom parity signal, and provide a phase-adjusted output field with noise immunity. An example pre-filter is disclosed in U.S. patent application Ser. No. 12/978,154.
[0060] The multiplexer 240 receives the previous and the next field at t−1 and t+1, and selects one of them as the coupling field 245 to form a complete frame with the current field 235 at time t in accordance with the cadence and phase information 70 provided by an external film mode detector.
[0061] The inter-frame motion detection 250 is configured to receive the previous and the next field at time t−1 and t+1, and provides the inter-frame motion signal 255 . An example embodiment of the inter-frame motion detection 250 is illustrated in FIG. 8 .
[0062] Similarly, an example embodiment of the inter-field motion detection 260 is illustrated in FIG. 9 . The inter-field motion detection 260 is configured to receive the two coupling fields 245 and 235 and provide the inter-field motion 265 .
[0063] Based on the detected inter-frame and inter-field motion, the false alarms of the inter-field motion could be excluded by the false motion exclusion unit 270 , with an example embodiment of the implementation shown in FIG. 10 . In this example embodiment, the false motion exclusion unit 270 compares the inter-frame motion signal 255 with a pre-determined motion threshold 271 , selects the received inter-field motion 265 or ‘0’ according to the result of comparison, and provides the motion value 275 . Other embodiments of the false motion exclusion unit 270 based on the inter-frame and inter-field motion signals could be easily derived by those of ordinary skilled in the art.
[0064] The optional motion post-processing unit 280 is configured to receive a plurality of the motion value 275 , and provides a post-processed motion detection signal 285 to the video fader value estimator 300 for more robust in-frame motion detection. An example motion post-processing method is illustrated in Equation 8 (a) and (b) with its local processing window shown in FIG. 11 .
[0000]
m_mid
=
(
∑
i
=
-
1
1
m
i
≥
IFMotCntTh
)
&
(
∑
i
=
-
1
1
(
m
i
>
0
)
≥
IFMotCntInRowTh
)
Eqn
8
(
a
)
where
m
i
=
∑
j
=
-
4
4
(
P
i
,
j
>
IFMotTh
)
i
∈
[
-
1
,
1
]
Eqn
8
(
b
)
[0065] According to the embodiment, motion post-processing uses motions in neighboring pixels to reinforce the detection of a motion pixel. As a result, motion detection accuracy is further improved as the target motion pixel can be confirmed and higher confidence is obtained. Motion post-processing according to the embodiment calculates and outputs m_mid as the detected motion signal 285 .
[0066] Referring now to FIG. 12 , there is illustrated an embodiment of a video fader value estimator 300 .
[0067] The video fader value estimator 300 receives the detected comb signal 180 , the detected motion signal 285 , the estimated comb value 190 , and the motion value 275 , and provides a video fader value 80 . It further comprises a pixel classification unit 310 , a video value calculator 320 , and a video value post-processing unit 330 .
[0068] The pixel classification unit 310 receives the detected comb signal 180 and the detected motion signal 285 , and provides the classification result 315 of the video pixel to the video value calculator 320 .
[0069] The video value calculator 320 then receives the comb value 190 , the motion value 275 , and the classification result 315 , and provides a better represented video value 325 based on the comb or in-frame motion classification.
[0070] The optional video value post-processing unit 330 receives a plurality of the video values 325 , and provides the video fader value 80 for better coverage of video pixels. An example video value post-processing method is illustrated in Equation 9 with its processing window shown in FIG. 13 .
[0000] R ′=max i=0 26 ( R i ) Eqn 9
[0071] In an alternative embodiment, the present invention can be implemented in software as executed by a central processing unit. Software programming code, which can embody the present invention is typically accessed by a microprocessor from long-term, persistent storage media of some type, such as a flash drive or hard drive. The software programming code may be embodied in any of a variety of known media for use with a data processing system, such as a diskette, hard drive, or CD-ROM. The code may be distributed on such media, or may be distributed from the memory or storage of one computer system over a network of some type to other computer systems for use by such other systems. Alternatively, the programming code may be embodied in the memory of the device and accessed by a microprocessor using an internal bus. The techniques and methods for embodying software programming code in memory, on physical media, and/or distributing software code via networks are well known and will not be further discussed herein.
[0072] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
|
Aspects of the invention are directed towards an apparatus and method for detecting local video pixels in mixed cadence video. The local video detector comprises a comb detector that is adaptive to the contour of moving objects and local contrast, a motion detector that is robust to false motion due to vertical details, and a fader value estimator that provides a video confidence value to a fader that combines film mode and video mode processing results. The coupling of the local video detector to a film mode detector increases the robustness, accuracy, and efficiency of local film/video mode processing as compared to the prior art.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates generally to semiconductor memory devices and, more particularly to priority resolvers, match detection and finding the longest match in a group of content addressable memory (CAM) device.
BACKGROUND OF THE INVENTION
[0002] An essential semiconductor device is semiconductor memory, such as a random access memory (RAM) device. A RAM allows a memory circuit to execute both read and write operations on its memory cells. Typical examples of RAM devices include dynamic random access memory (DRAM) and static random access memory (SRAM).
[0003] Another form of memory is the content addressable memory (CAM) device. A conventional CAM is viewed as a static storage device constructed of modified RAM cells. A CAM is a memory device that accelerates any application requiring fast searches of a database, list, or pattern, such as in database machines, image or voice recognition, or computer and communication networks. CAMs provide benefits over other memory search algorithms by simultaneously comparing the desired information (i.e., data in the comparand register) against the entire list of pre-stored entries. As a result of their unique searching algorithm, CAM devices are frequently employed in network equipment, particularly routers, gateways and switches, computer systems and other devices that require rapid content searching, such as routing tables for data networks or matching URLs. Some of these tables are “learned” from the data passing through the network. Other tables, however, are fixed tables that are loaded into the CAM by a system controller. These fixed tables reside in the CAM for a relatively long period of time. A word in a CAM is typically very large and can be 96 bits or more.
[0004] In order to perform a memory search in the above-identified manner, CAMs are organized differently than other memory devices (e.g., DRAM and SRAM). For example, data is stored in a RAM in a particular location, called an address. During a memory access, the user supplies an address and reads into or gets back the data at the specified address.
[0005] In a CAM, however, data is stored in locations in a somewhat random fashion. The locations can be selected by an address bus, or the data can be written into the first empty memory location. Every location has one or a pair of status bits that keep track of whether the location is storing valid information in it or is empty and available for writing.
[0006] Once information is stored in a memory location, it is found by comparing every bit in memory with data in the comparand register. When the contents stored in the CAM memory location does not match the data in the comparand register, the local match detection circuit returns a no match indication. When the contents stored in the CAM memory location matches the data in the comparand register, the local match detection circuit returns a match indication. If one or more local match detect circuits return a match indication, the CAM device returns a “match” indication. Otherwise, the CAM device returns a “no-match” indication. In addition, the CAM may return the identification of the address location in which the desired data is stored or one of such addresses, if more than one address contained matching data. Thus, with a CAM, the user supplies the data and gets back the address if there is a match found in memory.
[0007] Conventional CAMs use priority encoders to translate the physical location of a searched pattern that is located to a number/address identifying that pattern. Typically, priority encoders are designed as a major block common to the whole device. Such a design requires conductors from virtually every word in the CAM to be connected to the priority encoder. Typically, a priority encoder consists of two logical blocks—a highest priority indicator and an address encoder.
[0008] A priority encoder is a device with a plurality of inputs, wherein each of the inputs has an assigned priority. When an input is received on a high priority line in a highest priority indicator, all of the inputs of a lesser priority are disabled, forcing their associated outputs to remain inactive. If any numbers of inputs are simultaneously active, the highest priority indicator will activate only the output associated with the highest priority active input, leaving all other outputs inactive. Even if several inputs are simultaneously active, the priority encoder will indicate only the activity of the input with the highest priority. The priority address encoder is used in the CAM as the means to translate the position (within the CAM) of a matching word into a numerical address representing that location. The priority address encoder is also used to translate the location of only one word and ignore all other simultaneously matching words. However, often times, there is a need to resolve the priority among multiple inputs, each having a different assigned priority.
[0009] Furthermore, there is a need to effectively resolve “imperfect” matches, that is, stored CAM words that may match only a certain number of bits of the data in the comparand, but does not match every bit. Such CAM words are referred to as having a “longest match” condition. In prior art CAMs, search results typically require an exact match (i.e., 100% of the bits) before a system can process those results. Under one method, if an exact match is not found between the stored word and the full comparand, then selected bits in the comparand are masked and the search operation is repeated in an attempt to find a shorter match. If one bit of the comparand is masked at a time, then finding the longest match will require many repeated and undesirable operations/searches. Furthermore, as more bits become masked, multiple matches are indicated for any search result. Without a way to resolve multiple matches, users are typically left to examine the matches manually to find specific properties making one match more desirable than another.
[0010] In an alternative method, data in the CAM is stored in an ordered fashion, wherein data of a certain kind or location is assigned a higher priority, while data of another kind or location is given a lower priority. The priority can be established through assigned priority codes provided by a user. Like the first method described above, the alternative method also requires an exact match. Without an exact match, multiple search attempts are required, wherein, on each attempt, selected bits are masked so that they will not be involved in the matching process. As a result, several matches may be indicated for any search.
[0011] The alternative method is most often found in network communications, where routing tables are used to determine how a message is routed. Messages communicated through the network typically carry data pointing to the desired final destination, as well as topological data that informs the network of how the message is to be routed. Most network systems are configured in a way that only the last router, in a chain of routers in a network, will have the complete routing information and paths. All of the other routers in the path have information on only neighboring routers in a path. Accordingly, when a search is conducted on any router (other than the last router), the routing tables will not have the complete routing information, and will form matches between the searched routing information and the masked data available in the routing table.
[0012] Similar to the first method, a disadvantage of the alternative method is that multiple matching attempts have to be made before a usable match can be found. Secondly, the process of masking bits typically produces multiple matches, where users are left to re-examine each of the matches manually to prioritize the search results. Finally, CAM searches in network communication do not always require an exact match in order for the search to be useful. Often times, an imperfect match result contains sufficient network and “nearest router” data to be used to route the message. However, conventional network systems have not been able to process this data effectively to make use of a “longest match” condition. Accordingly, a system and method is thus needed to determine a “longest match” in a group of CAM words and assign a priority value to each of the longest matches in a single operation.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention provides a CAM match detection circuit and method that detects and resolves multiple CAM words having “longest match” conditions. An embodiment of the invention identifies at least one CAM word that has the largest number of bits matching a search parameter. A priority resolver is disclosed that establishes “longest match” detection on a group of CAM words. A decoder circuit is further disclosed, which assists the system in the present invention to resolve CAM priorities.
[0014] In the present invention data in the CAM does not have to be stored in a specific order in the CAM in order to enable the search for a longest match. Instead a lateral priority code is attached to every entry in the CAM, identifying the level of completeness of the data in that word. CAM words with complete data are assigned the highest lateral priority, and the level of the assigned lateral priority descends as the data in a word has fewer matching bits.
[0015] In a search for a word in the CAM with the most complete data, also known as the search for the longest match, certain bits in the comparand register are masked such that those bits are not involved in the matching process. In the ensuing search, several words in the CAM can match the unmasked data in the comparand register. In the word selection process, the lateral priority of only the matching words (i.e., where each unmasked bit of the comparand matches each corresponding bit of the CAM word) are resolved. Matching CAM words with the highest lateral priority are selected to the second stage of the process wherein a single word is selected, and its address provided at the output of the CAM.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other features and advantages of the invention will be more readily understood from the following detailed description of the invention which is provided in connection with the accompanying drawings.
[0017] [0017]FIG. 1 illustrates a priority match detection circuit according to an embodiment of the invention;
[0018] [0018]FIG. 2 illustrates a bit-for-bit match detection circuit for a CAM word;
[0019] [0019]FIG. 3 illustrates a priority setting circuit used in the priority match detection circuit of FIG. 1;
[0020] [0020]FIG. 4 illustrates a priority selection circuit used in the priority match detection circuit of FIG. 1;
[0021] [0021]FIG. 5 illustrates an address decoder as used in the FIG. 3 priority setting circuit;
[0022] [0022]FIG. 6 illustrates a highest priority pointer as used in the FIG. 4 priority selection circuit;
[0023] [0023]FIG. 7 depicts a simplified block diagram of a router employing the FIG. 1 priority match detection circuit in accordance with another exemplary embodiment of the invention; and
[0024] [0024]FIG. 8 depicts a block diagram of a processor system employing the FIG. 1 priority match detection circuit, in accordance with yet another exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to make and use the invention, and it is to be understood that structural, logical or procedural changes may be made to the specific embodiments disclosed without departing from the spirit and scope of the present invention.
[0026] [0026]FIG. 1 illustrates an embodiment showing a priority match detection circuit, which detects “longest match” conditions on every pattern stored in the space of a CAM, and further assigns a priority to each of the “longest match” CAM words having the largest amount of matching bits. Generally, CAM words having the largest amount of matching bits are assigned the highest priority and vice versa. The comparand register 303 shown in FIG. 1 is loaded with search data. The bits in the comparand register 303 are transmitted in parallel to the “bit for bit” match detectors 404 - 407 that accompany each CAM word 400 - 403 . The results of the match detection are forwarded to a respective priority setting circuit 700 , which also includes a respective priority code circuit ( 201 - 204 ). The results of the priority setting circuit 700 are then forwarded to priority encoder 900 for ultimately selecting one CAM word with the highest lateral priority.
[0027] [0027]FIG. 2 discloses in further detail the “bit for bit” match detector (e.g., 404 ) for each CAM word (e.g., 400 ). Bit lines from the comparand register ( BIT LINE B 0 - BIT LINE Bm) connect through each CAM word in parallel and are outputted 340 at the same bit line location at each CAM word. The bit lines are also connected to one input of an AND gate 353 - 358 in the match detector 404 . Flip flops 350 - 352 are used as a memory device for each bit in the CAM word 312 , wherein each output (Q) and complement (QN) is connected to a respective second input of the AND gates ( 353 - 358 ) as shown in FIG. 2. Each two AND gates associated with one bit ( 353 - 354 , 355 - 356 & 357 - 358 ) are then connected to the inputs of a respective OR gate ( 359 - 361 ). The output of each OR gate 359 - 361 is then connected to an input terminal of an NOR gate 663 . This gate combination is used to compare the data stored in the CAM word 312 with the corresponding data stored in the comparand register 303 . As will be described below, each time a match is detected between a bit in the CAM word 400 and a corresponding bit in the comparand 303 (e.g., each time any of the outputs on OR gates 359 - 361 are logic “0”) then NOR gate 663 outputs a MATCH signal to a priority setting circuit 700 (of FIG. 3), described below.
[0028] The logic function generated by each group of gates 353 - 361 is an exclusive OR (EXOR) function [(B m *QN m )+(BN m *Q m )]. Whenever there is a mismatch, the Q output of a CAM word flip-flop will be the same as the respectively compared bit BN m from the comparand register 303 , providing a logic “1” output on the respective OR gate ( 359 - 361 ). Conversely, if there is a match, then the output on the respective OR gate ( 359 - 361 ) will be a logic “0.” If the outputs from all the OR gates 359 - 361 are “0,” then there is a match between all of the unmasked bits in the comparand register 303 and the corresponding bits in the CAM word (e.g., 400 ). In any case, as the bits in the CAM word 400 are compared one by one with the bits in the comparand 303 , for every match detected, a MATCH signal is sent by NOR gate 663 to the priority setting circuit 700 of FIG. 3.
[0029] [0029]FIG. 3 illustrates a priority setting circuit 700 used in the priority match detection circuit 399 of FIG. 1. A separate priority setting circuit 700 is associated with each CAM word ( 400 - 403 ), wherein a priority code 201 associated with a CAM word, is connected to current decoder 100 and address decoder 378 . Priority code 201 is comprised of a set of flip-flops 660 - 662 , each of which are programmed with a bit of the priority code assigned to each respective CAM word. The priority code may be preset by the user for each CAM word (e.g., depending upon the type of data being stored by the CAM word). Whenever a logic “high” MATCH signal is received from an associated CAM word, it is inputted to and activates transistor 130 . This, in turn, activates decoder circuit 100 . The logic “high” MATCH signal is also forwarded to a first terminal of each of AND gates 368 - 375 .
[0030] The exemplary decoder 100 depicted in FIG. 3 is a 3×8 current-based decoder, where a priority input code comprising 3 bits (D 0 -D 2 ) and their respective complements (DN 0 -DN 2 ) is entered into the decoder 100 , generating an 8-bit priority code output (P 0 -P 7 ). When activated, each priority code output line (P 0 -P 7 ) may pass a current to ground via transistor 130 . As will be described more fully below, the presence of such a current dictates which priority code output (P 0 -P 7 ) is activated. It is understood that, while a 3×8 decoder is used in this exemplary embodiment, that any size decoder may be used having n inputs, with associated m complement inputs, and 2 n outputs.
[0031] The input line D 0 (i.e., the LSB for the priority code for the CAM word) of decoder 100 is connected to the gate terminal of n-type transistors 105 - 108 . The drain terminals of transistors 105 - 108 are connected to the output lines P 7 , P 5 , P 3 and P 1 respectively. Similarly, complement input line DN 0 is connected to a respective gate terminal of n-type transistors 101 - 104 . The drain terminal of transistors 101 - 104 are connected to output lines P 6 , P 4 , P 2 and P 0 respectively. Thus, if input D 0 is logic “high,” input DN 0 will be logic “low.” Accordingly, a voltage will be transmitted to the gates of transistors 105 - 108 , while no voltage flows to the gates of transistors 101 - 104 .
[0032] Input lines D 1 and DN 1 are connected to the gate terminals of n-type transistors 111 - 112 and 109 - 110 , respectively, and input lines D 2 and DN 2 are connected to the gate terminals of n-type transistors 113 and 114 , respectively. Each input line that transmits logic “high,” will turn on the transistors having a gate terminal connected to that line, while input lines transmitting a logic “low” will turn off the transistors having a gate terminal connected to the line.
[0033] The transistors connected in series in the decoder 100 can be thought of as performing a logic AND function, while transistors connected in parallel perform a logical OR function. Thus, transistor 113 performs a logical AND function with transistors 111 and 109 , wherein transistors 111 and 109 are performing a logic OR respective to each other. In turn, transistor 111 performs a respective logical AND with transistors 105 and 101 , which perform a logical OR respective to each other, and so on.
[0034] Still referring to FIG. 3, as a first example, if an input “001” (D 2 =0, D 1 =0, D 0 =1) is transmitted to decoder circuit 100 , the complement “110” (DN 2 =1, DN 1 =1, DN 0 =0) will also be transmitted from mismatch counter 320 . Since lines D 0 , DN 1 , and DN 2 are logic high (i.e., “1”), transistors 105 - 108 , 109 - 110 , and 114 will be turned on. Since the three series-connected transistors 114 , 110 , and 108 are conducting, output line P 1 will be coupled to ground and a current will flow along the line connecting P 1 and transistors 114 , 110 and 108 .
[0035] As a second example, if an input “110” (D 2 =1, D 1 =1, D 0 =0) is transmitted to the decoder circuit 100 , the complement “001” (DN 2 =0, DN 1 =0, DN 0 =1) will be transmitted along with the original input. Since lines DN 0 , D 1 and D 2 are logic high (i.e., “1”), transistors 101 - 104 , 111 - 112 and 113 will be turned on. Since the only current path open is the path along transistors 113 , 111 and 101 (the only active transistors in the pathway to ground), output line P 6 will be coupled to ground and a current will flow along the line connecting P 6 and transistors 113 , 111 , and 101 . As will be described in greater detail below in connection with FIG. 4, each of the priority code positions P 0 -P 7 are sensed to determine which one or ones are carrying current.
[0036] Each time the MATCH signal is activated, current will flow through one of the priority code output lines (P 0 -P 7 ) of decoder 100 . In this manner, a priority code value is established for the CAM word depending on the longest match detected. Generally, the longer the match, the greater the priority and vice versa.
[0037] Turning to FIG. 4, a priority selection circuit 701 is disclosed, wherein each corresponding priority output line (P 0 -P 7 ) from each priority setting circuit 700 is coupled together to a respective resistor in resistor bank 383 . Since the priority output lines are connected in parallel, current flowing through any of the priority output code lines (P 0 -P 7 ) causes a voltage drop across a respective resistor 383 . There can be a voltage drop across one resistor or any number of resistors simultaneously. Each resistor 383 is further connected to respective sense amplifiers 384 A-H to sense the respective quantities of current flowing through the priority code lines P 0 -P 7 , with P 0 being configured to have the highest priority, and inputs P 1 -Pn having a progressively lower priority. The outputs of the sense amplifiers 384 A-H are in turn connected to a highest priority pointer circuit 450 .
[0038] Highest priority pointer 450 points to the CAM word(s) from the group being tested having the highest lateral priority. The highest priority pointer 450 points back to the CAM word having the highest lateral priority. The logic configuration in the highest priority pointer 450 is set so that, no matter how many inputs are simultaneously active, the pointer will only output one line (R 0 -R 7 ) as the active line (logic “1”).
[0039] Looking together at FIGS. 3 and 4, the output of the highest priority pointer 450 (R 0 -R 7 ) is fed back to each priority setting circuit 700 of each CAM word ( 400 - 403 ). Each output of the pointer 450 is inputted (R 0 -R 7 ) into a respective AND gate 368 - 375 as shown in FIG. 3. The outputs of priority code circuit 201 in FIG. 3 are also connected to address decoder 378 that enables only one AND gate 368 - 375 to be active. Accordingly, the combination of the priority code (D 0 -D 2 ), as decoded by the address decoder 378 and the fed-back output (R 0 -R 7 ) of the highest priority pointer 450 selects one gate for output to gate 376 and output (G n ). Respective outputs G 0 -G n from each CAM word are then inputted to a priority encoder 900 which establishes the address of the CAM word with the longest match.
[0040] Turning now to FIG. 5, the address decoder 378 (of FIG. 3) is described in greater detail. Inputs D 0 -D 2 and complement signals DN 0 -DN 2 are input into logic AND gates 600 - 607 , wherein AND gates 600 - 607 respectively output signals S 0 -S 7 which are then transmitted to a respective input on NAND gates 368 - 375 shown in FIG. 3, whose outputs are collectively NORed at gate 376 . NOR gate 376 generates a priority signal G n . The outputs S 0 -S 7 are determined by the following logical functions:
[0041] S 0 =DN 0 *DN 1 *DN 2 S 4 =DN 0 *DN 1 *D 2
[0042] S 1 =D 0 *DN 1 *DN 2 S 5 =D 0 *DN 1 *D 2
[0043] S 2 =DN 0 *D 1 *DN 2 S 6 =DN 0 *D 1 *D 2
[0044] S 3 =D 0 *D 1 *DN 2 S 7 =D 0 *D 1 *D 2
[0045] Turning to FIG. 6, a portion of the highest priority pointer 450 (of FIG. 4) is described in greater detail. Each input line shown (only P 0 -P 3 are shown for simplicity) is connected to an input terminal of NOR gates 618 - 621 and NAND gates 610 - 613 . The output of each NAND gate 611 - 613 is shown as being inputted into a second terminal of NOR gates 618 - 620 , respectively. The output of each NAND gate 611 - 613 is further inverted by inverters 614 - 616 and transmitted to adjacent NAND gates 610 - 613 .
[0046] [0046]FIG. 7 is a simplified block diagram of a router 1100 as may be used in a communications network, such as, e.g., part of the Internet backbone. The router 1100 contains a plurality of input lines and a plurality of output lines. When data is transmitted from one location to another, it is sent in a form known as a packet. Oftentimes, prior to the packet reaching its final destination, that packet is first received by a router, or some other device. The router 1100 then decodes that part of the data identifying the ultimate destination and decides which output line and what forwarding instructions are required for the packet.
[0047] Generally, CAMs are very useful in router applications because historical routing information for packets received from a particular source and going to a particular destination is stored in the CAM of the router. As a result, when a packet is received by the router 1100 , the router already has the forwarding information stored within its CAM. Therefore, only that portion of the packet that identifies the sender and recipient need be decoded in order to perform a search of the CAM to identify which output line and instructions are required to pass the packet onto a next node of its journey.
[0048] Still referring to FIG. 7, router 1100 contains the added benefit of employing a semiconductor memory chip containing a priority match detection circuit, such as that described in connection with FIGS. 1 - 6 . Therefore, the CAM has the benefit of providing “longest match” detection and expanded pattern recognition, in accordance with an exemplary embodiment of the invention.
[0049] [0049]FIG. 8 illustrates an exemplary processing system 1200 which utilizes a CAM priority match detection circuit such as that described in connection with FIGS. 1 - 6 . The processing system 1200 includes one or more processors 1201 coupled to a local bus 1204 . A memory controller 1202 and a primary bus bridge 1203 are also coupled the local bus 1204 . The processing system 1200 may include multiple memory controllers 1202 and/or multiple primary bus bridges 1203 . The memory controller 1202 and the primary bus bridge 1203 may be integrated as a single device 1206 .
[0050] The memory controller 1202 is also coupled to one or more memory buses 1207 . Each memory bus accepts memory components 1208 . Any one of memory components 1208 may contain a CAM array performing priority match detection as described in connection with FIGS. 1 - 6 .
[0051] The memory components 1208 may be a memory card or a memory module. The memory components 1208 may include one or more additional devices 1209 . For example, in a SIMM or DIMM, the additional device 1209 might be a configuration memory, such as a serial presence detect (SPD) memory. The memory controller 1202 may also be coupled to a cache memory 1205 . The cache memory 1205 may be the only cache memory in the processing system. Alternatively, other devices, for example, processors 1201 may also include cache memories, which may form a cache hierarchy with cache memory 1205 . If the processing system 1200 include peripherals or controllers which are bus masters or which support direct memory access (DMA), the memory controller 1202 may implement a cache coherency protocol. If the memory controller 1202 is coupled to a plurality of memory buses 1207 , each memory bus 1207 may be operated in parallel, or different address ranges may be mapped to different memory buses 1207 .
[0052] The primary bus bridge 1203 is coupled to at least one peripheral bus 1210 . Various devices, such as peripherals or additional bus bridges may be coupled to the peripheral bus 1210 . These devices may include a storage controller 1211 , a miscellaneous I/O device 1214 , a secondary bus bridge 1215 , a multimedia processor 1218 , and a legacy device interface 1220 . The primary bus bridge 1203 may also be coupled to one or more special purpose high speed ports 1222 . In a personal computer, for example, the special purpose port might be the Accelerated Graphics Port (AGP), used to couple a high performance video card to the processing system 1200 .
[0053] The storage controller 1211 couples one or more storage devices 1213 , via a storage bus 1212 , to the peripheral bus 1210 . For example, the storage controller 1211 may be a SCSI controller and storage devices 1213 may be SCSI discs. The I/O device 1214 may be any sort of peripheral. For example, the I/O device 1214 may be an local area network interface, such as an Ethernet card. The secondary bus bridge may be used to interface additional devices via another bus to the processing system. For example, the secondary bus bridge may be an universal serial port (USB) controller used to couple USB devices 1217 via to the processing system 1200 . The multimedia processor 1218 may be a sound card, a video capture card, or any other type of media interface, which may also be coupled to one additional device such as speakers 1219 . The legacy device interface 1220 is used to couple legacy devices, for example, older styled keyboards and mice, to the processing system 1200 .
[0054] The processing system 1200 illustrated in FIG. 8 is only an exemplary processing system with which the invention may be used. While FIG. 8 illustrates a processing architecture especially suitable for a general purpose computer, such as a personal computer or a workstation, it should be recognized that well known modifications can be made to configure the processing system 1200 to become more suitable for use in a variety of applications. For example, many electronic devices which require processing may be implemented using a simpler architecture which relies on a CPU 1201 coupled to memory components 1208 and/or memory devices 1209 . The modifications may include, for example, elimination of unnecessary components, addition of specialized devices or circuits, and/or integration of a plurality of devices.
[0055] While the invention has been described in detail in connection with preferred embodiments known at the time, it should be readily understood that the invention is not limited to the disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. For example, although the invention has been described in connection with specific circuits employing different configurations of p-type and n-type transistors, the invention may be practiced with many other configurations without departing from the spirit and scope of the invention. In addition, although the invention is described in connection with flip-flop memory cells, it should be readily apparent that the invention may be practiced with any type of memory cell. It is also understood that the logic structures described in the embodiments above can substituted with equivalent logic structures to perform the disclosed methods and processes. Accordingly, the invention is not limited by the foregoing description or drawings, but is only limited by the scope of the appended claims.
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An apparatus and method is disclosed for a CAM priority match detection circuit that identifies one or more CAM words from a group of CAM words having a “longest match” that matches the bits in a corresponding comparand register. A decoder is further disclosed, wherein the decoder uses n input lines and m complement lines to generate 2 n outputs, wherein only one of the outputs will be active. A priority setting circuit and a priority resolving circuit are also disclosed, wherein the priority setting circuit resolves an initial matching operation to supply priority values to CAM words, and the priority resolving circuit processes the priority values to determine an overall priority for a group of CAM words.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims the benefit of U.S. patent application Ser. No. 09/916,709, by Doyle et al. entitled, METHOD AND SYSTEM FOR THE MULTIDIMENSIONAL MORPHOLOGICAL RECONSTRUCTION OF GENOME EXPRESSION ACTIVITY, filed Jul. 27, 2001 which claims priority from Provisional Application No. 60/221,611, by Doyle et al. entitled, METHOD AND SYSTEM FOR THE MULTIDIMENSIONAL MORPHOLOGICAL RECONSTRUCTION OF GENOME EXPRESSION ACTIVITY filed Jul. 28, 2000, the disclosures of which are incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
Genome Sequencing
[0002] Although biological science finds its roots in a grand tradition of exploratory investigation, for many years, basic research in biology and medicine has focused on a constructionist approach. With the advent of powerful manipulative techniques in molecular biology, most researchers in recent decades have focused on constructing new biological “scenarios” rather than merely observing existing systems. They have done this by perturbing various parameters of otherwise naturally-occurring systems and observing the effect on system dynamics, functional characteristics, etc.
[0003] The federally sponsored Human Genome Project (HGP) has recently re-legitimized the exploratory approach for life scientists. The new availability of complete genome sequence information for a variety of species has motivated many large new projects focused entirely on “mining” these data in order to learn more about the basic functions of biological structures and their development through time.
[0004] Early progress in the HGP took a directed approach. The federally funded sequencing centers concentrated on the targeted sequencing of specific important genes, working out the gene sequence from start to finish. This approach promised a long and difficult road to completing the entire genome.
[0005] Craig Venter, a former NIH researcher, advocated taking a different approach. His idea was rather to take the approach of splitting up the entire genome into small fragments and working on them en masse. This involved dividing the sequencing task among many automatic sequencing machines and attacking the task in parallel, with large numbers of short sequences being determined, and then proceeding to process more batches of the short fragments. Computer scientists then proceeded to reconstruct the fragments' proper order using algorithmic overlap-analysis methods first proposed by Leroy Hood. This method became called “shotgun sequencing” and although persistently derided by the established authorities in the HGP, it proved to be extremely effective in making rapid progress toward the goal of sequencing an entire genome. This work led to the joint announcement on Jun. 26, 2000 by Craig J. Venter, president of Celera Genomics (http:///www.celera.com), and National Human Genome Research Institute director Francis S. Collins of completion of “the first survey of the entire human genome.” The “survey” is the “working draft” of the human genome produced by the publicly funded international consortium HGP and the “first assembly of the human genome” produced by privately funded Celera Genomics.
[0006] With the sequencing of the genome nearly complete, the major focus of research is changing. Since gene sequences code for amino acids, the basic building blocks for proteins, many molecular biologists feel that the best place to focus is on creating large libraries of the specific proteins that are coded for by the known genes in the genomic sequence. This field of research is referred to as proteomics [Pandey, A. and M. Mann, Nature, 405(6788):837-46 (2000)]. Other scientists are focused on the task of computational prediction of the 3-dimensional structure of protein molecules directly through analysis of the primary genomic sequences. This area of work is called structural genomics.
[0007] Still other scientists, recognizing that the ultimate goal for most life scientists is understanding biological function in normal and diseased states, are focusing more directly on the task of attempting to find specific correlations between gene systems and phenotypic patterns, linking gene sequences directly to clinically-relevant effects. This work is part of what is called functional genomics [Eisenberg, D., et al., Nature, 405(6788):823-6 (2000)]. Functional genomics begins with all available sequence information in pursuit of biological understanding [Lockhart, D. J. and E. A. Winzeler, Nature, 405(6788):827-36 (2000)].
[0008] A primary focus of functional genomics is gene expression analysis. This involves the use of a variety of techniques to detect the presence of mRNA sequences within specific tissues. This is done by taking advantage of an effect first observed by Southern, that of the tendency of free nucleotide sequence fragments to hybridize with their complementary mates (see [Southern, E. et al., Nat Genet, 21(1 Suppl):5-9 (1999)] for a recent review). By attaching these sequence fragments to solid supports, and by taking advantage of the binding of various marker molecules to solubilized mRNA, researchers are able to image specific gene expression activity.
[0000] cDNA Microarrays
[0009] Since that early work, DNA hybridization technology took a tremendous leap forward when the ability was provided to screen a broad spectrum of gene messages at once, through the use of cDNA microarrays [Eisen, M. B. and P. O. Brown, Methods Enzymol, 303:179-205 (1999); Brown, P. O. and D. Botstein, Nat Genet, 21(1 Suppl):33-7 (1999); Cheung, V. G., et al., Nat Genet, 21(1 Suppl):15-9 (1999)]. “Gene chips” consist of a solid support to which is attached a regular array of DNA fragments. They are generally created through the use of a robotic system, which coordinates the laying down of a “raster” grid of the DNA probe fragments. The robot deposits this regular grid of pre-determined DNA sequence “spots” onto a fixed substrate, such as a specially-coated glass slide.
[0010] These broad-spectrum cDNA chips are organized so that a wide assortment of probes are arrayed in a geometric grid layout, so that the x,y grid coordinate of the grid can be used by a computer system to keep track of which probe is at each location.
[0011] The basic steps of a typical microarray analysis is as follows: 1) The tissue to be studied is selected and prepared for RNA extraction. This typically involves homogenization of the tissue to free into solution the desired macromolecules. 2) The mRNA is extracted using standard techniques and then is subjected to reverse transcription in order to produce complementary strands of cDNA molecules. 3) The cDNA molecules are usually synthesized using labeled nucleotides. Use of different labels allows for easy comparison of different mRNA populations. 4) The cDNA probes are then tested by hybridizing them to a DNA microarray. Arrays with more than 250,000 oligonucleotides or 10,000 different cDNAs per square centimeter can now be mass-produced [Lockhart, D. J. and E. A. Winzeler, Nature, 405(6788):827-36 (2000)]. 5) Finally, computer-based image acquisition, processing and analysis is used to quantitate the strength of fluorescent signal at each of the microarray grid locations, thereby providing evidence of the presence and concentration of mRNA corresponding to each of the genes associated with the microarray chip.
Laser Capture Microdissection
[0012] Since the gene expression activity of organs and tissues can be quite complex, it is desirable to use a technique which allows analysis of the gene expression, but which permits the morphologic localization of the area to be studied, thus avoiding the loss of morphological detail that results from the homogenization process. Laser capture microdissection (LCM) allows this to be done with great specificity [Bonner, R. F., et al., Science, 278(5342):1481, 1483 (1997); Cole, K. A. et al., Nat Genet, 21(1 Suppl):38-41 (1999); Emmert-Buck, M. R., et al., Science, 274(5289):998-1001 (1996)] (http :/mecko.nichd.nih.gov/lcm/lcm.htm).
[0013] Microdissection-based gene expression analysis begins with the use of a nonaldehyde fixation of the tissue to be studied, using a fixative such as 70% ethanol, since aldehyde fixatives disrupt RNA structure. A low-temperature embedding medium, such as polyethylene glycol distearate, is used to embed the tissue in preparation for histological sectioning. Thin tissue sections are cut, at a thickness of 8 μm, for example, and then are mounted on uncovered glass slides. A thin membrane is typically applied to the section surface to prevent cross-contamination of macromolecules. A UV laser is then used to perform cold ablation of thin lines of tissue, creating an incision around a specific area of the tissue section without disturbing surrounding tissue. A specialized adhesive carrier film is used to transfer the incised portion of the tissue section to an eppendorf microfuge tube with lysis buffer. The cells are lysed in the buffer and can be used for mRNA analysis.
3D Localization
[0014] The above microdissection technique has been used by Cole, et al. [Cole, K. A. et al., Nat Genet, 21(1 Suppl):38-41 (1999)], to study the cellular-level gene expression activity associated with prostate cancer. These investigators used serial-section histological techniques to precisely identify and then excise specific tumor cells within the prostate gland for microarray analysis of expression activity. The investigators then interactively annotated 3D volume reconstructions of gland section images to overlay expression data relating to the specific cells that had been micro dissected. It should be noted that this study focused on only small groups of specific tissue areas, since the microdissection approach requires a skilled operator and is extremely exacting work. Tissue that isn't used for expression analysis is stained for anatomical reconstruction of the gland architecture, rendering it unusable for further expression analysis. Since this approach is targeted to specific areas of the tissue, it is most useful for specifically targeted studies, and is poorly suited for survey-based exploratory analysis.
[0015] Volumetric reconstruction is well known for the macroscopic-level medical imaging techniques of MRI and CT scanning. These 3-dimensional raster-imaging techniques provide useful volumetric surveys for specific anatomical features, but are typically suited for imaging specific sorts of biologic activity. In order to increase the usefulness of these methods, various researchers investigated the combination of multiple imaging modalities, such as MRI and PET scanning, in order to take advantage of the anatomical structure imaging features of the MRI approach, while exploiting the functional data yielded by the PET scanning approach. These multiple datasets are sometimes superimposed upon the same 3-dimensional coordinate space in order to aid in visualization of the functional and structural details.
[0016] A similar capability can be provided at a microscopic histological level, through the use of multi-modal imaging of serial microscopic sections for 3D reconstruction and analysis. Alternating serial sections are placed on separate glass slides, with one set of alternating sections stained and coverslipped for histological detail, and the other set of adjacent alternating sections left uncovered for further processing. For each structure seen in a stained coverslipped section, the adjacent section could be easily processed using other techniques. This method is described in detail in Doyle [Doyle, M. D., The intraorgan lymphatic system of the rat left ventricle in normalcy and aging, Univ. of Illinois at Urbana-Champaign, University Microfilms, order number 9210786 (1991)], where it was used to coordinate light microscopic and electron microscopic examination of the three-dimensional aspects of tissue specimens.
[0017] Various tools are available for the interactive volume visualization of 3-D biomedical image data. One example is given by the MultiVIS client-server Internet-based distributed visualization system developed by Doyle, et al. [Doyle, M. et al., The Visible Embyro Project: A Platform for Spatial Genomics. in 28th AIPR Workshop: 3D Visualization for Data Exploration and Decision Making (2000); Doyle, M., et al., MultiVIS: A Web-based interactive remote visualization environment and navigable volume imagemap system. in 28th AJPR Workshop: 3D Visualization for Data Exploration and Decision Making (2000)] The MultiVIS system also is a good example of a system which allows for the mapping of both volume image data and other types of data, such as object identity information, onto a single x,y,z coordinate space. This system has been used for a variety of purposes, such as for providing an interactive online 3-D atlas of the Visible Human Project male dataset [Doyle, M., et al., MultiVIS: A Web-based interactive remote visualization environment and navigable volume imagemap system. in 28th AJPR Workshop: 3D Visualization for Data Exploration and Decision Making (2000)]. All the references listed in this paragraph are hereby incorporated by reference for all purposes.
Unsolved Problems
[0018] Although the above-described existing technologies have enabled numerous advances in biomedical science and industry, there are several long-felt but unsolved needs for which a solution has not been obvious before the present invention. One need is to gather gene expression data in a manner that supports the types of exploratory research that can take advantage of the broad-spectrum types of biologic activity analysis enabled by today's microarray tools. Further, there is a serious need for methods to visualize the spatial distribution of the biologic activity of a wide range of genes, across a wide array of species and tissue types. There is a great need for technology to allow the collection of large volumes of these types of data, to enable exploratory investigations into patterns of biologic activity that may provide insights into both normal and abnormal biologic states. And there is certainly a need to correlate gene expression data with morphological structure in a useful and easy to understand manner, such as in a volume visualization environment.
[0019] Each of these needs is evident across all species and ages, however there is a particular need for these problems to be solved in order to enable researchers to make significant progress in the study of early development. Many breakthroughs in biomedical science will only occur through study of organism growth and development. Deciphering the delicate interplay between the spatial expression patterns of various genes and the timings of these biological events is among the most difficult of biomedical research questions. In order to solve such problems, tools are needed to allow the collection of larger volumes of expression data across a wider spectrum of gene types than ever before.
BRIEF SUMMARY OF THE INVENTION
[0020] The present invention provides novel and useful methods and systems which help to solve these problems. A new field of work, which is enabled by the present invention, is called “spatial genomics.”
[0021] According to one aspect of the present invention, a method and system for the multidimensional morphological reconstruction of tissue biological activity makes it possible for a biological tissue specimen to be imaged in multiple dimensions to allow morphological reconstruction. The same tissue specimen is physically sampled in a regular raster array, so that tissue samples are taken in a regular multidimensional matrix pattern across each of the dimensions of the tissue specimen. Each sample is isolated and coded so that it can be later correlated to the specific multidimensional raster array coordinates, thereby providing a correlation with the sample's original pre-sampling morphological location in the tissue specimen. Each tissue sample isolate is then analyzed with broad-spectrum biological activity methods, providing information on a multitude of biologic functional characteristics for that sample. The resultant raster-based biological characteristic data may then be spatially mapped onto the original multidimensional morphological matrix of image data.
[0022] According to another aspect of the invention, various types of analysis may then be performed on the resultant correlated multidimensional spatial datasets.
[0023] Other features and advantages of the invention will be apparent in view of the following detailed description and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a flowchart illustrating a preferred embodiment of the invention; and
[0025] FIG. 2 is a diagram depicting the application of an embodiment of the invention to rasterize embryo tissue.
DETAILED DESCRIPTION OF THE INVENTION
[0026] A specific embodiment of the invention can be used for the study of gene expression analysis as described below.
1) Morphological Imaging
[0027] Biological tissue is processed for histological sectioning, using the non-aldehyde fixation method (70% ethanol) and low-temperature embedding medium as described in Cole, et al. [Cole, K. A. et al., Nat Genet, 21(1 Suppl):38-41 (1999)] Histological thin section are then cut, at a thickness of 8 μm, from the embedded tissue, producing two sets of alternating serial sections, as described in Doyle [Doyle, M. D., The intraorgan lymphatic system of the rat left ventricle in normalcy and aging, Univ. of Illinois at Urbana-Champaign, University Microfilms, order number 9210786 (1991)], with one set being histologically-stained for morphological detail and coverslipped for light microscopy. The other set is mounted on glass slides and left unstained with no coverslips, with a microdissection membrane to prevent cross-contamination of macromolecules (see http://mecko.nichd.nih.gov/lcm/LCMTAP.htm#Laser Transfer and http://www.sl-microtest.com/MICRO/m — 04_e.htm for detailed protocols.)
2) Tissue Rasterization
[0028] A UV laser of the type described in Cole, et al., [Cole, K. A. et al., Nat Genet, 21(1 Suppl):38-41 (1999)] is used to incise a grid pattern across each tissue section of the uncovered set of alternating serial sections described in #1 above. This is done with the use of said UV laser adapted to the application end of a microarray-creation robotic apparatus, as described in Cheung [Cheung, V. G., et al., Nat Genet, 21(1 Suppl):15-9 (1999)]. This allows for unattended section incising of a large number of specimens. A second adaptation of the robotic apparatus [Cheung, V. G., et al., Nat Genet, 21(1 Suppl): 15-9 (1999)] adds a microdissection-transfer film holder to the application end of the apparatus. This transfer film holder is then used to lift each incised section sample from each grid location on each section and transfer each sample to a uniquely-coded isolation tube for lysis and further processing. The sample isolation tubes are arranged in spatial arrays, where each tube is bar coded to indicate the x,y,z tissue-space coordinate of the original pre-sampling morphological matrix location of the sample.
3) RNA Amplification
[0029] The mRNA can be amplified [Phillips, J. and J. H. Eberwine, Methods, 10(3):283-8 (1996)]. Amplification can also be done using PCR on the cDNA produced by reverse transcription of the mRNA.
[0000] 4) cDNA Microarray Analysis
[0030] Each of the mRNA samples is then subjected to DNA microarray analysis [Eisen, M. B. and P. O. Brown, Methods Enzymol, 303:179-205 (1999)]. Reverse transcription is performed on each tissue sample isolate, in order to produce complementary strands of cDNA molecules. The cDNA can be labeled by using labeled nucleotides or the cDNA can be fluorescently labeled. The cDNA probes are then tested by hybridizing them to a DNA microarray. A preferred embodiment uses redundancy of probe locations as an internal control against solution inhomogeneity and other processing variations. Finally, computer-based image acquisition, processing and analysis is used to quantitate the strength of fluorescent signal at each of the microarray grid locations.
5) Spatial Data Mapping
[0031] The gene expression data resulting from #4 are then spatially mapped onto the original multidimensional morphological matrix of image data. This is done by setting parameter bits in voxel data, to superimpose the expression message distribution upon the morphological volume image data. The volume image data is correlated with the x, y, z coordinates of the rasterized tissue samples so that tissue samples the locations of tissue samples are accurately located in the image data. This allows various types of analysis to be performed on the resultant correlated multidimensional spatial datasets. The details of implementing spatial mapping are well-known in the computer arts and not described in detail here.
[0032] Some exemplary uses of the spatially mapped data will now be described. A researcher may desire information regarding mRNA synthesis at a particular location, expressed in x, y, z coordinates, of a tissue sample. A 3-dimensional view of the tissue would be displayed on the computer screen allowing the researcher to click on a voxel at the desired location. Techniques for creating an interactive 3-D volume visualization are described in the MultiVIS references described above. The mRNA synthesis data mapped to the voxel would be displayed in a variety of possible formats, e.g., as a table or a graph.
[0033] Alternatively, a researcher may desire information about the expression of a specific gene throughout the tissue sample. In this case, the gene expression data for each voxel is searched to determine whether the specific gene has been expressed. The display is the modified so that the three dimensional image is coded to show the locations where the specific gene is expressed and, optionally, the relative amount of expression.
[0034] Most aspects of each of these elements of the invention can be completely automated, thereby allowing for large scale analysis of many tissue specimens.
6) A Specific Example
[0035] A specific example illustrating the use and advantages of the above-described techniques will now be described. A human embryo 100 having a length of about 5 mm is micro dissected. The z axis is defined along the dorsal axis and slices of about 8 microns are prepared along the length of the z axis. As described above, alternating sets of serial slices are formed. Each slice from one of the sets is then micros dissected into squares of about 8 microns to rasterize the slice. Thus, voxels 104 in the form of 8 micron cubes are defined, each voxel labelled by its x, y, z coordinates.
[0036] The tissue in each voxel is then processed as described above to determine amount of mRNA expression for each tissue sample. This expression data for each voxel is then mapped to the coordinates of each voxel.
ALTERNATIVE EMBODIMENTS
[0037] Although the specific embodiment described above focuses on the study of gene expression activity, and uses a specific embodiment suited to that purpose, it will be clear to one with normal skill in the art that other types of biological activity can be studied using the method of the present invention and that many alternative embodiments are possible which conform to the structure and method of the present invention.
[0038] Various alternative embodiments of the present invention are possible without changing the fundamental nature of the system. These include, in part: 1) use of a variety of other imaging methods, 2) use of other raster-based sampling methods, 3) use of other ways to isolate tissue samples, 4) use of other types of RNA amplification, such as modified PCR approaches or amplification of the cDNA 5) analysis of other types of biologic activity, such as proteins and other ligands, by monoclonal antibody binding, or any other types of local reactivity that can trigger a visible signal, 6) use of other types of broad spectrum macromolecular hybridization analysis, by microbead columns, for example, and 7) use of a variety of other types of data mapping and analysis.
[0039] The invention has now been described with reference to the preferred embodiments. Alternatives and substitutions will now be apparent to persons of skill in the art. For example, the dimensions and particular micro dissection techniques described above are not critical to the invention. Various types of computer systems and languages are suitable for use of the invention and implementation utilizing the Internet would be appropriate. Accordingly, it is not intended to limit the invention except as provided by the appended claims.
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A method of morphological reconstruction of biological activity in a tissue sample maps biological data resulting from analysis of tissue samples onto a 3-D morphological rendering of the biological sample. Each slice in a set of histological slices, indexed by a first index, is micro dissected into micro samples indexed by a pair of first and second indices. The indices are utilized to spatially map biological data to the 3-D rendering.
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This application is a continuation of application Ser. No. 08/205,331 filed on Mar. 3, 1994 and now U.S. Pat. No. 5,472,417, which is a continuation of application Ser. No. 07/785,351 filed on Oct. 30, 1991 and now abandoned, which is a continuation of application Ser. No. 07/288,364 filed on Dec. 22, 1988 and now U.S. Pat. No. 5,195,962.
BACKGROUND OF THE INVENTION
This invention relates to a multiple lumen catheter and more particularly to such a catheter for insertion into a vein of a patient to be used in haemodialysis treatments. The invention also relates to methods for manufacturing the multiple lumen catheter.
FIELD OF THE INVENTION
Multiple lumen catheters have been available for many years for a variety of medical purposes. It is only in recent years, however, that such catheters have been developed for use in haemodialysis. The general form of multiple lumen catheters goes back to as early as 1882 when Pfarre patented such a catheter in the United States under U.S. Pat. No. 256,590. This patent teaches a flexible dual lumen catheter which is used primarily for cleaning and drainage of, for example, the bladder, rectum, stomach and ear. In this type of catheterization, the catheter is introduced into an existing body orifice without the use of any puncturing needle or guidewire.
More recently, a catheter was developed and patented by Blake et al under U.S. Pat. No. 3,634,924. This 1972 patent teaches a double lumen cardiac balloon catheter which is introduced into a large vein and the balloons inflated to control the flow in the vein. The catheter can in fact be placed by using the balloon as sails to move the blood into or through the heart to a position where the catheter takes up its intended function. This patent uses two lumens and teaches a method of making a tip which involves the use of a plug and a wire which retains the shape of one of the lumens during formation of the tip in a moulding technique.
Further patents which teach multiple lumen catheters for general use including the following U.S. Pat. Nos: 701,075; 2,175,726; 2,819,718; 4,072,146; 4,098,275; 4,134,402; 4,406,656 and 4,180,068.
Vascular catheter access by surgical cut-down techniques has been known to the medical procession for many years and, in fact, can be traced back to the 17th century. However, it was only with the introduction of the Seldinger technique in 1953 or thereabouts that a new approach could be used to improve vascular access. This technique was taught in an article published by Seldinger resulting from a presentation made at the Congress of the Northern Association of Medical Radiology at Helsinki in June of 1952. The technique essentially involves the use of a hollow needle to make an initial puncture and then a wire is entered through the needle and positioned in the vessel. The needle is withdrawn and the catheter is entered percutaneously over the wire which is later withdrawn. With this technique it became possible to make less traumatic vascular access and has now become the accepted method of performing access in numerous medical techniques. One of these techniques which has been the subject of much research and development, is haemodialysis.
Haemodialysis can be defined as the temporary removal of blood from a patient for the purpose of extracting or separating toxins therefrom and the return of the cleansed blood to the same patient. Haemodialysis is indicated in patients where renal impairment or failure exists, that is, in cases where the blood is not being properly or sufficiently cleansed, (particularly to remove water) by the kidneys.
In the case of chronic renal impairment or failure, haemodialysis has to be carried out on a repetitive basis. For example, in end stage kidney disease where transplantation of kidneys is not possible or for medical reasons is contra-indicated, the patient will have to be dialysed about 100 to 150 times per year. This can result in several thousand accesses to the blood stream to enable the active haemodialysis to be performed over the remaining life of the patient.
Towards the end of 1960, Dr. Stanley Shaldon and colleagues developed, in the Royal Free Hospital in London, England, a technique for haemodialysis by percutaneous catheterization of deep blood vessels, specifically the femoral artery and vein. The technique was described in an article published by Dr. Shaldon and his associates in the Oct. 14th, 1961 edition of The Lancer at pages 857 to 859. Dr. Shaldon and his associates developed single lumen catheters having tapered tips for entry over a Seldinger wire to be used in haemodialysis. Subsequently, Dr. Shaldon and his colleagues began to insert both inlet and outlet catheters in the femoral vein and this was reported in the British Medical Journal of Jun. 19th, 1963. The purpose of providing both inlet and outlet catheters in the femoral vein was to explore the possibility of a "self-service" approach to dialysis. Dr. Shaldon was subsequently successful in doing this and patients were able to operate reasonably normally while carrying implanted catheters which could be connected to haemodialysis equipment periodically.
Some use was made of a flexible dual lumen catheter inserted by surgical cut-down as early as 1959. An example of such a catheter is that of McIntosh and colleagues which is described in the Journal of the American Medical Association of Feb. 21, 1959 at pages 137 to 138. in this publication, a dual lumen catheter is made of non-toxic vinyl plastic and described as being inserted by cut-down technique into the saphenous vein to the inferior vena cava.
The advantages of dual lumen catheters in haemodialysis is that only one vein access need be affected to establish continued dialysis of the blood, because one lumen serves as the conduit for blood flowing from the patient to the dialysis unit and the other lumen serves as a conduit for blood returning from the dialysis unit to the patient. This contrasts with prior systems where either two insertions were necessary to place the two catheters as was done by Dr. Shaldon, or a single catheter was used with a complicated dialysis machine which alternatively removed blood and returned cleansed blood.
The success of Dr. Shaldon in placing catheters which will remain in place for periodic haemodialysis caused further work to be done with different sites. Dr. Shaldon used the femoral vein and in about 1977 Dr. Uldall began clinical testing of a subclavian catheter that would remain in place. An article describing this was published by Dr. Uldall and others in Dialysis and Transplantation, Volume 8, No. 10, in October 1979. Subsequently Dr. Uldall began experimenting with a coaxial dual lumen catheter for subclavian insertion and this resulted in Canadian Patent No. 1,092,927 which issued on Jan. 6, 1981. Although this particular form of catheter has not achieved significant success in the market place, it was the forerunner of dual lumen catheters implanted in the subclavian vein for periodic haemodialysis.
The next significant step in the development of a dual lumen catheter for haemodialysis is U.S. Pat. No. 1,150,122 to Martin who produced a catheter which achieved some commercial success. The catheter avoided the disadvantages of the Uldall structure.
A subsequent development is shown in U.S. Pat. No. 4,451,252 also to Martin. This utilizes the well known dual lumen configuration in which the lumens are arranged side-by-side separated by a diametric septum. The structure shown in this patent provides for a tip making it possible to enter a Seldinger wire through one of the lumens and to use this wire as a guide for inserting the catheter percutaneously. Patents to this type of structure followed and include European Patent Application to Edelman published under No. 0 079 719, U.S. Pat. Nos. 4,619,643; 4,583,968; 4,568,329 and U.S. Design Pat. No. 272,651.
All of the above examples of haemodialysis catheters suffer from the disadvantages that they can not be used readily for intravenous injection of liquid medication. A person who is using haemodialysis therapy with a dual lumen catheter will have to receive a needle for intravenous injection when medication of this kind is required. It would be desirable that the catheter not only perform the function of haemodialysis, but also provide a facility for intravenous injection without further puncturing of the patient's veins. It is one of the objects of the present invention to provide such a catheter.
The foregoing problems associated with haemodialysis catheters may on some instances be specific to the treatment. However, the catheter of the present invention, in overcoming the disadvantages of the prior art of renal dialysis catheters, provides a catheter which has utility in other procedures. Accordingly, although the present description is directed to haemodialysis, such use is exemplary and it will be evident that catheters according to the invention may be used for other procedures.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic view of a triple lumen catheter according to a preferred embodiment of the present invention, inserted into the subclavian vein of a patient;
FIG. 2 is a diagrammatic perspective view of the catheter drawn to a larger scale than that used in FIG. 1;
FIG. 3 is an enlarged sectional view of the distal end of the catheter of FIG. 1 drawn on line 3--3 of FIG. 2;
FIGS. 4 and 5 are enlarged sectional views taken on the lines 4--4, 5--5 of FIG. 3, respectively, and showing complete sections;
FIG. 6 is an end view of the catheter in the direction generally of arrow of FIG. 3;
FIG. 7 is a sectional view of a trident-shaped branching connector seen at the proximal end of the catheter in FIG. 2 and drawn to a larger scale;
FIGS. 8, 9, 10 and 11 are diagrammatic perspective views of an end of the catheter showing the various steps in the manufacture of the trident-shaped branching connector and associated parts;
FIG. 12 is a sectional view of the connector after assembly;
FIG. 13 is a view similar to FIG. 3 of the distal end of another embodiment of the present invention;
FIG. 14 is a sectional view taken on line 14--14 of FIG. 13;
FIG. 15 is a sectional view of a further embodiment of the catheter;
FIG. 16 is a perspective view of a plug for use in making yet another embodiment of the catheter;
FIG. 17 is a sectional view of still another embodiment of the catheter and using a separate bonded tip;
FIG. 18 is a sectional view illustrating an alternative method of manufacturing a tip according to the invention; and
FIG. 19 is a side view of a tip made using the method illustrated in FIG. 18.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will be described in detail with reference to a preferred embodiment to be used for haemodialysis. However the drawings and description are exemplary of the invention and unless otherwise state, are not intended to be limited by its restraints of size and properties dictated by haemodialysis procedures.
Reference is made first to FIG. 1 of the drawings which illustrates a triple lumen catheter, indicated generally by reference numeral 20, according to a preferred embodiment of the present invention, and showing by way of example, a patient receiving the catheter in the subclavian vein using a Seldinger wire 21. The catheter is to be used for haemodialysis treatment and could of course also be entered in a similar fashion in the femoral vein.
The catheter 20 is secured to a conventional dressing 22 by an attachment fitting 23 having wing tabs 24, and the dressing 22, in turn, is secured to the skin of the patient. As shown, the catheter 20 passes through the dressing 22 and, as can be seen in broken outline, an elongate and flexible cylindrical body 26, formed of a polyurethane extrusion, is inserted through the skin and into the subclavian vein in the downstream direction. The catheter 20 has at its distal end 28 a conical tapered tip 29 which is described in greater detail below. The other end of the body 26 is a generally trident-shaped branching connector 30, which protrudes outwardly from and is secured by dressing 22. Cylindrical blood extraction and return tubes 23, 34 and an intravenous (IV) tube 35 are attached to the trident-shaped branching connector 30, a full description of which is provided below. For the moment it is sufficient to state that these tubes are connected to lumens running through the body 26.
FIG. 2 shows the catheter 20 in greater detail. The body 26 has at its proximal end the connector 30 for receiving the blood extraction and return tubes 32, 34. These tubes terminate at their outer ends in respective female luer fittings 36, 37 for connection to complementary male luer fittings (not shown) leading to a dialysis machine, and carry closure clamps 38 (one of which is shown) to selectively close the tubes.
The IV tube 35 terminated at its outer end in a luer lock fitting 39 for receiving a syringe or male luer lock connector.
The wing tabs 24, sometimes known as suture wings, are formed integrally with a central tubular portion 40 which can rotate on the body 26 and is retained in place by a shoulder on the end of the connector 30 and a second shoulder in a reinforcing portion 42 so that the catheter 20 can be rotated relative to the tabs 24. This rotation is sometimes necessary after insertion of the catheter 20 to re-orientate intake side apertures in the distal end 28 if the apertures happen to be occluded by engagement with the wall of the vein. Details of the apertures are provided below.
As will be described, the reinforcing portion 42 is blended into the body 26 over the length of the portion and assists in strengthening the catheter to minimize the likelihood of kinking. Also, the portion 42 assists in sealing the puncture site where the catheter enters the patient.
As will be described in more detail with reference to subsequent views, the tube 35 is aligned with a central lumen to permit the Seldinger wire 21 to pass through the catheter. The wires exists distal end 28 of catheter body 26 through a tip aperture 64 at the apex of at tip 29 which is essentially conical so that the catheter can slide over the wire and into the patient during insertion. The extraction and return tubes 32, 34 are linked at connector 30 with lumens in the body 26 to connect with respective groups of side apertures 44, 45 (some of which can be seen in this view) near the distal end of the catheter 28. As a result, when inserted and in use, blood can be removed and returned in a closed loop with a haemodialysis machine using the tubes 32, 34. Between treatments the tube 35 is available for intravenous infusion of liquid medicaments.
Reference is next made to FIGS. 3 to 6 of the drawings which illustrate the distal end 28 including tip 29. The body 26 comprises an outer wall 46 and an integral septum 48 extending diametrically across the body 26 and defining an extraction lumen 50 and a return lumen 52, both lumens being generally C-shaped in cross-section and extending from the proximal end towards the distal end. As best seen in FIG. 4, a bulbous middle portion 53 of the septum 48 projects into the lumens 50, 52 and contains the intravenous (IV) lumen 54 which extends along the longitudinal axis of the body portion 26 from the proximal end to the distal end. This lumen is an extension of the IV tube 35 and is proportioned in this embodiment to receive a 0.038 inch diameter Seldinger wire.
The extraction lumen 50 is blocked short of the tip 29 by a first insert 56 which is formed of polyurethane and bonded in place using a suitable solvent such as cyclohexanane, leaving a hollow extension A of extraction lumen 50 distal of first insert 56. Extraction apertures 44 are provided in the outer wall 46 of the cylindrical portion 26, just short of the insert 56, to permit blood to flow from the patient's vein into the extraction lumen 50 and thus through the connector 30 to the extraction tube 32 and the dialysis machine. It should be noted that the apertures 44 are conveniently circular but may be of any suitable shape or size including scaphoid. Also, further extraction apertures may be provided around the lumen 50 as required consistent with the aperture nearest the tip being immediately adjacent the insert 56 to minimize dead spaces.
The return lumen 52 is similarly blocked by a second insert 60 immediately adjacent the last of several return apertures 45. This last aperture is positioned closer to the tip 29 than is the last of the intake apertures 44 in the extraction lumen 50 to minimize the risk of cross flow as returning blood finds its way back into the lumen 50. A hollow extension B of return lumen 52 remains distal of second insert 60. Although some cross-flow is not critical, excess cross-flow will extend the time needed for haemodialysis.
As can be seen in FIGS. 3 and 6, the tip 29 is smoothly rounded at the end 28 of the catheter and tapered slightly gently to facilitate insertion of the catheter 20 into a patient. As mentioned previously, the catheter is intended to be used with a Seldinger wire. It is, therefore, clearly desirable that the tapered tip 29 be concentric with the axis of the body 26 and of the lumen 54. Accordingly, the centrally located IV lumen 54 extends to the tip 29 and terminates at a circular IV aperture 64.
The catheter 20 is made from a length of cylindrical polyurethane extrusion forming the cylindrical body 26. The extrusion is cut to the required length and the ends formed by further operations. The formation of the tapered tip 29 will be described with reference firstly to FIG. 3, followed by a description of the formation of the connector 30.
Before shaping the tapered tip 29, the inserts 56, 60 are positioned and affixed in the respective lumens 50, 52 as shown in FIG. 3. The inserts are shaped to the cross-section of the lumens and affixed as previously described. A cylindrical wire 66 (shown in chain dotted outline), of corresponding diameter to that of the guide wire 21 (FIG. 2), is inserted through the IV lumen 54 to extend from the distal end of the tubing which is then located in a conical tapered mould 68 (shown in chain-dotted outline). The extrusion is heated by R.F. and as it softens it is pushed into the mould 68 in the direction of arrow D, such that the outer wall 46 and the septum 48 merge at the tip 29. The end of the body assumes a conical tapered shape with a radiused end and the material masses in the lumens 50, 52 forming ends 70, 72. The IV lumen 54 retains its internal shape because it is supported on the wire 66. The now tapered tip is cooled to some extent and then removed from the mould 68 and allowed to cool further and harden.
The deformation of the tip results in a thickening of the outer wall 46 and septum 48 to provide a concentration of material substantially exceeding the concentration of material in the main catheter body, and this has the effect of stiffening the tip, which facilitates insertion of the catheter.
Because the wire 66 is not deflected at any time from its normal straight condition during the moulding operation, there is no energy stored in the wire and consequently there is no tendency for the wire to deflect the tip from the desired orientation after removal from the mould 68.
The wire can therefore be left inside the tip during cooling. The apertures 44, 45 are then cut or otherwise formed in the outer wall 46 of the body 26. Also, because the extrusion is symmetrical about the wire, the deformed material at the tip will move evenly to each side of the central septum. The resulting similar masses at ends 70,72 of the lumens will cool and shrink equally so that the tip will remain concentric about the central or IV lumen 54. This will result in a well formed tapered tip.
The method of manufacture of the trident-shaped branching connector 30 and reinforcing portion 42 will next be described with reference to FIGS. 7 to 12. The figures are arranged in order of the steps used in the manufacture and it will be seen in FIG. 7 that the extruded body 26 has received a short sleeve 71 of polyurethane and preferably the same color as that used for the body. The sleeve 71 is snug fit on the cylindrical body 26 and after positioning on the body, the assembly is moved into a heated moulded 73 which has a frustro-conical interior wall 75 designed to deform the sleeve 71 to create the blended reinforcing portion 42 shown in FIG. 2. If preferred, suitable shaped mandrels can be placed inside the lumens of the body 26 to ensure that the lumens are not deformed while the collar is shaped in the mould 73. The sleeve 71 is heated and the body pushed into the heated mould 73 so that material flows to the desired shape.
The upper edge of the sleeve 71 (as drawn) forms a shoulder and is positioned for engagement with the attachment fitting 23 shown in FIG. 2 to locate this fitting longitudinally on the body.
After completing the process illustrated in FIG. 7, the fitting 23 is slipped over the end of the body 26 and into engagement with the sleeve 71. The fitting is a loose fit so that it can rotate freely on the body 26. The positioning can be seen in FIG. 8 which also shows the completed reinforcing portion 42 and how it blends into the body 26.
Next another sleeve 74 is engaged over the end of the tube 26 and, if the first sleeve has been positioned correctly, the sleeve 74 will be positioned so that its trailing end becomes flush with the end of the body 26 as shown in FIG. 9. The sleeve 74 should not be pushed tightly against the attachment fitting 23 in order to provide clearance of free movement of the fitting. With the sleeve in position, a set of deforming mandrels are brought into play as seen in FIG. 9. There are three mandrels, one for each of the lumens. The two outer mandrels 76, 78 are mirror images of one another and positioned about a central mandrel 80. The intent of the mandrels are to form the corresponding lumens to have conical outer portions for receiving shaped ends of the tubes 32, 34 and 35 (FIG. 2) as will be described with reference to FIG. 12.
The mandrels 76, 78 have respective leading ends 82, 84 which are proportioned simply to provide location as they enter corresponding lumens 50, 52 and similarly, a leading portion on the mandrel 80 is proportioned to engage the central lumen 54. The leading portions 82, 84 and 86 blend into respective conical portions 88, 90 and 92 which are arranged to complement one another so that the cones will flair outwardly to receive the tubes. Of course for simplicity of engagement, each of the mandrels is supported from shanks which are arranged in parallel so that the mandrels can be brought into the extrusion longitudinally and deformation will take place simply because the conical portions are larger than the lumens and the material around the lumens will be forced outwardly under the influence of heat provided by heating the mandrels. The second sleeve 74 supports the extrusion which is itself insufficient to support this deformation as the size is increased.
it will be seen in FIG. 10, that after the mandrels are engaged, the second sleeve 74 and contained portion of the extrusion are expanded to form connector 30 and, after completion, the appearance of connector 30 will be as shown in FIG. 11.
Reference is next made to FIG. 12 which shows the engagement of the tubes 32, 34 and 35 in the connector 30. These tubes have their engagement ends deformed to thin the wall and this is done by conical deformations so that the outer surface of the tubes are slightly conical to engage the corresponding internal cones 94, 96 and 98 shown in FIG. 11 and formed by the use of the mandrels. It will be seen in FIG. 12 that the result in assembly is compact, and provides a relatively smooth internal surface to minimize the risk of blood damage caused by turbulence as blood flows through the tubes and associated lumens 32, 34 and 50, 52. Similarly, the tube 35 is engaged so that there is no interference with the Seldinger wire which will slide freely through this tube and lumen 54.
The tubes are attached in the connector 30 using a suitable solvent in a similar fashion to the attachment of the plugs 56, 60 described with reference to FIG. 3.
it is of course possible to make the assembly starting with the trident shaped structure and then add the fitting 23 from the distal end of the body before ending by adding and forming sleeve 71.
In use, as mentioned above, the catheter 20 is inserted such that it points downstream in the patient's vein, that is, the extraction aperture 44 are upstream of the return apertures 45, which, in turn, are upstream of the IV tip aperture 64. When a treatment is in progress the extraction tubes 32, 34 are connected to a dialysis machine which draws blood through the extraction lumen 50 and returns it through return lumen 52 in a similar manner to a conventional dual lumen cannula. Between blood treatments the lumens may be filled with a heparin solution to prevent them from being filled with clotted blood. However, if the patient requires medication or is required to give blood between treatments, the IV lumens 54 may be used. This avoids the trauma and discomfort of inserting a further needle or catheter into the patient and does not disturb the heparin lock.
Between uses the third lumen may be filled with a relatively small volume of heparin or may be occupied by cylindrical solid and flexible patency obturator, similar to guide wire 21. This obturator prevents the entrance of blood into the lumen and thus eliminates the need for heparin in the third lumen. Generally, it will be easier to keep the third lumen free of blood due to its smaller cross-section, regular shape and absence of side holes.
In addition to this advantage the centrally located lumen offers considerable advantages for insertion and removal of the catheter. As there are no side holes in the lumen, "J" ended guide wires may be used without the possibility that the guidewire will exit through a side hole, rather than the end aperture. In addition, because it is easier to keep the smaller lumen free of clotted blood, it should be possible to use a guidewire to replace a catheter which has clotted blood in the blood lumens without dislodging any blood clots which may have accumulated in the blood lumens. This would be done by first entering the Seldinger wire into the third lumen of the catheter in place in the vein, withdrawing this catheter over the wire leaving the wire in place, and then using the wire to guide a replacement catheter over the guide wire.
The exemplary catheter described with reference to the drawings does not have the proportions of a haemodialysis catheter. As mentioned previously, the description is exemplary and in practice, if the catheter is to be used in the subclavian vein it will have proportions as follows. The central lumen will have a diameter of about 0.04 inches to receive a Seldinger wire of diameter 0.038 inches or 0.036 inches. The walls about the central lumen and forming the septum will be about 0.010 inches in thickness and will blend into the outer wall which is about 0.013 inches in thickness. The outer diameter of the body 26 will be 0.149 inches and this will give an area available for blood flow in the lumens of about 0.0048 square inches. The flow rate will be approximately 237 millilitres per minute using accepted pressures to drive the blood through the lumens.
Clearly catheters can be made with a variety of proportions depending upon the use and structures defined by the claims and incorporating the description are within the scope of the invention.
The tip structure shown in FIG. 3 can be made in a number of ways. An alternative is shown in FIGS. 13 and 14. For ease of reference the reference numerals used in relation to these figures correspond to those used above prefixed with the numeral 1. The distal end 128 and tip 129 of a catheter 126 has inserts 156, 160 which extend to fill the unused portions of the extraction and return lumens. The inserts are entered in the lumens 150, 152 and may be affixed therein by a solvent. When the end 128 is heated in the mould the inserts 156, 160 are softened and deformed and the outer wall 146 collapses to merge with the septum 148. The leading ends of the inserts 156, 160 also merge with the septum 148, as represented by the ghost outlines in FIGS. 13 and 14. The resulting catheter has an appearance similar to the catheter described above with a tip opening 164, but with a stiffer leading end.
It will be evident that the form of the inserts can vary. For instance the ends originally near the end 128 could be thinned to allow for easier deformation of the extrusion into the shape shown in FIG. 13.
The catheters illustrated and described above feature septums having a bulbous middle portion 153 to accommodate the IV lumen 154. However, the catheter of the invention is not limited to this particular cross-section and FIG. 15 shows an alternative cross-section. For ease of reference the numerals used in relation to this figure correspond to those used to describe the preferred embodiment prefixed with the numeral 2. The catheter 226 illustrated has a septum 248 with planar sides such that the extraction and return lumens 250, 252 have a D-shaped cross-section. This thicker septum 248 requires the use of more material to form the catheter and also reduces the ratio between the cross-sectional area of the extraction and return lumens and the cross-sectional area of the catheter. However, there may be uses above where this cross-section is advantageous, for instance, where the outer diameter of the catheter body is less critical than it is when used in a vein for haemodialysis.
Reference is now made to FIG. 16 to describe a moulded plug of polyurethane for use in making tips. This plug P has end pieces 200,202 shaped to fit snugly in the lumens 50, 52 (FIG. 3). The end pieces are attached to respective spacers 204,206 which depend from a hub 208 at respective weakened joints 210,212. The hub has a central opening 214 matching the third IV lumen 254 so that the wire used in moulding can be used to locate the hub centrally.
The procedure, when using the plug P of FIG. 16, is to first bend the spacers 204,206 about the joints 210,212 so that the end pieces 200,202 come together for insertion in the end of the extruded body 26. The pieces are pushed home with solvent until the hub 208 meets the end of the body. The pieces 200,202 will then automatically be in the required positions controlled by the lengths of the spacers 204,206. Moulding then proceeds as before so that the hub and adjacent parts of the spacers will become integral portions of the tip.
A further embodiment is shown in FIG. 17. This structure includes a separate moulded tip 216 preferably of polyurethane, which is engaged in and bonded to distal end F of an extruded catheter body E. The tip 216 has an outer conical form and defines a central opening 218 at one end of a central passageway G that forms a continuation of the third lumen 220. A pair of extensions 222, 224 are shaped to fit in the respective lumens 226, 228 and have lengths to match the positions of the apertures 230,232 in the side wall of the lumens. The ends of the extensions are preferably shaped to meet the apertures and complement the natural flow patterns so that dead spaces will be minimized, if not eliminated.
The structure shown in FIG. 17 can also be partly formed by heating in a mould to blend the joint between the tip and the extrusion. This technique can also be used to part form the assembly to improve the tip, if necessary.
The method of shaping the end is described as utilizing radio frequency heating devices to soften the plastic material. This is intended to be illustrative of a softening technique, and other techniques, for example, the use of electrical heating elements, are equally effective.
The third method of manufacturing the tip is illustrated in FIG. 18. Numerals corresponding to those used in FIG. 3 will be repeated with a prefix "3".
In this embodiment, a body 326 receives an extension piece 400 shaped to fit roughly on the end of the body and having a projection 402 of the shape needed as a continuation of the central aperture or third lumen. The parts are located relative to one another by a central rod 404 within two halves 406, 408 of a heated dye shaped to correspond to the tip shape shown in FIG. 3. This shape can of course be modified to provide varying ends on the catheter depending upon the desired configuration.
The body 326 receives first and second mandrels 410, 412 shaped to fit within the lumens 350, 352 and positioned so that material flowing under the influence of the heat will engage with the ends of the mandrels in a fashion corresponding to the plugs 56, 60 shown in FIG. 3. The result will be continuous material from the distal end of the catheter to the ends of the mandrels 410,412. The shaping can be seen in FIG. 3 but without the spacing between the plugs 56, 60 and the solid end of the catheter.
Under the influence of heat, the material of the body 326 and extension 400 will flow and be shaped by the closing dye halves 406, 408. The necessary quantity of material required to complete the shape can be augmented by the provision of plugs in the lumens 350, 352 of a material which will also flow under the influence of heat. However, with some care in design, it is possible to complete the tip without the use of these plugs.
The structure shown in FIG. 18 has the advantage that the extension 400 can be of any durometer hardness require, consistent of course with the material matching that of the body 326. Consequently, it is possible to create a distal end on the tip having different characteristics from the main body. The very end of the catheter can be quite soft so that, when it is inserted, it will have minimal strength and therefore reduce the risk of damage to the wall of the vein after insertion. Such a tip may well make it possible to leave the catheter in place for longer periods than would be possible with a tip having a stiff end.
Reference is now made to FIG. 19 which illustrates a further embodiment of tip made using the method of FIG. 18. As mentioned, the mould house can be of different shapes and the shapes chosen to make the structure in FIG. 19 provide a cylindrical central extension 414 made from a part similar to that identified as 402 in FIG. 18. There is a transition zone defining a shoulder 416 where the extension 414 blends smoothly into the body 326. In this embodiment, to provide sufficient material to block the lumens 350, 352, plugs 418 and 420 are provided and these flow into the material around them as indicated by the broken outline at the shoulder 416. With a suitable selection of material, it is possible to provide the extension 414 with significantly different physical characteristics from the body, notably it can be made of soft material which will have very little effect on the inner wall surface of a vein. Similarly, the strength at the shoulder can be changed by using inserts of soft material or even providing plugs rather than inserts in the manner described with reference to FIG. 3.
Structures such as shown in FIGS. 3, 13, and 19 are exemplary of tips which are tapered. Some are frustro-conical whereas others tend to have a shoulder such as that shown in FIG. 19. However, functionally they are all tapered since they will dilate tissue as they are moved along a Seldinger wire into position in a patient. For this reason, in the terminology of this application, the word "tapered" is intended to include any structure at the end which is capable of such dilation.
It will be appreciated that various other modifications may be made to the catheter, and to the processes for making parts of the catheter as described, without departing from the scope of the invention, for example, the material used to form the tube and inserts may be any suitable medical grade thermoplastic. Also, the positioning of the apertures and the number of apertures is to some extent a matter of choice. Also the length of the conical tip can be varied to include apertures in the wall of the tip. While such a structure is more complicated to make, the flow pattern would be advantageous.
Although the catheter has been described in use in haemodialysis in a subclavian vein, it would also be appreciated that it can be used in both femoral and jugular veins, and can also be used in other blood treatments including apheresis, haemoperfusion and non-blood related treatments involving nutrition and drug therapies.
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The invention provides a cylindrical elongate body extending from a proximal to a distal end, the body defining two similar longitudinally extending lumens separated by a septum and a further lumen defined within the septum, a tip extending from the distal end of the body defining a part of the further lumen, a connector at the proximal end, tubes coupled to the connector and in fluid communication through the connector one with each of the respective lumens, the body defining openings providing access one to each of the longitudinally extending lumens, the openings being spaced from one another longitudinally of the body and the further lumen extending longitudinally beyond the longitudinally extending lumens and through the tip, the further lumen terminating at an opening at the distal end of the tip and the tip being convergently tapered as it extends longitudinally from the body and the longitudinally extending lumens being blocked immediately adjacent and distally of the openings.
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This application claims priority under 35 U.S.C. §119 to patent application no. DE 10 2014 224 259.2, filed on Nov. 27, 2014 in Germany, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
The disclosure relates to a linear actuator which serves to move a load. One preferred field of use is movement systems such as driving simulators and flight simulators, in which a cab is mounted on a platform which can be moved in six degrees of freedom by a total of six identical linear actuators. Linear actuators are known which have an actuator housing with a tube, with a housing bottom at the one end of the tube and with a housing head at the other end of the tube, a piston which is guided longitudinally in the actuator housing, and an actuator rod which is assembled with the piston and protrudes out of the actuator housing in a manner which is guided on the housing head.
Linear actuators of this type are often electromechanical linear actuators, there being a threaded spindle which can be driven rotatably by an electric motor, is mounted rotatably in the housing bottom of the actuator housing and extends in the interior of the actuator housing from the housing bottom in the direction of the housing head, the piston comprising a spindle nut which is in engagement with the threaded spindle, and the actuator rod being hollow and the threaded spindle dipping into the hollow actuator rod.
It is also known to equip a linear actuator of this type with means for compensating for the static load, up to 75% of the static load being supported, for example, by way of said means. The remaining proportion of the load is absorbed by the threaded spindle. If a plurality of linear actuators are provided to carry the load, each linear actuator of course accepts only a certain proportion of the load. If desired, up to 100% of the static load can also be compensated for.
In an emergency or in the case of incorrect control, it can occur that, depending on the movement direction and structural design, the piston impacts against the housing bottom or against the housing head or a flange which is fastened to the outside of the actuator rod impacts against the housing head. Here, damage of structurally essential parts can occur which is such that said parts have to be replaced. On account of the damage, the actuator can also be blocked, with the result that emergency operation is no longer possible. There is also the risk that people are injured who are situated in the cab of the simulator and who are subjected to large negative accelerations in the case of an impact of the piston or the actuator rod.
SUMMARY
The disclosure is based on the object of configuring a linear actuator, in such a way that the reliability of operation is increased and damage of structural parts and injury of people are largely avoided.
In a linear actuator of the generic type, the object is achieved in a first way by virtue of the fact that there is at least one plastically deformable buffer element which can be supported on the housing head on its inner side which faces the interior of the actuator housing and can be deformed in the case of an impact of the piston, kinetic energy being converted into deformation work and, if the buffer element also rebounds somewhat, possibly also potential energy.
In a linear actuator of the generic type, the object is achieved in a second way by virtue of the fact that there is at least one plastically deformable buffer element which can be supported on the housing head on its outer side which faces away from the interior of the actuator housing and can be deformed in the case of an impact of a flange which is fastened to the actuator rod, kinetic energy being converted into deformation work and, if the buffer element also rebounds somewhat, possibly also potential energy.
In the case of a linear actuator according to the disclosure, there is therefore at least one plastically deformable buffer element which can be supported on the housing head and can be deformed in the case of an impact of the piston, kinetic energy being converted into deformation work.
If, in a linear actuator according to the disclosure, the piston impacts the housing head from the inner side or the flange on the actuator rod impacts the housing head from the outer side, the buffer element or elements is/are deformed. The buffer elements therefore form a small crash zone in a similar manner to modern automobiles, within which crash zone the movement energy of the actuator rod with the piston and with the load is converted into deformation work, and the actuator rod is braked to a standstill in a safe way. After an incident of this type, the linear actuator can still be actuated, since no structurally important parts are damaged. The deformed buffer elements are replaced immediately after an above-described incident.
The buffer element or the buffer elements is/are configured in such a way that the construction and people are subjected only to a maximum force or deceleration. Here, the deceleration depends on the area extent and on the strength of the buffer material. A greater area is required with a softer or weaker material, in order to achieve the same damping action as with a firmer or stronger material. As an alternative, the path, on which the buffers are deformed, can be extended, in order to absorb the same amount of energy. A longer path with a softer or weaker material influences the deceleration of the actuator. The optimum maximum force and deceleration can be set by way of the selection of the strength, the area and the deformation path for the buffer elements.
Advantageous refinements of a linear actuator according to the disclosure can be gathered from the subclaims.
An existing plastically deformable buffer element advantageously has a honeycomb-like structure, the cavities of the structure extending in the movement direction of the actuator rod. An aluminum material is preferably used as material for the buffer elements. Honeycomb-like structures made from an aluminum material are known per se as so-called aluminum honeycombs.
A buffer element can be configured as a closed ring which surrounds the actuator rod. A buffer element can also, however, have the shape of an annular segment. In the latter case, it is favorable that a plurality of buffer elements are arranged distributed uniformly over 360° around the actuator rod, in order that the actuator rod is not braked on one side and possibly tilts.
In the context of a compact design of the housing head and therefore of the entire linear actuator, it is advantageous if the buffer elements are situated within the axial extent of a guide bushing for the actuator rod, which guide bushing belongs to the housing head. A certain length is necessary for the guide bushing which usually accommodates guide bands for the actuator rod, one or more sealing rings and a stripper. If the buffer elements are now situated within the axial extent of the guide bushing, the overall length is not influenced by them. In order that this arrangement of the buffer elements is possible, the guide bushing can be displaced axially with respect to the disk in one particularly advantageous development of a linear actuator according to the disclosure.
For buffering a retracting movement of the actuator rod, an outer annular space is then formed in a simple way, on that side of the disk which faces away from the interior space of the actuator housing, radially between said disk and the guide bushing, in which outer annular space at least one buffer element is arranged, and into which outer annular space a flange on the actuator rod can dip. During dipping, the flange displaces the guide bushing into the actuator housing.
For buffering of an extending movement of the actuator rod, one buffer element or a plurality of buffer elements is/are arranged in an inner annular space depending on the required force and deceleration, which inner annular space is delimited axially by the disk and the bushing flange which the guide bushing has at an axial spacing from the disk in front of that side of the disk which faces the interior space of the actuator housing. If the interior space of the actuator housing is loaded with pressure in order to compensate for a static load, the bushing flange is pressed by the pressure against the buffer elements which are situated in the inner annular space. In this way, the guide bushing is held in a defined axial position. At the same time, the buffer elements are secured captively.
In order that the housing pressure acts on the guide bushing on the entire annular area between the actuator rod and the tube of the actuator housing, the inner annular space is connected to atmosphere. A sealing ring between the bushing flange and the tube then prevents oil or gas being lost through the gap between the bushing flange and the tube and the pressure in the housing dropping.
BRIEF DESCRIPTION OF THE DRAWINGS
One exemplary embodiment of a linear actuator according to the disclosure is shown in the drawings. The disclosure will now be explained in greater detail using said drawings, in which:
FIG. 1 shows the linear actuator partially in a longitudinal section, and in a greatly simplified illustration,
FIG. 2 shows a longitudinal section through the linear actuator in the region of the piston on an enlarged scale, and
FIG. 3 shows a longitudinal section through the linear actuator in the region of the housing head of the actuator housing on an enlarged scale.
DETAILED DESCRIPTION
As can be seen from FIG. 1 , the linear actuator has an actuator housing 9 with a tube 10 , at the one end of which a housing bottom 11 is situated and at the other end of which a housing head 12 is situated. A threaded spindle 14 is mounted rotatably in the housing bottom via an anti-friction bearing 13 , which threaded spindle 14 extends with a section 15 which is provided with a thread from the anti-friction bearing into the interior space of the actuator housing 9 in an axially non-displaceable manner. Together with further components, the housing bottom 11 at the same time forms a housing 16 for a toothed belt mechanism 17 , via which the threaded spindle 14 can be driven rotationally by an electric motor 18 which is arranged in parallel next to the actuator housing 9 . The belt mechanism 17 consists of a first toothed pulley wheel 19 which is seated fixedly so as to rotate with it on the shaft 20 of the electric motor 18 which protrudes into the housing 16 , a second toothed pulley wheel 21 which is larger than the first pulley wheel 19 and is seated fixedly so as to rotate with it on a shaft journal 22 of the threaded spindle 14 which protrudes into the housing 16 , and a toothed belt 23 which runs over the two pulley wheels 19 and 21 . The passage of the shaft journal 22 is sealed by way of a shaft sealing ring 24 .
Furthermore, the linear actuator has an actuator rod 30 which is configured as a tube, is fastened to a piston 31 in the interior of the actuator housing 9 and protrudes through the housing head 12 to the outside. That end of the hollow actuator rod which is situated outside the actuator housing 9 is closed by way of an adapter 32 which is centered with a collar in the actuator rod and is screwed to a flange 33 which is screwed onto the actuator rod. A sealing ring 34 is arranged between the collar of the adapter 32 and the actuator rod 30 , by way of which sealing ring 34 the interior of the actuator rod 30 is sealed to the outside.
The construction of the piston 31 is apparent in greater detail from FIG. 2 . According to said figure, the piston 31 has a sleeve-like guide part 35 with an outer circumferential groove, into which a guide band 36 is inserted, by way of which the piston 31 is guided longitudinally in the actuator housing 9 . A plurality of bores 37 which run in the axial direction are situated in the guide part, through which bores 37 that part volume of the interior of the actuator housing 9 which is situated between the wall of the actuator housing and the actuator rod and the part volume on the other side of the piston 31 are open fluidically with respect to one another. From the end side which points in the same direction as the actuator rod 30 , a turned groove 38 is made in the guide part 35 up to a small spacing from the groove which receives the guide band 36 , with the result that there is an annular clearance between the actuator housing 9 and the piston 31 .
In the center, the sleeve-like guide part 35 of the piston 31 has a projecting collar 39 which is provided with an internal thread and into which the actuator rod 30 which is provided with an external thread over a defined section from its piston-side end is screwed as far as an inwardly projecting shoulder of the guide part 35 . The connection is advantageously secured by way of a threaded pin (not shown in greater detail) which is radially screwed into the collar 39 .
From the side which faces away from the actuator rod 30 , a spindle nut 40 which is configured as a flange bushing is inserted into the guide part 35 of the piston 31 and is connected fixedly to the guide part 35 . With an internal thread, the spindle nut 40 interacts with the thread of the threaded spindle 14 . During operation, the unit comprising actuator rod 30 and piston 31 including the spindle nut is secured against rotation by way of the fastening of the actuator rod on a load. A rotational movement of the threaded spindle 14 therefore leads to an axial movement of piston and actuator rod. The threaded spindle 14 extends through the spindle nut 40 into the actuator rod to a greater or lesser extent depending on the position of the actuator rod 30 .
Distributed at an identical angular offset with respect to one another, a plurality of axial bores 45 are made in the collar 39 of the guide part 35 , which axial bores 45 open on the inside into a hollowed-out portion 46 which surrounds the spindle nut over part of its longitudinal extent. The inner end side of the spindle nut is at a spacing from the one end of the hollowed-out portion 46 , with the result that there is an open siphon-like fluidic connection between the interior space of the actuator rod 30 and the interior space of the actuator housing 9 via the axial bores 45 and the hollowed-out portion 46 .
The housing head 12 of the actuator housing 9 comprises a disk 47 which is screwed onto the tubular part of the actuator housing 9 with a collar 48 which is provided with an internal thread. The disk 47 has a stepped through bore 49 with a section 50 of large diameter adjacently to the outer end side which faces away from the interior of the actuator housing 9 and with a section 51 of smaller diameter adjacently to the inner end side which faces the interior of the actuator housing 9 . The diameter of the section 51 is larger than the external diameter of the actuator rod 30 , however. From the inner end side, a guide bushing 52 which is configured as a flange bushing with a bushing flange 61 is inserted into the disk 47 , the diameter of which in front of the bushing flange is slightly smaller than the diameter of the through bore 49 in the region of the section 51 , and which guide bushing 52 reaches as far as that end side of the disk 47 which faces away from the interior of the actuator housing 9 . On the inside, the guide bushing 52 is provided with annular grooves, into which two guide bands 53 and 54 which interact with the actuator rod, a sealing ring 55 which seals the gap between the guide bushing and the actuator rod in a gastight manner, and a stripper 56 are inserted. The outer diameter of the bushing flange 61 of the guide bushing 52 is slightly smaller than the inner diameter of the tube 10 of the actuator housing 9 . The gap is sealed by way of a sealing ring 57 . On account of the selected dimensions, there is an annular space 62 between the guide bushing 52 and the wall of the section 50 of the through bore 49 , which annular space 62 is covered with a thin plate 60 , in order that it does not become contaminated.
The bushing flange 61 of the guide bushing 52 is at a spacing from that end side of the disk 47 which faces the interior of the actuator housing 9 , with the result that there is an annular clearance 58 between the disk 47 and the bushing flange 61 . Said clearance 58 is ventilated to the outside via radial bores 59 in the disk 47 . The inner diameter of the bushing flange 61 is somewhat larger than the outer diameter of the collar 39 on the piston 31 , with the result that there is an annular space 63 between the bushing flange 61 and the actuator rod, into which annular space 63 the collar 39 can dip. The annular space 63 and the collar 39 on the piston therefore allow the provision of the necessary thread length for fastening the actuator rod, without the stroke of the actuator rod 30 being shortened by the bushing flange 61 .
A plurality of (four in the present case, for example, for a defined payload) honeycomb-like annular segments 70 which are spaced apart from one another uniformly and are made from an aluminum material are inserted into the annular space 62 , which annular segments 70 are held in their positions distributed over the circumference of the annular space 62 on their radial outer side by way of an adhesive on the disk 47 . A plurality of (four in the present case, for example) honeycomb-like annular segments 71 which are spaced apart from one another uniformly and are made from an aluminum material are inserted into the annular space 58 , which annular segments 71 are held in their positions distributed over the circumference of the annular space 58 on their radial outer side by way of an adhesive on the tube 10 . The annular segments 70 and 71 serve as deformation elements for the conversion of kinetic energy into deformation energy if the actuator rod moves in an uncontrolled manner in an emergency or in the case of a malfunction of the linear actuator. The annular segments 70 and 71 are therefore the buffer elements which are denoted thus further above in the exemplary embodiment. The annular segments 71 are designed differently from the annular segments 70 , and have, for example, a shorter maximum deformation path than the annular segments 70 . In the case of a greater payload, more than four (for example, eight) annular segments can be situated in the annular spaces 58 and 62 , with an area which is then twice as large as in the case of four annular segments.
Other cross-sectional shapes than the shape of an annular segment are also conceivable for the buffer elements, for example a circular-cylindrical shape or a parallelepiped shape.
If the actuator rod 30 retracts in an uncontrolled manner in the case of a malfunction, the flange 33 impacts on the guide bushing 52 and via the plate 60 on the deformation elements which are situated in the annular space 62 , and is decelerated, the guide bushing 52 being pushed inward and the deformation elements being deformed. If the actuator rod 30 extends in an uncontrolled manner in the case of a malfunction, the piston 31 impacts on the bushing flange 61 of the guide bushing 52 and displaces the bushing flange and therefore the guide bushing counter to the force which is necessary for deforming the deformation elements which are situated in the annular space 58 . Here, air which is situated in the annular space can escape through the bores 59 .
The buffer force depends on what angular region of the annular spaces 58 and 62 is filled by deformation elements and how the deformation elements are configured. If an annular space is to be filled completely, this can be achieved by way of a single annular deformation element.
The entire interior space of the linear actuator is filled with dry nitrogen and oil, there being no dividing element which would separate the nitrogen and the oil from one another. In the case of a completely retracted actuator rod, approximately 60% of the interior space is filled with oil and approximately 40% is filled with nitrogen. In FIG. 1 , the oil level in the case of a vertical operating position of the linear actuator is indicated by the dashed line 75 . The nitrogen is filled via a valve 65 and is subjected to a pressure which is selected depending on the magnitude of the load. The relatively small volume of nitrogen means that the inner pressure in the actuator is discernibly higher in the case of a retracted actuator rod than in the case of an extended actuator rod. The acceleration and extension of the actuator rod counter to the weight of the payload are assisted by the high inner pressure in the actuator. During retraction of the actuator rod, the weight acts in the movement direction of the actuator rod. The lower inner pressure in the actuator inhibits the acceleration of the payload to a lesser extent.
The inner pressure also acts on the guide bushing 52 and secures it in an axial position, in which the bushing flange 61 bears against the deformation elements 71 which are situated in the annular space 58 and, via said deformation elements 71 , against the disk 47 . The guide bushing 52 can therefore run easily in the disk 47 and in the tube 10 .
The linear actuator is preferably provided for applications, in which only limited angles with respect to the vertical are inclined, the actuator rod protruding upward out of the actuator housing, with the result that the oil is situated above the housing bottom 11 . The gas is situated above the oil. During operation, the piston 31 can be dipped completely into the oil or can be situated completely or partially above the oil level. As a result of the siphon-like design of the connection between the interior space of the actuator housing 9 with the axial bores 45 and as a result of the turned groove 38 on the outside of the guide part 35 of the piston 31 , two storage spaces for oil are provided, in which oil is provided even when the piston 31 is situated above the oil level. It is therefore ensured, even if the piston 31 moves in the gas, that the threads of the threaded spindle 14 and the spindle nut 40 and the guide band 36 are lubricated with oil.
LIST OF DESIGNATIONS
9 Actuator housing
10 Tube of 9
11 Housing bottom
12 Housing head
13 Anti-friction bearing
14 Threaded spindle
15 Section of 14
16 Housing
17 Toothed belt mechanism
18 Electric motor
19 Pulley wheel
20 Shaft of 18
21 Pulley wheel
22 Shaft journal of 14
23 Toothed belt
24 Shaft sealing ring
30 Actuator rod
31 Piston
32 Adapter
33 Flange
34 Sealing ring
35 Guide part of 31
36 Guide band
37 Bores
38 Turned groove
39 Collar of 35
40 Spindle nut
45 Axial bores in 35
46 Hollowed-out portion in 35
47 Disk of 12
48 Collar of 47
49 Through bore in 47
50 Section of 49
51 Section of 49
52 Guide bushing
53 Guide band
54 Guide band
55 Sealing ring
56 Stripper
57 Sealing ring
58 Annular space
59 Radial bores
60 Plate
61 Bushing flange on 52
62 Annular space
63 Annular space
65 Valve
70 Buffer elements
71 Buffer elements
75 Oil level
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A linear actuator provided for moving a load includes an actuator housing having a tube and a housing bottom at one end of the tube and a housing head at another end of the tube. The linear actuator further includes a piston guided longitudinally in the actuator housing, and an actuator rod assembled with the piston and configured to protrude out of the actuator housing in a manner which is guided in the housing head. The linear actuator is configured such that reliability of operation is increased and damage of structural parts is largely avoided. The linear actuator achieves these results by virtue of the fact that there is at least one plastically deformable buffer element which can be supported on the housing head and can be deformed in the case of an impact of the piston. The buffer element is configured to convert kinetic energy into deformation work.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. application Ser. No. 13/064,987, filed Apr. 29, 2011, which was a continuation of U.S. application Ser. No. 12/801,952, filed Jul. 2, 2010, which was a continuation of U.S. application Ser. No. 12/659,980, filed Mar. 26, 2010, which issued as U.S. Pat. No. 7,797,970, which was a divisional of U.S. application Ser. No. 11/806,245, filed May 30, 2007, which issued as U.S. Pat. No. 7,743,633, which in turn claims the benefit of Korean Patent Application Nos. 2006-49501 and 2006-49482, both filed on Jun. 1, 2006, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates generally to a washing machine having at least one balancer, and more particularly to a washing machine having at least one balancer that increases durability by reinforcing strength and that is installed on a rotating tub in a convenient way.
2. Description of the Related Art
In general, washing machines do the laundry by spinning a spin tub containing the laundry by driving the spin tub with a driving motor. In a washing process, the spin tub is spun forward and backward at a low speed. In a dehydrating process, the spin tub is spun in one direction at a high speed.
When the spin tub is spun at a high speed in the dehydrating process, if the laundry leans to one side without uniform distribution in the spin tub or if the laundry leans to one side by an abrupt acceleration of the spin tub in the early stage of the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, which thus causes noise and vibration. The repetition of this phenomenon causes parts, such as a spin tub and its rotating shaft, a driving motor, etc., to break or to undergo a reduced life span.
Particularly, a drum type washing machine has a structure in which the spin tub containing laundry is horizontally disposed, and when the spin tub is spun at a high speed when the laundry is collected on the bottom of the spin tub by gravity in the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, thus resulting in a high possibility of causing excess noise and vibration.
Thus, the drum type washing machine is typically provided with at least one balancer for maintaining a dynamic balance of the spin tub. A balancer may also be applied to an upright type washing machine in which the spin tub is vertically installed.
An example of a washing machine having ball balancers is disclosed in Korean Patent Publication No. 1999-0038279. The ball balancers of a conventional washing machine include racers installed on the top and the bottom of a spin tub in order to maintain a dynamic balance when the spin tub is spun at a high speed, and steel balls and viscous oil are disposed within the racers to freely move in the racers.
Thus, when the spin tub is spun without maintaining a dynamic balance due to an unbalanced eccentric structure of the spin tub itself and lopsided distribution of the laundry in the spin tub, the steel balls compensate for this imbalance, and thus the spin tub can maintain the dynamic balance.
However, the ball balancers of the conventional washing machine have a structure in which upper and lower plates formed of plastic by injection molding are fused to each other, and a plurality of steel balls are disposed between the fused plates to make a circular motion, so that the ball balancers are continuously supplied with centrifugal force that is generated when the steel balls make a circular motion, and thus are deformed at walls thereof, which reduces the life span of the balancer.
Further, the ball balancers of the conventional washing machine do not have a means for guiding the ball balancers to be installed on the spin tub in place, so that it takes time to assemble the balancers to the spin tub.
In addition, the ball balancers of the conventional washing machine have a structure in which a racer includes upper and lower plates fused to each other, so that fusion scraps generated during fusion fall down both inwardly and outwardly of the racer. The fusion scraps that fall down inwardly of the racer prevent motion of the balls in the racer, and simultaneously result in generating vibration and noise.
SUMMARY
Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide a washing machine having at least one balancer that increases durability by reinforcing the strength of the balancer, which is installed on a rotating tub in a rapid and convenient way.
Another object of the present invention is to provide a washing machine having at least one balancer, in which fusion scraps generated by fusion of the balancer are prevented from falling down inward and outward of the balancer.
Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
In order to accomplish these objects, according to an aspect of the present invention, there is provided a washing machine having a spin tub to hold laundry to be washed and at least one balancer. The balancer includes first and second housings, the first housing having at least one support for reinforcing a strength of the balancer. The first and second housings have an annular shape and are fused together to form a closed internal space.
Here, the first housing may have the cross section of an approximately “C” shape, and the support protrudes outwardly from at least one of opposite walls of the first housing.
Further, the spin tub may include at least one annular recess corresponding to the balancer such that the balancer is able to be coupled to the spin tub by being fitted within the recess.
Further, the support may protrude from the first housing and comes into contact with a wall of the recess, and guides the balancer to be maintained in the recess in place.
Also, the supports may be continuously formed along and perpendicular to the opposite walls of the first housing.
Further, the supports may be disposed parallel to the opposite walls of the first housing at regular intervals.
Meanwhile, the washing machine may be a drum type washing machine. A front member may be attached to a front end of the spin tub and a rear member may be attached to a rear end of the spin tub. The recesses may be provided at the front and rear members of the spin tub, and the balancers may be coupled to opposite ends of the spin tub at the recesses of the front and rear members.
The foregoing and/or other aspects of the present invention can be achieved by providing a washing machine having at least one balancer. The balancer includes a first housing and a second housing fused to the first housing, and the first and second housings are fused together to form at least one pocket between the first housing and the second housing, the pocket capable of collecting fusion scraps generated during fusion.
Here, the first housing may include protruding fusion ridges protruding from ends of the first housing, and the second housing may include fusion grooves receiving the fusion ridges of the first housing when the first housing and the second housing are fused together.
Further, the first housing may further include inner pocket ridges protruding from the first housing and spaced inwardly apart with respect to the fusion ridges of the first housing.
Further, the second housing may further include outer pocket flanges protruding from the second housing and being situated on outer sides of the fusion grooves when the first housing is fused together with the second housing so the outer pocket flanges are spaced apart from the fusion ridges of the first housing by a predetermined distance, causing an outer pocket to be formed between the fusion ridges and the outer pocket flanges.
Further, the second housing may include guide ridges protruding from the second housing and protruding toward the first housing to closely contact the inner pocket ridges of the first housing when the first and second housings are fused together.
Also, the balancer may further include a plurality of balls disposed within an internal space formed by fusing the first and second housings together, the balls performing a balancing function.
In addition, the washing machine may further include a spin tub disposed horizontally, and the balancers may be installed at front and rear ends of the spin tub.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which
FIG. 1 is a sectional view illustrating a schematic structure of a washing machine according to the present invention;
FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub;
FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention;
FIG. 4 is an enlarged view illustrating section A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention;
FIG. 5 is a perspective view illustrating a balancer according to a second embodiment of the present invention;
FIG. 6 is an enlarged view illustrating the sectional structure of a balancer according to the second embodiment of the present invention;
FIG. 7 is a perspective view illustrating a disassembled balancer according to a third embodiment of the present invention;
FIG. 8 is a perspective view illustrating an assembled balancer according to the third embodiment of the present invention;
FIG. 9 is a partially enlarged view of FIG. 7 ; and
FIG. 10 is a sectional view taken line A-A of FIG. 8 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
Hereinafter, exemplary embodiments of the present invention will be described with reference to the attached drawings.
FIG. 1 is a sectional view illustrating the schematic structure of a washing machine according to the present invention.
As illustrated in FIG. 1 , a washing machine according to the present invention includes a housing 1 forming an external structure of the washing machine, a water reservoir 2 installed in the housing 1 and containing washing water, a spin tub 10 disposed rotatably in the water reservoir 2 which allows laundry to be placed in and washed therein, and a door 4 hinged to an open front of the housing 1 .
The water reservoir 2 has a feed pipe 5 and a detergent feeder 6 both disposed above the water reservoir 2 in order to supply washing water and detergent to the water reservoir 2 , and a drain pipe 7 installed therebelow in order to drain the washing water contained in the water reservoir 2 to the outside of the housing 1 when the laundry is completely done.
The spin tub 10 has a rotating shaft 8 disposed at the rear thereof so as to extend through the rear of the water reservoir 2 , and a driving motor 9 , with which the rotating shaft 8 is coupled, installed on a rear outer side thereof. Therefore, when the driving motor 9 is driven, the rotating shaft 8 is rotated together with the spin tub 10 .
The spin tub 10 is provided with a plurality of dehydrating holes 10 a at a periphery thereof so as to allow the water contained in the water reservoir 2 to flow into the spin tub 10 together with the detergent to wash the laundry in a washing cycle, and to allow the water to be drained to the outside of the housing 1 through a drain pipe 7 in a dehydrating cycle.
The spin tub 10 has a plurality of lifters 10 b disposed longitudinally therein. Thereby, as the spin tub 10 rotates at a low speed in the washing cycle, the laundry submerged in the water is raised up from the bottom of the spin tub 10 and then is lowered to the bottom of the spin tub 10 , so that the laundry can be effectively washed.
Thus, in the washing cycle, the rotating shaft 8 alternately rotates forward and backward by of the driving of the driving motor 9 to spin the spin tub 10 at a low speed, so that the laundry is washed. In the dehydrating cycle, the rotating shaft 8 rotates in one direction to spin the spin tub 10 at a high speed, so that the laundry is dehydrated.
When spun at a high speed in the dehydrating process, the spin tub 10 itself may undergo misalignment between the center of gravity and the center of rotation, or the laundry may lean to one side without uniform distribution in the spin tub 10 . In this case, the spin tub 10 does not maintain a dynamic balance.
In order to prevent this dynamic imbalance to allow the spin tub 10 to be spun at a high speed with the center of gravity and the center of rotation thereof matched with each other, the spin tub 10 is provided with balancers 20 or 30 according to a first or a second embodiment of the present invention (wherein only the balancer 20 according to a first embodiment is shown in FIGS. 1-4 ) at front and rear ends thereof. The structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 2 through 6 .
FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub.
As illustrated in FIG. 2 , the spin tub 10 includes a cylindrical body 11 that has open front and rear parts and is provided with the dehydrating holes 10 a and lifters 10 b , a front member 12 that is coupled to the open front part of the body 11 and is provided with an opening 14 permitting the laundry to be placed within or removed from the body 11 , and a rear member 13 that is coupled to the open rear part of the body 11 and with the rotating shaft 8 (see FIG. 1 ) for spinning the spin tub 10 .
The front member 12 is provided, at an edge thereof, with an annular recess 15 that has the cross section of an approximately “C” shape and is open to the front of the front member 12 in order to hold any one of the balancers 20 . Similarly, the rear member 13 is provided, at an edge thereof, with an annular recess 15 (not shown) that is open to the rear of the front member 12 in order to hold the other of the balancers 20 .
The front and rear members 12 and 13 are fitted into and coupled to the front or rear edges of the body 11 in a screwed fashion or in any other fashion that allows the front and rear members 12 and 13 to be maintained to the body 11 of the spin tub 10 .
The balancers 20 , which are installed in the recesses 15 of the front and rear members 12 and 13 , have an annular shape and are filled therein with a plurality of metal balls 21 performing a balancing function and a viscous fluid (not shown) capable of adjusting a speed of motion of the balls 21 .
Now, the structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 3 through 6 .
FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention, and FIG. 4 is an enlarged view illustrating part A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention.
As illustrated in FIGS. 3 and 4 , a balancer 20 according to a first embodiment of the present invention has an annular shape and includes first and second housings 22 and 23 that are fused to define a closed internal space 20 a.
The first housing 22 has first and second walls 22 a and 22 b facing each other, and a third wall 22 c connecting ends of the first and second walls 22 a and 22 b , and thus has a cross section of an approximately “C” shape. The second housing 23 has opposite edges that protrude toward the first housing 22 and that are coupled to corresponding opposite ends 22 d of the first housing 22 by heat fusion.
The opposite ends 22 d of the first housing 22 protrude outward from the first and second walls 22 a and 22 b of the first housing 22 , and the edges of the second housing 23 are sized to cover the ends 22 d of the first housing 22 .
Thus, when the balancer 20 is fitted into the recess 15 of the front member 12 of the spin tub 10 , the first and second walls 22 a and 22 b are spaced apart from a wall of the recess 15 because of the ends and edges of the first and second housings 22 and 23 which protrude outward from the first and second walls 22 a and 22 b . Further, because the first and second walls 22 a and 22 b are relatively thin, the first and second walls 22 a and 22 b are raised outward when centrifugal force is applied thereto by the plurality of balls 21 that move in the internal space 20 a of the balancer 20 in order to perform the balancing function.
In this manner, the plurality of balls 21 make a circular motion in the balancer 20 , so that the first and second walls 22 a and 22 b are deformed by the centrifugal force applied to the first and second walls 22 a and 22 b of the first housing 22 . In order to prevent this deformation, the second housing 22 is provided with supports 24 according to a first embodiment of the present invention.
The supports 24 protrude from and perpendicular to the first and second walls 22 a and 22 b of the first housing 22 which are opposite each other, and may be continued along an outer surface of the first housing 22 , thereby having an overall annular shape.
The supports 24 have a length such that they extend from the first housing 22 to contact the wall of the recess 15 . Hence, the first and second walls 22 a and 22 b are further increased in strength, and additionally function to guide the balancer 20 so as to be maintained in the recess 15 in place.
Here, when the plurality of balls 21 make a circular motion in the first housing 22 , the centrifugal force acts in the direction moving away from the center of rotation of the spin tub 10 . Hence, the centrifugal force acts on the first wall 22 a to a stronger level when viewed in FIG. 4 . Thus, the supports 24 may be formed only on the first wall 22 a.
In the balancer 20 according to the first embodiment of the present invention, when the first and second housings 22 and 23 are fused together and fitted into the recess 15 of the spin tub 10 , the supports 24 are maintained in place while positioned along the wall of the recess 15 . Finally, the balancer 20 is coupled and fixed to the front member 12 of the spin tub 10 by screws (not shown) or in any other fashion that allows the balancer 20 to be coupled to the front member 12 .
Although not illustrated in detail, the balancer 20 is similarly installed on the rear member 13 of the spin tub 10 .
The ends 22 d of the first housing 22 include fusion ridges 42 a that protrude toward the second housing 23 . The fusion ridges 42 a are inserted within fusion grooves 43 a of the second housing 23 .
FIGS. 5 and 6 correspond to FIGS. 3 and 4 , and illustrate a balancer 30 according to a second embodiment of the present invention.
The balancer 30 according to the second embodiment of the present invention has an annular shape and includes first and second housings 32 and 33 that are fused together forming an internal space 30 a therebetween in which a plurality of balls 31 are disposed. The balancer 30 according to the second embodiment of the present invention is similar to that of balancer 20 according to the first embodiment of the present invention, except the structure of supports 34 of balancer 30 is different from that of the structure of the supports 24 of balancer 20 .
As illustrated in FIGS. 5 and 6 , the supports 34 according to the second embodiment of the present invention protrude parallel to first and second walls 32 a and 32 b of a first housing 32 which are opposite each other, and the supports 34 are disposed at regular intervals along the first and second walls 32 a and 32 b . The first housing 32 further includes a third wall 32 c . Ends 22 d of the first housing 32 extend from an end of the first and second walls 32 a and 32 b.
Similar to the supports 24 according to the first embodiment, the supports 34 of the second embodiment have a length such that the supports 34 extend from the first housing 32 to contact the wall of the recess 15 . The surfaces of the supports 34 thereby abut portions of the front member 12 . Hence, the first and second walls 32 a and 32 b are further increased in strength, and additionally function to guide the balancer 30 so as to be maintained in the recess 15 in place.
Next, the construction of a balancer 40 according to a third embodiment of the present invention will be described with reference to FIGS. 7 through 10 .
FIGS. 7 and 8 are perspective views illustrating disassembled and assembled balancers according to the third embodiment of the present invention, FIG. 9 is a partially enlarged view of FIG. 7 , and FIG. 10 is a sectional view taken along line A-A of FIG. 8 .
As illustrated in FIGS. 7 and 8 , a balancer 40 includes a first housing 42 having an annular shape and a second housing 43 having an annular shape that is fused to the first housing 42 , thereby forming an annular housing corresponding to the recess 15 (see FIG. 2 ) of the spin tub 10 . The first and second housings 42 and 43 may be, for example, formed of synthetic resin, such as plastic by injection molding.
As illustrated in FIG. 9 , the first housing 42 has a cross section of an approximately “C” shape, includes fusion ridges 42 a protruding to the second housing 43 at opposite ends thereof which are coupled with the second housing 43 , and inner pocket ridges 42 b protruding to the second housing 43 spaced inwardly apart from the fusion ridges 42 a.
The second housing 43 , which is coupled to opposite ends of the first housing 42 in order to form a closed internal space 40 a for holding a plurality of balls 41 and a viscous fluid, includes fusion grooves 43 a recessed along edges thereof so as to correspond to the fusion ridges 42 a , outer pocket flanges 43 b and guide ridges 43 c . The outer pocket flanges protrude to the first housing 42 on outer sides of the fusion grooves 43 a so as to be spaced apart from the fusion ridges 42 a of the first housing 42 by a predetermined distance. The guide ridges 43 c protrude to the first housing 42 on inner sides of the fusion grooves 43 a and closely contact the inner pocket ridges 42 b of the first housing 42 .
The guide ridges 43 c of the second housing 43 move in contact with the inner pocket ridges 42 b of the first housing 42 when the second housing 43 is fitted into the first housing 42 , to thereby guide the fusion ridges 42 a of the first housing 42 to be fitted into the fusion grooves 43 a of the second housing 43 rapidly and precisely.
Thus, when the fusion ridges 42 a of the first housing 42 are fitted into the fusion grooves 43 a of the second housing 43 in order to fuse the first housing 42 with the second housing 43 , as shown in FIG. 10 , an inner pocket 40 b having a predetermined spacing is formed between the fusion ridges 42 a and inner pocket ridges 42 b , and an outer pocket 40 c having a predetermined spacing is formed between the fusion ridges 42 a and the outer pocket flanges 43 b.
In this state, when heat is generated between the fusion ridges 42 a of the first housing 42 and the fusion grooves 43 a of the second housing 43 , the fusion ridges 42 a and the fusion grooves 43 a are firmly fused with each other. At fusion, fusion scraps that are generated by heat and fall down inward of the first housing 42 are collected in the inner pocket 40 b , so that the scraps are not introduced into the internal space 40 a of the balancer 40 in which the balls 41 move. Fusion scraps falling down outward of the first housing 42 are collected in the outer pocket 40 c , and thus are prevented from falling down outward of the balancer 40 .
In the embodiments, the balancers 20 , 30 and 40 have been described to be installed on a drum type washing machine by way of example, but it is apparent that the balancers can be applied to an upright type washing machine having a structure in which a spin tub is vertically installed.
As described above in detail, the washing machine according to the embodiments of the present invention has a high-strength structure in which at least one balancer is provided with at least one support protruding outward from the wall thereof, so that, although the strong centrifugal force acts on the wall of the balancer due to a plurality of balls making a circular motion in the balancer, the wall of the balancer is not deformed. Thus, the plurality of balls can make a smooth circular motion without causing excess vibration and noise, and thus increasing the durability and life span of the balancer.
Further, the washing machine according to the embodiments of the present invention has a structure in which the balancer can be rapidly and exactly positioned in the recess of the spin tub by the supports, so that an assembly time of the balance can be reduced.
In addition, the washing machine according to the present invention has a structure in which fusion scraps generated when the balancer is fused are collected in a plurality of pockets, and thus are prevented from falling down inward and outward of the balancer, so that the internal space of the balancer, in which a plurality of balls are filled and move in a circular motion, has a smooth surface without the addition of fusion scraps. As a result, the balls are able to move more smoothly, and excess noise and vibration are minimized. The balancer may have a clear outer surface to provide a fine appearance without the fusion scraps, so that it can be exactly coupled to the spin tub without obstruction caused by the fusion scraps.
Although a few embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims and their equivalents.
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A drum type washing machine, including a housing, a spin tub to hold laundry to be washed, the spin tub rotating with respect to a horizontal axis of the washing machine, and a ball balancer coupled to the spin tub to compensate for a dynamic imbalance during rotation thereof, the ball balancer including a first plastic member and a second plastic member joined to each other to define a closed internal space in which a plurality of balls and viscous fluid are accommodated, the first plastic member having an open side, and the second plastic member adapted to cover the open side of the first plastic member. The first plastic member includes a plurality of supports formed on an outer surface thereof to establish contact with the spin tub, and the ball balancer is fastened to the spin tub via a plurality of screw members.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 10/939,010, now U.S. Pat. No. 7,137,366, filed Sep. 10, 2004.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to engines, and in particular to swash plate internal combustion engines.
BACKGROUND OF THE INVENTION
An internal combustion engine derives power from the volumetric compression of a fuel-air mixture, followed by a timed ignition of the compressed fuel-air mixture. The volumetric change generally results from the motion of axially-reciprocating pistons disposed in corresponding cylinders. In the course of each stroke, a piston will vary the gas volume captured in a cylinder from a minimum volume to a maximum volume. In an Otto cycle, or “four-stroke” internal combustion engine, the reciprocal motion of each piston compresses the fuel-air mixture, receives and transmits the force generated by the expanding gases, generates a positive pressure to move the spent gases out the exhaust port and generates a negative pressure on the intake port to draw in a subsequent fuel-air gas charge.
The modern internal combustion engine arose from humble beginnings. As early as the late 17 th century, a Dutch physicist by the name of Christian Huygens designed an internal combustion engine fueled with gunpowder. It is believed that Huygens' engine was never successfully built. Later, in the early nineteenth century, Francois Isaac de Rivaz of Switzerland invented a hydrogen-powered internal combustion engine. It is reported that this engine was built, but was not commercially successful.
Although there was a certain degree of early work on the idea of the internal combustion engine, development truly began in earnest in the mid-nineteenth century. Jean Joseph Etienne Lenoir developed and patented a number of electric spark-ignition internal combustion engines, running on various fuels. The Lenoir engine did not meet performance or reliability expectations and fell from popularity. It is reported that the Lenoir engine suffered from a troublesome electrical ignition system and a reputation for a high consumption of fuel. Approximately 100 cubic feet of coal gas were consumed per horsepower hour. Despite these early setbacks, a number of other inventors, including Alphonse Beau de Rochas, Siegfried Marcus and George Brayton, continued to make substantial contributions to the development of the internal combustion engine.
An inventor by the name of Nikolaus August Otto improved on Lenoir's and de Rochas' designs to develop a more efficient engine. Well aware of the substantial shortcomings of the Lenoir engine, Otto felt that the Lenoir engine could be improved. To this end, Otto worked to improve upon the Lenoir engine in various ways. In 1861, Otto patented a two-stroke engine that ran on gasoline. Otto's two-stroke engine won a gold medal at the 1867 World's Fair in Paris. Although Otto's two-stroke engine was novel, its performance was not competitive with the steam engines of the time. A successful two-stroke engine would not be developed until 1876.
In or around 1876, at approximately the same time that an inventor named Dougald was building a successful two-stroke engine, Klaus Otto built what is believed to be the first four-stroke piston cycle internal combustion engine. Otto's four-stroke engine was the first practical power-generating alternative to the steam engines of the time. Otto's revolutionary four-stroke engine can be considered the grandfather of the millions of mass-produced internal combustion engines that have since been built. Otto's contribution to the development of the internal combustion engine is such that the process of combusting the fuel and air mixture in a modern automobile is known as the “Otto cycle” in his honor. Otto received U.S. Pat. No. 365,701 for his engine.
Ten years after Klaus Otto built his first four-stroke engine, Gottlieb Daimler invented what is often recognized as the prototype of the modern gasoline engine. Daimler's engine employed a single vertical cylinder, with gasoline imparted to the incoming air by means of a carburetor. In 1889, Daimler completed an improved four-stroke engine with mushroom-shaped valves and two cylinders. Wilhelm Maybach built the first four-cylinder, four-stroke engine in 1890. The carbureted four-stroke multi-cylinder internal combustion engine became the mainstay of ground transportation from the early 1900s through the 1970s, ultimately being supplanted by fuel-injected engines in the 1980s.
SUMMARY OF THE INVENTION
The present invention is a swash-plate engine having a number of features and improvements distinguishing it not only from traditional crankshaft engines, but also from prior swash plate designs.
In a first embodiment, the present invention is a power-generation device comprising at least one cylinder having an internal volume, an internal cylinder surface, a central axis, a first end and a second end. At least one cylinder head, having an internal cylinder head surface, is disposed at, and secured to, the first end of one of the at least one cylinders. At least one piston, having an axis of motion parallel to the central axis of at least one of the cylinders, and having a crown disposed toward the internal surface of the cylinder head secured to that cylinder, is disposed in the internal volume of the cylinder. The crown of the piston, an internal cylinder surface, and the internal surface of the cylinder head for that cylinder together form a combustion chamber for that cylinder.
The first embodiment further includes an output shaft, having a central axis having a fixed angular relationship to the central axis of the cylinder. A swash plate, having a first swash plate surface having a normal axis disposed at a first fixed angle to the central axis of the output shaft, is fixed to the output shaft. At least one connecting rod, having a principal axis, a first end axially and rotationally fixed to a piston, and a second end, is secured to at least one piston. At least one follower, having a first follower surface having a normal axis disposed at the first fixed angle to the principal axis of the connecting rod to which it is secured, is secured to the second end of a connecting rod. The first follower surface contacts, and conforms to, the orientation of the first swash plate surface.
In a second embodiment, the present invention is a power-generation device comprising an output shaft, having a central axis, and at least two cylinders, disposed symmetrically about the central axis of the output shaft. Each cylinder has a central axis parallel to the central axis of the output shaft, an internal volume, an internal cylinder surface, a central axis, a first end and a second end.
At least two cylinder heads, each having an internal cylinder head surface, is disposed at, and secured to, the first end of one of the cylinders. The device includes at least two pistons, each piston having an axis of motion aligned to the central axis of a cylinder, disposed in the internal volume of the cylinder and having a crown disposed toward the internal surface of the cylinder head secured to that cylinder. The crown of the piston, an internal cylinder surface, and the internal surface of the cylinder head for that cylinder together form a combustion chamber for that cylinder.
A swash plate is fixed to the output shaft, having a swash plate clocking interface fixed to the orientation of the output shaft about the central axis of the output shaft. At least two connecting rods, each having a principal axis, a first end and a second end are each axially and rotationally fixed to a piston. At least two followers, having a follower clocking interface fixed to the orientation of the connecting rod about the principal axis of the connecting rod and the orientation of the swash plate clocking interface, are each secured to the second end of a connecting rod.
In a third embodiment, the present invention is a power-generation device comprising an output shaft, having a central axis, four cylinders, disposed symmetrically and regularly about the central axis of the output shaft and axially-movable with respect to the output shaft, four cylinder heads, and four pistons connected to a swash plate by four followers.
The four cylinders are disposed symmetrically and regularly about the central axis of the output shaft and are axially-movable with respect to the output shaft. Each cylinder has a central axis parallel to the central axis of the output shaft, an internal volume, an internal cylinder surface, a central axis, a first end and a second end. The four cylinder heads, each have an internal cylinder head surface, an intake port, and an exhaust port. Each such cylinder head is disposed at, and secured to, the first end of a cylinder.
Each of the four pistons has an axis of motion aligned to the central axis of a cylinder, is disposed in the internal volume of the cylinder, and has a crown disposed toward the internal surface of the cylinder head secured to that cylinder. The crown of the piston, an internal cylinder surface, and the internal surface of the cylinder head for that cylinder together form a combustion chamber for that cylinder.
The swash plate is fixed to the output shaft, and has a substantially-planar swash plate surface having a normal axis disposed at an angle of approximately 45 degrees to the central axis of the output shaft. The four connecting rods, each having a principal axis, a first end axially and rotationally fixed to a piston, and a second end, are connected to the swash plate by four followers, each secured to the second end of a connecting rod. Each of the followers has a substantially-planar follower surface fixed to the connecting rod and has a normal axis disposed at an angle of approximately 45 degrees to the central axis of the output shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
For more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying Figures.
FIG. 1 depicts a partial cutaway isometric view of an internal combustion engine according to one embodiment of the present invention;
FIG. 2 depicts an isometric view of the reciprocating assembly of the internal combustion engine of FIG. 1 ;
FIG. 3 depicts an front view of the reciprocating assembly of the internal combustion engine of FIG. 1 ;
FIG. 4 depicts an right side view of the reciprocating assembly of the internal combustion engine of FIG. 1 ;
FIG. 5 depicts a top view of the reciprocating assembly of the internal combustion engine of FIG. 1 ;
FIG. 6 depicts an isometric view of a piston used in the reciprocating assembly of FIG. 2 ;
FIG. 7 depicts a front view of a piston used in the reciprocating assembly of FIG. 2 ;
FIG. 8 depicts a side view of a piston used in the reciprocating assembly of FIG. 2 ;
FIG. 9 depicts a top view of a piston used in the reciprocating assembly of FIG. 2 ;
FIG. 10 depicts an isometric view of the swash plate used in the reciprocating assembly of FIG. 2 ;
FIG. 11 depicts a front view of the swash plate used in the reciprocating assembly of FIG. 2 ;
FIG. 12 depicts a side view of the swash plate used in the reciprocating assembly of FIG. 2 ;
FIG. 13 depicts a top view of the swash plate used in the reciprocating assembly of FIG. 2 ;
FIG. 14 depicts a side section view of the cylinder head and crankcase assembly of FIG. 1 ;
FIG. 15 depicts an isometric section view, of the cylinder head along line 15 - 15 of FIG. 14 ; and
FIG. 16 depicts an isometric section view of the cylinder head along line 16 - 16 of FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
Although the making and using of various embodiments, of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Engine 100 incorporates cylinder block 102 and crankcase 104 disposed about output shaft 106 . A swash plate 108 is rigidly secured to the output shaft 106 . Swash plate 108 has a generally-planar bearing surface 118 having a normal axis disposed at an angle to the principal longitudinal axis of the output shaft 106 . A set of four cylindrical pistons 110 are disposed in four corresponding cylinders 112 and operably connected to swash plate 108 through connecting rods 114 via rod feet 116 , which ride on bearing surface 118 of swash plate 108 . Each of rod feet 116 has a generally planar bottom surface having a principal normal axis disposed at an angle to the principal longitudinal axis of the connecting rod 114 to which it is secured.
Each piston 110 incorporates a skirt 150 and a crown 152 . In the embodiment shown in FIGS. 1-9 , the crown 152 incorporates a pair of valve pockets 154 and 156 , although alternate embodiments may omit either or both of pockets 154 and 156 . Similarly, while pockets 154 and 156 are shown as being symmetrical and having a particular shape, pockets 154 and 156 may have different shapes in alternate embodiments.
Piston skirt 150 incorporates a compression ring groove 158 and oil control rings 160 and 162 . Alternate embodiments may incorporate more or fewer piston ring grooves 158 - 162 as a particular application demands. It will be understood by those of skill in the art that a wide variety of piston ring styles may be employed in the present invention, again depending on the particular application.
Connecting rod 114 connects piston 150 to an elliptical rod foot 116 . Rod foot 116 incorporates an upper surface 164 , a lower surface 166 and an outer edge 168 . When assembled to swash plate 108 , rod foot 116 is captured by inner ridge 120 and outer ridge 122 against upper surface 164 , while lower surface 166 rides against swash plate bearing surface 118 . Swash plate 108 incorporates a conical transition 200 to brace the wash plate 108 against moment loading on the swash plate bearing surface 118 .
Those of skill in the art will recognize that engine 100 differs markedly from traditional internal combustion engines. In the most common layout of the traditional internal combustion engine, the engine's pistons are tied to a rotary crankshaft through a set of connecting rods, in order to convert the reciprocal axial motion of the pistons into continuous rotary motion of the crankshaft. Although a wide variety of cylinder layouts have been devised and implemented, including the well-known “V” geometry (as in “V8”), in-line, opposed (also known as “flat”) and radial geometries, all such engines share the basic crankshaft geometry described above.
Despite their overwhelming successes, crank-articulated reciprocating powerplants incorporate certain inherent limitations. Except at two discrete points in the range of piston motion—namely top dead center and bottom dead center—the connecting rod is disposed at an angle to the center line of the cylinder within which the piston is exposed. Axial forces in the connecting rod must, therefore, be counteracted at the interface between the piston and the cylinder wall. The load on the cylinder wall by the piston is known as “side loading” of the piston. As the pressure in the cylinder rises, side-loading can become a serious concern, with respect to durability as well as frictional losses. Further, dynamic centrifugal loads on the engine components rise geometrically with engine speed in a crankshaft engine, limiting both the specific power output and power-to-weight ratio of crankshaft engines.
In a crankshaft engine, the geometry of the crankshaft and connecting rod is such that, as the crank rotates and the piston moves through its range of motion, the piston spends more time near bottom dead center (where no power is generated) than near top dead center (where power is generated). This inherent characteristic can be countered somewhat with the use of a longer connecting rod, but the motion of the piston with respect to time can only approach, and cannot ever match, perfectly sinusoidal motion. The magnitude of this effect is inversely related to the ratio of the effective length of the connecting rod to the length of the crankshaft stroke, but is particularly pronounced in engines having a connecting rod-to-stroke ratio at or below 1.5:1.
The rate of acceleration of the piston away from top dead center in an engine having a low rod-to-stroke ratio is such that useful combustion chamber pressure cannot be maintained at higher crank speeds. This occurs because the combustion rate of the fuel-air mixture in the combustion chamber, which governs the pressure in the combustion chamber, is limited by the rate of reaction of the hydrocarbon fuel and oxygen. In a long stroke, short rod engine running at a high crankshaft speed, the increase in volume caused by the piston motion outstrips the increase in pressure caused by combustion. In other words, the piston “outruns” the expanding fuel-air mixture in the combustion chamber, such that the pressure from the expanding mixture does not contribute to acceleration of the piston or, therefore, the crankshaft.
The dwell time of the piston near top-dead-center can be increased somewhat through the use of a larger rod-to-stroke ratio. A larger rod-to-stroke ratio can be achieved either with a shorter stroke or a longer connecting rod. Each of the two solutions presents its own problems. With respect to the use of a shorter stroke, although shorter stroke engine can be smaller and lighter than a longer stroke engine, the advantages are not linear. For example, the length of the crankshaft stroke does not have any effect on the size and weight of the pistons, the cylinder heads, the connecting rods or the engine accessories. A shorter stroke does allow for a somewhat smaller and lighter crankshaft and cylinder block, but even these effects are not linear, that is, a halving of the crankshaft stroke does not allow for a halving of the mass of the crankshaft or cylinder block.
With all other performance-related engine attributes being equal, a shorter-stroke engine will have a proportionally-lower displacement as compared to a longer-stroke engine. Accordingly, the shorter-stroke engine will generally produce a lower torque output as compared to the longer-stroke engine. This lower torque output translates to a lower power output at the same crankshaft speed. Accordingly, the shorter-stroke engine will have to be run at a higher speed in order to generate the same power output. The loss of torque resulting from the lower displacement could also be offset with efficiency enhancements, such as more-efficient valve timing, better combustion chamber design or a higher compression ratio. More efficient valve timing and combustion chamber designs, however, generally require substantial investment in research and development, and the maximum compression ratio in an internal combustion engine is limited by the autoignition characteristics of the engine fuel. For naturally-aspirated engines running premium grade gasoline, there is a practical compression ratio limit of approximately 11:1 imposed by the autoignition characteristics of the fuel-air mixture, thereby limiting the efficiency improvements available from an increase in compression ratio alone.
The lost output caused by the shortening of the stroke can also be recouped by increasing the bore diameter of the engine cylinders, thereby increasing engine displacement. While the displacement of the engine is linearly proportional to the stroke length, it is geometrically proportional to the cylinder bore diameter. Accordingly, a 10% reduction in stroke length can be more than offset with a 5% increase in cylinder bore diameter. All other things being equal, an increase in cylinder bore diameter requires an increase in piston mass, which requires a corresponding increase in connecting rod strength and crankshaft counterweight mass. If two or more of the engine's cylinders are arranged in a line, as is common in most modern crankshaft engines, the larger-diameter cylinders will also require a longer cylinder block, cylinder heads and crankshaft, thereby increasing engine size and weight.
A second approach to increasing the rod-to-stroke ratio is to lengthen the rods. This has the advantage of increasing the rod-to-stroke ratio without reducing the engine displacement. Lengthening the rods while leaving all other parameters of the engine alone, however, will move the top-dead-center position of the pistons further away from the centerline of the crankshaft. In other words, a one-inch increase in connecting rod length will result in a one-inch increase in the distance between the crankshaft centerline and the top of a piston crown at top-dead-center. This will require a corresponding increase in the length of the cylinders in order to provide sufficient operating volume for the pistons. Again, the engine size and mass are increased.
In contrast to the trade-offs inherent in the construction of a traditional crankshaft engine, a swash plate engine of the type depicted and shown herein can move the piston along a sinusoidal profile, thereby increasing the dwell time at top dead center, and therefore the performance potential of the engine.
In addition to the kinematics advantages realized from the use of a swash plate, the movement of the pistons within the cylinders can be exploited to improve the performance and versatility of the engine, and particularly so in a two-stroke configuration, although the design is by no means limited to that configuration. As one of skill in the art can appreciate, alternate embodiments of the present invention may employ any of the power cycles known for producing power in the art of thermodynamics, including but certainly not limited to the four-stroke (Otto) cycle, the Diesel cycle, the Stirling cycle, the Brayton cycle, the Carnot cycle and the Seiliger (5-point) cycle, as examples.
Engine 100 shown in FIGS. 1-16 is a two-stroke configuration, having intake and exhaust ports disposed in the sidewalls of the cylinders 112 . The layout of the cylinder block 102 and intake and exhaust porting of engine 100 is shown in detail in FIGS. 14-16 . Cylinder block 102 is secured to crankcase 104 by capscrews 250 . Cylinder block cover 254 is secured to crankcase 104 by capscrews 252 . Swash plate 108 is secured vertically within crankcase 104 between upper bearing race 256 and lower bearing race 258 . A set of connecting rod guides 260 , shaped and sized to receive and guide the connecting rods 114 , is disposed on top of the crankcase 104 .
Air and fuel passes into each cylinder 112 through a set of intake ports 270 - 274 . Alternate embodiments may make use of more or fewer intake ports, as appropriate. In the embodiment shown in FIGS. 14-16 , fuel is introduced to the intake charge by means of a single fuel injection port 290 disposed in each intake port 270 . Depending on the application, alternate embodiments may make use of one or more fuel injection ports disposed in one or more alternate locations, or may make use of carburetion or throttle-body fuel injection, as appropriate. As the piston crown descends on the downward power stroke, burned air/fuel mixture exits each cylinder 112 through one or more exhaust ports, such as ports 280 - 284 .
The flow of intake through ports 270 - 274 and exhaust through ports 280 - 284 is controlled by the position and orientation of the piston 110 disposed within each cylinder 112 . While traditional two-stroke engine designs have been known to use the axial position of the piston to control the timing of intake and/or exhaust valving, engine 100 employs the axial position of each piston 110 in combination with the radial orientation of each position 110 to control the timing of intake and/or exhaust timing. Accordingly, engine 100 provides a significant degree of additional flexibility to engine designer and turner as compared to the degree of flexibility available from previous designs.
Although this invention has been described in reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that this description encompass any such modifications or embodiments.
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A power-generation device comprising at least one cylinder, at least one cylinder head, at least one piston and an output shaft, having a central axis having a fixed angular relationship to the central axis of the cylinder. A swash plate, having a first swash plate surface having a normal axis disposed at a first fixed angle to the central axis of the output shaft, is fixed to the output shaft. At least one connecting rod is connected to at least one piston. At least one follower is secured to the second end of a connecting rod. The first follower surface contacts, and conforms to, the orientation of the first swash plate surface.
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FIELD OF THE INVENTION
[0001] The present invention relates to an efficient process for the preparation of optically active R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N,α-Dimethylphenethylamine (Metharnphetamine) free of its optical antipode from d-ephedrine or l-ephedrine respectively.
BACKGROUND AND PRIOR ART
[0002] The invention relates to a novel process for the synthesis of levmetamfetamine or methamphetamine from d-ephedrine or l-ephedrine. Levmetamfetamine and methamphetamine are the intermediates for the production of Selegiline hydrochloride and Benzaphetamine hydrochloride.
[0003] Many methods are known in the literature for making these molecules. The various methods of synthesis of these compounds are categorized broadly in the following types:
Chiral synthesis Racemic synthesis and separation by resolution From appropriate ephedrines via chlorination and catalytic hydrogenation From appropriate ephedrines via catalytic hydrogenation From appropriate ephedrine hydrochlorides via O-acylation and catalytic hydrogenation
[0009] 1) a.) Chiral synthesis of 1-alkyl-2-phenyl ethylamines via grignard reaction of 4-phenyl-1,3-oxazolidines and subsequent hydrogenolysis yields levmetamfetamine (Tahkasahi Hiroshi et. al., Chem. Pharm. Bull. 1985, 33(11), 4662-70).
[0010] b) Other chiral synthesis is from chiral Oxazolidines (Henri Phillipe Husson et. al., Synthetic communications, 1987, 17(6), 669-676). Thus, successive dialkylation of 1,3-Oxazolidines afforded substituted N-cyano methyl-1,3-Oxazolidine which was decyanated using NaBH 4 in ethanol at room temperature and the chiral appendage of this product was removed by hydrogenolysis giving methamphetamine in 56-62% yield. This method though useful to prepare optically pure methamphetamine, is expensive and labor intensive.
[0011] 2). In the synthesis of racemic methyl amphetamine, various methods were described in the prior art. Some of them are:
[0012] a) Racemic Methyl amphetamines were prepared by reductive alkylation hydrogenolysis of phenyl-2-propanone with N-Benzyl methyl amine (Skinner, Harry P., Forensic Sci. Int. 1993, 60 (3) 155-62).
[0013] b) The commercial use of the Wallach-Leucart reaction was explored in the synthesis of methyl amphetamines from phenyl acetone and ammonium formate and hydrolysis of the intermediate yielded amphetamines. This was treated with formic acetic anhydride to form (±)—N-formyl amphetamine which was reduced by LAH to get racemic methyl amphetamine in 67% yield (Cervinka, Otakar et. al., Collect. Czech. Chem. Comm 1968, 33 (11) 3551-7).
[0000] c) In the illegal synthesis of methyl amphetamines (Masano Isutsumi et.al., Science and Crime detection (Japan), 1953, 6, 50-2), phenyl acetic acid was treated with Pb (OAc) 2 to get phenyl acetone. This was reacted with MeNH 2 and reduced to get racemic methyl amphetamine.
[0014] d) Racemic methyl amphetamine was prepared from acetaldehyde (Adolph C. J. Opfermann et.al., Brit. 782,887) via grignard reaction with benzyl magnesium chloride in ether and the intermediate was treated with methyl amine.
[0015] The racemic methyl amphetamine obtained via any of these processes is then resolved to get levmetamfetamine and methamphetamine via resolution with optically active carboxylic acids through a lengthy and labour intensive process with less over all yields.
[0016] Hence it is desirable to have the simple and economically viable process to get an optically pure form of these methyl amphetamines.
[0017] 3) In another procedure, heating the appropriate hydrochloride salts of ephedrine with thionyl chloride at reflux temperature to get the appropriate 1-phenyl-1-chloro-2 methylamino propane hydrochloride, followed by catalytic hydrogenation gave appropriate enantiomers of methyl amphetamines (Hajicek Josef et.al., Czech. CS 272,434). Though the reaction gives appropriate methyl amphetamines, the reaction scheme is undesirable because of the usage of hazardous and eco un-friendly thionyl chloride and expensive palladium based hydrogenating catalysts.
[0018] 4. a) In another procedure, appropriate hydrochloride salts of Ephedrine were converted directly to appropriate methyl amphetamines by hydrogenating in glacial acetic acid using sulphuric acid and Pd wool (Karl Kindler et. al., Ann., 1948, 560, 215-21).
[0019] b) In another procedure, appropriate hydrochloride salts of Ephedrine were converted directly to appropriate methyl amphetamines by hydrogenating in glacial acetic acid using hydrochloric acid and Pd at 90° C. (Knoll et.al., Ger. 968,545).
[0020] c) In another procedure, l-ephedrine was reacted with Phosphorous oxychloride to give 1-2-Chloro-3,4-dimethyl-5-phenyl-1,3,2-oxaazaphospholidine-2-oxide. Hydrolysis of this yielded l-ephedrine Phosphate, which was catalytically hydrogenated to form the methamphetamine (A. Larizza et. al., J. Med. Chem., 1966, 9, 966-67).
[0021] d) One of the illegal manufactures of methyl amphetamines is from appropriate ephedrines via reduction with hydroiodic acid and red phosphorous (Skinner, Harry F et. al., Forensic Sci. Int. 1990, 48 (2),123-34). This method has disadvantages which includes hydroiodic acid is toxic and strong irritant and contact must be minimised. Red phosphorous is a flammable and explosive solid and must be handled with care. So another route was desirable which could overcome these problems.
[0022] 5) Recent process (Robert Fredrick Rosewell et. al, U.S. Pat. No. 6,399,828) for the preparation of Methyl amphetamine involves O-acylation of the appropriate hydrochloride salts of ephedrine to hydrochloride salts of O-Acetyl ephedrine and subsequent hydrogenolysis provides methyl amphetamines. Thus methamphetamine was obtained from either 1R, 2S-(−) ephedrine or 1S,2S-(+)-pseudoephedrine via O-acylation and hydrogenolysis process. Though this process produces required methyl amphetamines, it is an expensive process because of the cost of the hydrogenating catalyst, which is Palladium on carbon (Pd/C).
[0023] Thus, there was a long felt need for a process which is eco-friendly, cost effective and less labor intensive. The process of the present invention was investigated on these lines and found to be good in all respects. Using the present invention levmetamfetamine and methamphetamine were prepared in high overall yields from d-ephedrine and 1-ephedrine respectively in an efficient, cost effective and industrially safe manner as will be evident from the accompanying detailed description.
OBJECTS OF THE INVENTION
[0024] It is thus an object of the invention to provide a process for the preparation of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N, α-Dimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, that overcomes the drawbacks existing in the prior art.
[0025] It is a further object of the invention to provide a process for preparation of optically active R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N,α-Dimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, free of its optical antipode.
[0026] Yet another object of the invention is to provide a process for the preparation of optically active R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N, α-Dimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, that has a high overall yield of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N,α-Dimethylphenethylamine (Methamphetamine).
[0027] A further object of the invention is to provide a process for the preparation of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N, a Dimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, that is cost effective and industrially feasible.
[0028] Yet another object of the invention is to provide a process for the preparation of R-(−)—N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N,α-Dimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, that avoids use of complex and cost extensive reagents and precious metal hydrogenating catalysts.
SUMMARY OF THE INVENTION
[0029] The present invention relates to a process for asymmetric synthesis of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) of formula I
[0000]
[0000] from d-ephedrine precursor or S-(+)-N,α-Dimethylphenethylamine (Methamphetamine) enantiomer of formula II,
[0000]
[0000] from l-ephedrine precursor, which are free from their optical antipode comprising:
a) Reacting d-ephedrine or l-ephedrine base of formula III
[0000]
or Formula IV
[0000]
with an acylating agent to make a reaction mixture containing a N-acylated ephedrine of formula V
[0000]
or Formula VI,
[0000]
b) deoxygenation of N-acylated ephedrines (formula V or VI) to make the compound of the formula VII
[0000]
or Formula VIII
[0000]
by using Raney Nickel catalyst.
c) effecting acid hydrolysis of the above deoxygenated products to get the compound of formula I or II.
DETAILED DESCRIPTION
[0038] After considerable investigation of the prior art and various modifications thereof, it was concluded that a new approach was required for development of cost effective process for the preparation of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)-N,α-Dimethylphenethylamine (Methamphetamine). Further, the literature procedures for making amphetamines and methamphetamines report the retention of configuration at the carbon bearing amino group (.Noggle, Deruiter, and Clarke, J. Chrom. Sci., 1987, 25, 38-42); Allen and Kiser, J. Forensic Sciences., 1987, 32, (4),953-962). Therefore d,l ephedrine is expected to give d,l-methyl amphetamines, d-ephedrine is expected to give levmetarnfetamine and 1-ephedrine is expected to give methamphetamine respectively. Thus, the obvious choice of starting materials were d-ephedrine or l-ephedrine since they have the right stereochemistry at C-2 carbon atom of the molecule. These compounds are further advantageous in that they are easily available commercially.
[0039] The process of the present invention comprises (a) amide formation and (b) removal of the benzylic hydroxyl group by refluxing with Raney Nickel catalyst and (c) subsequent hydrolysis of the amide group. When this process is applied to the production of levmetamfetamine and methamphetamine, the process has several advantages over current production methods, which are:
Shorter cycle times Convenient work up (filtration and solvent removal) Economic viability because of the use of inexpensive and easily available catalyst No additional hydrogenator required in the reaction route, and Better chemical hygiene and eco-friendliness Avoids the use of metal hydrides, which are not suitable for plant scale operations. Use of industrially safe reagents.
[0047] Further optimization of yields and operation cycle times using optimization methods known to those skilled in the art would only increase these advantages.
[0048] The present inventors have surprisingly found that Raney Nickel catalyst can be used for deoxygenation of benzylic alcoholic group. This catalyst is hitherto unreported for the deoxygenation of the secondary benzylic alcohols. It was in fact known that Raney Nickel catalyst deoxygenates tertiary alcohols to the corresponding hydrocarbons (J. Amer. Chem. Soc., 1967,89, 4233; Tet. Lett., 1994, 35, 5611; J. Org. Chem., 1988, 53, 432 and 3158). The use of Raney Nickel catalyst for deoxygenation of benzylic alcohol is not only cost effective since Raney Nickel is inexpensive compared to other precious catalysts such as Pd—C, Pd—BaSO 4 and Pt—O 2 , which are normally used for deoxygenations but also industrially safe. One of the other advantages of the present invention is the convenient workup of every step including Raney Nickel reaction—filtration and solvent removal. This synthetic route for the deoxygenation of secondary benzylic alcohol is applicable to related compounds as well, with substitution patterns obvious to those skilled in the art and are intended to be within the scope of the present invention.
[0049] The general reaction scheme employed in the present invention is as shown in the accompanying FIGURE:
[0000]
[0050] In step A, the starting material d-ephedrine of formula III or l-ephedrine of formula IV are converted into their corresponding amides of formula V or formula VI, wherein R may be hydrogen, methyl or phenyl group using an appropriate reagent. When R is hydrogen, the appropriate reagent is ethyl formate. When R is methyl group, the appropriate reagent is acetic anhydride and when R is phenyl group, the appropriate reagent is benzoyl chloride. In the most preferred embodiment of the invention, R corresponds to hydrogen atom wherein the appropriate reagent used is ethyl formate.
[0051] In step B, the corresponding amides of formula V or formula VI are deoxygenated using Raney Nickel as reagent in refluxing toluene to obtain the corresponding deoxygenated amides of formula VII or VIII wherein R may be as defined above.
[0052] In step C, the deoxygenated amides of formula VII or VIII are hydrolysed by refluxing in 1:1 aq. HCl to the corresponding title compounds of the formula I (Levmetamphetamine) or formula II (Methamphetamine) in surprisingly good yields.
[0053] The present invention thus provides an efficient process for stereoselective preparation of optically active R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine) or S-(+)—N,αDimethylphenethylamine (Methamphetamine) from d-ephedrine or l-ephedrine respectively, free from its optical antipode.
[0054] An important feature of the present invention is the deoxygenation of N-acyl ephedrine by means of an easily accessible and inexpensive Raney Nickel catalyst. The first step (step A) in the reaction scheme is amide formation of ephedrine. N-Formyl ephedrines of Formula V(a) or VI(a)(when R is hydrogen) were prepared by known process from appropriate ephedrine and ethyl formate (Dieter Enders et. al., Liebigs Ann/Recueil, 1997, 1101-1113).
[0000]
[0055] However these compounds can be prepared by methyl formate also. The temperature of reaction is between 50° C. and 60° C., preferably between 55° C. and 60° C. The reaction is carried out by mixing appropriate ephedrine and ethyl formate and carefully heating the reaction mixture to 55° C.-60° C. and the product was isolated by distilling off the excess reagent and ethanol.
[0056] N-Acetyl ephedrines [Formula V (b) and Formula VI(b)] is prepared from appropriate ephedrine and acetic anhydride in chloroform.
[0000]
[0057] N-Benzoyl ephedrines [Formula V (c) and Formula VI(c)] is prepared from appropriate ephedrine and benzoyl chloride in an organic solvent using aq. sodium hydroxide at 20° C. temperature.
[0000]
[0058] The organic solvent for this purpose may be any suitable solvent known to a person skilled in the art. The solvent may be preferably selected from dichloromethane or chloroform.
[0059] The second step (step B), which is a key reaction in the reaction scheme is benzylic secondary alcohol deoxygenation of the above ephedrine amides. The reaction is carried out by mixing appropriate ephedrine amides (N-formyl, N-acetyl, or N-benzoyl) and Raney Nickel catalyst in a suitable organic solvent and slowly heating the reaction mixture to reflux temperature to obtain compounds of Formula VII(a), VII(b) or VII(c) or VIII(a), VIII(b) or VIII(c).
[0000]
[0060] The organic solvent for this reaction may preferably be selected from toluene or benzene. Most preferably the solvent is toluene. The ratio of the ephedrine amide and Raney Nickel catalyst is crucial for this reaction. The ratio of ephedrine amide and Raney Nickel catalyst could be any thing between one gram to six ml. (settled catalyst in water) and one gram to two ml. Preferably the ratio is one gram to two ml. There is no appreciable deoxygenation of ephedrine amides below this range.
[0061] The temperature of reaction mixture for the deoxygenation is maintained between 70° C. and 85° C. The optimum temperature is in between 80° C. and 85° C. The product is recovered by filtering the catalyst and solvent evaporation. This crude product is reasonably pure enough to carry out hydrolysis without further purification and it contains mainly deoxygenated ephedrine amide. For all practical purpose N— acyl-ephedrine compounds were deoxygenated in high yield and these examples are described in the following section.
[0062] The third step (step C) in the scheme is hydrolysis of desoxy ephedrine amides. This step was carried out by mixing the appropriate desoxy ephedrine amide and 1:1 aq. HCl in the ratio of 1 gm to 5 ml. and then heating to reflux temperatures. The optimum temperature for this reaction is in between 103° C. and 108° C.
[0063] The reaction mixture is extracted with a non-polar organic solvent (preferably toluene) to remove non basic impurities and the aqueous layer was basified with aqueous sodium hydroxide. The product was taken into solvent and isolated the product by solvent removal. The solvent used for this extraction may preferably selected from a group comprising of benzene, toluene, methylene dichloride, diethyl ether and diisopropyl ether or mixtures thereof.
[0064] The details of the invention, its objects and advantages are explained hereunder in greater detail in relation to non-limiting exemplary illustrations. The examples are merely illustrative and do not limit the teaching of this invention and it would be obvious that various modifications or changes in the procedural steps by those skilled in the art without departing from the scope of the invention and shall be consequently encompassed with in the ambit and spirit of this approach and scope thereof.
[0065] In the following experiments the analytical instruments used for qualitative analysis includes Gas liquid chromatography, Infrared spectrometer and Polarimeter and thin layer chromatography. d- and l-Ephedrine bases are commercially available and were used to illustrate in the reactions useful in the process.
EXAMPLE 1
Preparation of Levmetamfetamine
[0066] Step A: Preparation of N-Formyl ephedrine (Va) from d-ephedrine (III).
[0067] In a three-necked 500 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 150 grams (0.9 mole) of d-ephedrine and ethyl formate 115 grams (1.55 mole). The reaction mixture was warmed with a water bath to 55-60° C. under stirring and maintained at this temperature for eight hours. Distilled off the excess reagent and formed ethanol. N-Formyl derivative was obtained as pale yellow to white viscous liquid (170 grams) Specific Optical rotation: −22.100 (2% solution in methanol), purity: (GLC: 99.6%)
[0000] Step B: Preparation of N-Formyl Desoxy Ephedrine (VIIa) from N-Formyl Ephedrine (Va)
[0068] In a three necked 2 Lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 345 geams; slurry volume 190 ml.) and 100 grams (0.5 mmole) of N-Formyl ephedrine and distilled toluene (0.8 lit.). The reaction mixture was heated on a water bath to reflux under stirring for fifteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (500 ml) twice. The combined toluene layers were washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N formyl desoxyephedrine as a pale yellow to white clear viscous liquid toluene (73 grams, 80% yield).
[0000] Step C: Preparation of Levmetamfetamine (I) from N-Formyl Desoxy Ephedrine (VIIa)
[0069] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-formyl desoxy ephedrine (50 grams, 0.28 mole) and 1:1 aq. HCl (250 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 10 hours. Cooled the reaction mass to 40° C. and extracted with toluene to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×250 ml). The organic layers were washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded levmetamfetamine as a pale yellow to white clear liquid. (38 grams, 90% yield), Specific optical rotation.: −17.40 (2% solution in 1.2N HCl); purity: (GLC: 98.5%)
EXAMPLE 2
Preparation of Methamphetamine
[0070] Step A: Preparation of N-Formyl Ephedrine (VIa) from l-Ephedrine (IV).
[0071] In a three-necked 500 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 200 grams (1.2 mole) of l-ephedrine and ethyl formate 160 grams (2.16 mole). The reaction mixture was warmed with a water bath to 55-60° C. under stirring and maintained at this temperature for eight hours. Distilled off the excess reagent and formed ethanol. N-Formyl derivative was obtained as pale yellow to white viscous liquid (220 grams), Specific optical rotation: +22.90° (2% solution in methanol), purity: (GLC): 99.90%
[0000] Step B: Preparation of N-Formyl Desoxy Ephedrine (VIIIa) from N-Formyl Ephedrine (VIa)
[0072] In a three necked 1 lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 180 grams; slurry volume 98 ml.) and 50 grams (0.26 mole) of N-Formyl ephedrine and distilled toluene (0.2 lit.). The reaction mixture was heated on a water bath to reflux (reaction temperature 84° C.) under stirring for fifteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (200 ml) twice. The combined toluene layers were washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N-formyl desoxyephedrine as a pale yellow to white clear viscous liquid (36 grams, 80% yield).
[0000] Step C: Preparation of Methamphetamine (II) from N-Formyl Desoxy Ephedrine (VIIIa)
[0073] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-formyl desoxy ephedrine (35 grams, 0.197 mole) and 1:1 aq. HCl (175 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 10 hours. Cooled the reaction mass to 40° C. and extracted with toluene to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×100 ml). The organic layers were washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded methamphetamine as a pale yellow to white clear liquid. (23 grams, 78% yield), Specific optical rotation.: +17.3° (2% solution in 1.2N HCl) purity: (GLC): 98.2%].
EXAMPLE 3
Preparation of Levmetamfetamine
[0074] Step A: Preparation of N-Acetyl Ephedrine (VB) from D-Ephedrine (III).
[0075] In a three-necked 1000 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 100 grams (0.606 mole) of d-ephedrine and acetic anhydride 185.5 grams (1.818 mole). The reaction mixture was warmed with a water bath to 65-70° C. under stirring and maintained at this temperature for two hours. Added 250 ml water. Extracted the N-acetyl derivative with toluene(3×150 ml). The combined organic layer was concentrated to get N-acetyl derivative (113 grams, MP:85-88° C.).
[0000] Step B: Preparation of N-Acetyl Desoxy Ephedrine (VIIb) from N-Acetyl Ephedrine (Vb)
[0076] In a three necked 2 Lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 345 grams; slurry volume 190 ml.) and 100 grams (0.483 mole) of N-acetyl ephedrine in distilled toluene (0.8 lit.). The reaction mixture was heated on a water bath to reflux under stirring for fifteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (500 ml) twice. The combined toluene layer was washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N Acetyl desoxyephedrine as a pale yellow to white clear viscous liquid (64 grams, 69.41% yield).
[0000] Step C: Preparation of Levmetamfetamine (I) from N-Acetyl Desoxy Ephedrine (VIIb)
[0077] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-acetyl desoxy ephedrine (50 grams, 0.261 mole) and 1:1 aq. HCl (250 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 12 hours. Cooled the reaction mass to 40° C. and extracted with toluene to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×200 ml). The organic layers were pooled and washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded levmetamfetamine as a pale yellow to white clear liquid. (35 grams, 89.7% yield), Specific optical rotation.: −17.60 (2% solution in 1.2N HCl); purity: (GLC: 98.9%)
EXAMPLE 4
Preparation of Methamphetamine
[0078] Step S: Preparation of N-Acetyl Ephedrine (VIb) from l-Ephedrine (Iv).
[0079] In a three-necked 1000 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 100 grams (0.606 mole) of l-ephedrine and acetic anhydride 185.5 grams (1.818 mole). The reaction mixture was warmed with a water bath to 65-70° C. under stirring and maintained at this temperature for two hours. Added 250 ml water. Extracted the N-acetyl derivative with toluene(3×150 ml). The combined organic layer was concentrated to get N-acetyl derivative (110 grams, MP: 86-87° C.)
[0000] Step B: Preparation of N-Acetyl Desoxy Ephedrine (VIIIb) from N-Acetyl Ephedrine (VIb)
[0080] In a three necked 2 Lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 345 grams; slurry volume 190 ml.) and 100 grams (0.483 mole) of N-acetyl ephedrine(VIb) in distilled toluene (0.8 lit.). The reaction mixture was heated on a water bath to reflux under stirring for fifteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (500 ml) twice. The combined toluene layer was washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N Acetyl desoxyephedrine as a pale yellow to white clear viscous liquid (66 grams, 71.70% yield).
[0000] Step C: Preparation of Methamphetamine (II) from N-Acetyl Desoxy Ephedrine (VIIIb)
[0081] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-acetyl desoxy ephedrine (50 grams, 0.261 mole) and 1:1 aq. HCl (250 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 12 hours. Cooled the reaction mass to 40° C. and extracted with toluene to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×200 ml). The organic layers were pooled and washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded methamphetamine as a pale yellow to white clear liquid. (34 grams, 87.17% yield), Specific optical rotation.: +17.80 (2% solution in 1.2N HCl); purity: (GLC: 99%)
EXAMPLE 5
Preparation of Levmetamfetamine
[0082] Step A: Preparation of N-Benzoyl Ephedrine (Vc) from d-Ephedrine (III).
[0083] In a three-necked 1000 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 100 grams (0.606 mole) of d-ephedrine in chloroform (175 ml). Added benzoyl chloride (91.99 grams) and 20% sodium hydroxide solution (134 ml) simultaneously at room temperature. The reaction mass was stirred further 90 minutes at room temperature. Separated the organic layer and aq. layer. Extracted the aq. layer with another 175 ml of chloroform. The organic layers were pooled and washed with water and concentrated. The residue was recrystallised in benzene/pet. ether which gave the product (128 grams, 78.45%)
[0000] Step B: Preparation of N-Benzoyl Desoxy Ephedrine (VIIc) from N-Benzoyl Ephedrine (Vc)
[0084] In a three necked 2 Lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 350 grams; slurry volume 193 ml.) and 100 grams (0.37 mole) of N-benzoyl ephedrine and distilled toluene (1 lit.). The reaction mixture was heated on a water bath to reflux under stirring for fourteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (500 ml) twice. The combined toluene layers were washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N Benzoyl desoxyephedrine as a pale yellow to white clear viscous liquid toluene (65.4 grams, 69.57% yield).
[0000] Step C: Preparation of Levmetamfetamine (I) from N-Benzoyl Desoxy Ephedrine (VIIc)
[0085] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-benzoyl desoxy ephedrine (50 grams, 0.1976 mole) and 1:1 aq. HCl (250 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 13 hours. Cooled the reaction mass to 60° C. and extracted with chloroform to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×200 ml). The organic layers were pooled and washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded levmetamfetamine as a pale yellow to white clear liquid. (20.8 grams, 71% yield), Specific optical rotation.: −17.20 (2% solution in 1.2N HCl); purity: (GLC: 99%)
EXAMPLE 6
Preparation of Methamphetamine
[0086] Step A: Preparation of N-Benzoyl Ephedrine (VIc) from l-Ephedrine (IV).
[0087] In a three-necked 1000 ml round bottom flask equipped with thermo controller, stirrer and condenser was charged with 100 grams (0.606 mole) of l-ephedrine in chloroform (175 ml). Added benzoyl chloride (91.99 grams) and 20% sodium hydroxide solution (134 ml) simultaneously at room temperature. The reaction mass was stirred further 90 minutes at room temperature. Separated the organic layer and aq. layer. Extracted the aq. layer with another 175 ml of chloroform. The organic layers were pooled and washed with water and concentrated. The residue was recrystallised in benzene/pet. ether which gave the product (126.5 grams, 78. % yield)
[0000] Step B: Preparation of N-Benzoyl Desoxy Ephedrine (VIIIc) from N-Benzoyl Ephedrine (VIc)
[0088] In a three necked 2 Lit. round bottom flask equipped with thermo controller, stirrer and condenser was charged with Raney Nickel catalyst (slurry weight 348 grams; slurry volume 193 ml.) and 100 grams (0.37 mole) of N-benzoyl ephedrine and distilled toluene (1 lit.). The reaction mixture was heated on a water bath to reflux under stirring for fourteen hours. Cooled the reaction mixture to 60° C. and filtered the catalyst and washed the catalyst with toluene (500 ml) twice. The combined toluene layers were washed with water and dried over sodium sulphate and concentrated under vacuum which afforded N Benzoyl desoxyephedrine as a pale yellow to white clear viscous liquid (65.grams, 69.5% yield).
[0000] Step C: Preparation of Methamphetamine (II) from N-Benzoyl Desoxy Ephedrine (VIIIc)
[0089] In a three necked 500 ml. round bottom flask equipped with thermo controller, stirrer and condenser was charged with N-benzoyl desoxy ephedrine (50 grams, 0.1976 mole) and 1:1 aq. HCl (250 ml). The reaction mixture was refluxed (reaction temperature 104-105° C.) while stirring for 13 hours. Cooled the reaction mass to 60° C. and extracted with chloroform to remove neutral impurities. Aqueous layer was basified with aq. Sodium hydroxide and extracted with diisopropyl ether (2×200 ml). The organic layers were pooled and washed with water and dried over sodium sulphate. Solvent was removed by distillation under vacuum, which afforded methamphetamine as a pale yellow to white clear liquid. (21.0 grams, 71% yield), Specific optical rotation.: +17.40 (2% solution in 1.2N HCl); purity: (GLC: 98.99%)
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A process for synthesis of R-(−)-N,α-Dimethylphenethylamine (Levmetamfetamine, formula I), or S-(+)-N,α-Dimethyl phenethylamine (Methamphetamine, formula II), from d-ephedrine of formula III or l-ephedrine formula IV, the process comprising the steps of (a) acylating the d- or l-ephedrine base of formula III or formula IV with an acylating agent to make a reaction mixture containing a N-acylated ephedrines of formula V or formula VI; (b) deoxygenation of N-acylated ephedrines to make the compound of the formula VII or Formula VIII by using Raney Nickel catalyst; and (c) acid hydrolysis of the above deoxygenated products to get the levmetamfetamine or methamphetamine.
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BACKGROUND OF THE INVENTION
The present invention relates to a round baler for harvested product.
More particularly, it relates to a round baler which has a housing swingable by a cylinder-piston unit for ejection of bales, and a pressure chamber limited at an end side by walls and at a peripheral side by driven transporting elements, for example endless belts, to form a harvested product inlet opening, with a driveable transporting rotor for closing the inlet opening.
Round balers are known in the practice, in which in the region of the harvested product inlet a transporting rotor is arranged and forms a part of pressure limiting means. This has the advantage that the harvested product transported in the pressure chamber is supplied in a rotary direction of the pressed bale to be formed in the pressure chamber, and thereby a bale formation or a bale rotation is improved, in particular in the starting phase. The bale pressure chamber is limited substantially over the periphery by endless bands outside of the transporting rotor. The endless bands deviate with increasing bale diameter, and thereby the pressure chamber is continuously increased. After ending the bale forming process, the finished bales are ejected rearwardly by flipping of the rear housing part rearwardly. During this ejection phase, the drive for the bands which forms simultaneously the drive for the transporting rotor is switched off, for avoiding possible damages to the bale peripheral surface by the rotating rotor. It is advantageous when the bale also during the ejection phase the bale is retained by the band in rotation as long as possible, to improve the ejection of the bale. When however the bale is released from the bands, the bands can no longer support the bale in its rotary movement so that it is substantially reduced. During this phase the bale is located with a part of its weight on the transporting rotor, since it is arranged in the lower part of the bale chamber. Since the rotor drive is coupled with the drive of the bands, the peripheral speed of the rotor is substantially higher than the peripheral speed of the bale which is almost immovable in this phase. Therefore, there is the disadvantage that the outer peripheral surface of the bale is substantially damaged by the rotor. In order to avoid this disadvantage it was proposed to connect the drive of the transporting rotor with the drive of the bands with interposition of a coupling. However, this approach did not provide a satisfactory result. The use of a form-lockingly operating coupling has the disadvantage that it can transmit very high forces, but simultaneously is subjected to little structural space. This has the disadvantage that it is switched-on by jerks. As a result, extremely high torque peaks are produced, when it is necessary to consider that a stationary transporting rotor, for example by a cam coupling, must be accelerated to the speed of the continuously rotating transporting bands. Another alternative was to use a friction coupling which is switchable substantially softer. The use of such a coupling however is not acceptable since in order to transfer the required torque, it must be very big, which is connected with exceptionally high costs.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a round baler of the above mention general type, which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a round baler in which the drive for the transporting bands and the transporting rotor can be adjusted in an optimal way to the corresponding conditions during the bale formation and during a bale ejection.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a round baler in which both the transporting elements and the transporting rotor are continuously driven during the bale formation and during the bale ejection, and the drive for the transporting rotor during the bale formation is performed in a substantially form-locking manner and during the time of the bale ejection is performed in a friction-locking manner.
When the round baler is designed in accordance with the present invention, there is the advantage that during the bale ejection the bands remain driven, whereby on the one hand they are selfcleaning and on the other hand they support the rotor movement of the bale in the ejection phase.
On the other hand, the transporting rotor which in this phase is driven only frictionally has the advantage that due to the relatively weak frictional connection the rotor is braked for the time during which the bale rests on it. At the same moment, since the bale is released from the rotor, the frictional force again fully engages, so that the rotor is driven with the same speed as the bands. As a result, no relative movement between the driven parts for the rotor and for the band occurs, so that the form-locking connection can be immediately produced without torque peaks.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a round baler in accordance with the present invention;
FIG. 2 is a view showing transporting elements of the baler of FIG. 1 on a plane view;
FIG. 3 is a view showing a coupling unit identified with broken lines in FIG. 1, in a detailed illustration in the section taken along the line III--III in FIG. 2; and
FIG. 4 is a side view with a partial section taken along the line IV--IV, in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
A baler in accordance with the present invention is identified as a whole with reference numeral 1. It has a stationary and a swingable housing part 2 and 3 correspondingly. The swinging movement is performed by a hydraulic cylinder-piston unit 4. The baler 1 has a pressure chamber 5 which is limited at a peripheral side by endless bands 6 deviating against the pressure of a bale which grows during a winding process.
The bands 6 are continuously driven both during the bale formation and also during the ejection of a finished bale. For this purpose a chain wheel 9 is fixedly arranged on a projecting shaft end 7 of a deviating roller 8 for the bands 6. The chain wheel 9 is connected through a chain 10 with a toothed wheel 11. The toothed wheel is formed of one-piece with a sleeve-shaped projection 12 having inner teeth 13. Outer teeth 14 at the end of a shaft 15 engage in the inner teeth 13, and the toothed wheel 11 with the projection 12 is fitted on the shaft 15. The projection 12 with the toothed wheel 11 is connected to the shaft 15 by a screw 17 which is partially screwed into the shaft end 16, through a pressure plate 18 and a spring 19. The end of the toothed wheel 11 is provided with a friction coating 20 and supported through the friction coating against the end side of a flange 21 which is connected with a toothed wheel 23 through a sleeve 22. The central opening of the sleeve 22 receives a sliding bushing 24 for supporting the sleeve 22 with the flange 21 and the toothed wheel 23 rotatably on the shaft 15. The sleeve 22 is supported through a pressure bearing 25 on an eccentric clamping disk 26 of the bearing 28 through a disc 27 and abuts against a collar 29 of the shaft 15. In this manner, the frictional connection is produced between the toothed wheel 11 which is form-lockingly connected to the shaft 15, and the toothed wheel 23.
The toothed wheel 23 is connected through a chain 54 shown in FIG. 2 with a chain wheel 55 for driving a transporting rotor 31 arranged in the region of an inlet opening. The transporting rotor 31 presses the harvested product which is transported from the pick-up 32 and the screw 33, into the baler pressure chamber 5 and guides the rotation of the harvested product in the baler pressure chamber 5 at the beginning of a bale formation. For providing the reliable transporting function of the harvested product, the frictional connection in the coupling 34 between the toothed wheel 11 and the toothed wheel 23 is however insufficient. For this reason, additionally to the frictional connection, a form-locking connection between the wheels 11 and 23 can be produced. For this purpose the flange 21 of the toothed wheel 23 is provided at its outer periphery with three blocking projections 35 which engage each a corresponding pin 36 during the form-locking connection, and the pin 36 is axially displaceably supported in the throughgoing openings 37 of the toothed wheel 11. The projections 35 and the openings 37 form therefore interengageable projection and recess means.
At the end facing away from the flange 21, the pin 36 is screwed with a rotatable collar 38 of a cup 39, whose cover 40 is connected fixedly with a cylinder 41. The hydraulic cylinder 41 is connected through a known rotary connector 43 with a pressure medium conduit 42. The rotatable collar 38 is pressed in direction of the chain wheel 11 by several pressure springs 44 which are distributed on the periphery. Each spring 44 is supported at one end against the rotatable collar 38 and at the other end against the head 45 of a screw 46 which is screwed in the toothed wheel 11. The screw 46 extends with a gap through the rotatable collar 38. The collar, however does not come to abutment against the toothed wheel 11 since the piston 47 of the cylinder 41 abuts against the head of the screw 17 with interposition of a plate 48. The plate 48 carries upwardly projecting pins 49 which extend with a gap through the cover 40 of the cup 39. Disks 50 are fixedly connected with the free ends of the pin 49 and pressure springs 51 abut at their end against the disks. The pressure springs 51 abut with their other ends against the cover 40, so that the piston 47 is pressed in the cylinder 41 when the cylinder chamber has no pressure.
In the position of the coupling 34 shown in FIGS. 3 and 4, the toothed wheel 23 for driving the transporting rotor 31 is form-lockingly connected with the shaft 15, to provide secure transportation of the harvested product into the bale chamber 5 by the transporting rotor 31. The shaft 15 is driven through an angular transmission 52 and a shaft 53 coupled with the tractor. When a finally wound bale must be ejected, the hydraulic cylinder-piston unit 4 is loaded with pressure to raise the housing part 3. In this moment oil is pumped through the conduit 42 into the cylinder 41, so that the piston 47 is extended and therefore lifts the cup 39. During this movement the pins 36 are pulled outwardly against the force of the springs 44 upwardly in FIG. 3 from the region of the blocking projections 35. As a result, the flange 21 and thereby also the toothed wheel 23 is connected only frictionally with the drive shaft 15 through the toothed wheel 11. Thereby, the transporting rotor 31 is driven and the frictional connection is adjusted so low that it no longer drives the harvested product bale, or in other words can set it in rotation. Moreover, the bale whose rotational speed during the injection continuously decreases, can stop the transporting rotor with overcoming the frictional connection, so that the bale can not be damaged on its periphery by the transporting rotor. When however the bale is ejected the transporting rotor assumes its high rotary speed provided by the shaft 15 actuated solely by the frictional connection between the shaft 15 and the toothed wheel 23. When now the housing part 3 is closed, the conduit 42 at the coupling 34 is no longer under pressure, and the oil can flow from the cylinder 41 being supported by the springs 51 which constantly press the piston 47 into the cylinder 41. Therefore the cup 39 is lowered by the force of the springs 44, together with the pins 36 screwed with its collar 38. The springs 44 move either in the space between the projection 35 or support in unfavorable condition on the projections. When a higher torque is required for driving the transporting rotor 31, the pins 36 displace by a low relative movement the toothed wheels 11 and 23 relative to one another, so that they come to abutment against the projection 35. Since however because of the continuously producing frictional connection in the coupling, immediately after the ejection of a bale a synchronism between the bands 16 and the transporting rotor 31 is produced, the starting of the form-locking is performed very soft and without significant torque peaks.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a round baler for harvested product, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by letters patent is set forth in the appended claims:
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A round baler for harvested product comprises a housing, a pressure chamber with walls limiting the pressure chamber at an end side and with driven transporting elements limiting the pressure chamber at a peripheral side and forming a harvested product inlet opening, a drivable transporting rotor arranged near the inlet opening for closing the inlet opening, and a drive provided for driving the transporting elements and the transporting rotor and formed so that during the formation of a bale the drive drives the transporting roller in a form-locking manner and during a time of ejection of the bale the drive drives the transporting rotor frictionally.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a light-scanning optical system and also to an image forming apparatus comprising such a light-scanning optical system. More particularly, the present invention relates to a light-scanning optical system that is adapted to realize high definition printing and can effectively avoid any printing slippage in the main scanning direction by partly excluding the incident luminous flux entering the photodetector (BD sensor) for generating write-start position synchronizing signals. Such an optical system may suitably be used for a laser beam printer or digital copying machine.
2. Related Background Art
FIG. 1 of the accompanying drawings is a schematic illustration of a known light-scanning optical system, illustrating a principal area thereof. Referring to FIG. 1, the luminous flux emitted from a semiconductor laser 51 with optical modulation in response to the image information given to it is thinned in terms of its cross section by an aperture stop 52 and transformed into a substantially collimated or converged flux by a collimator lens 53 before entering a cylindrical lens 54 . The luminous flux that enters the cylindrical lens 54 is let out without any modification within the main scanning section but focused in the sub scanning section to produce a substantially linear image (running along the main scanning direction) on the deflection surface (reflection surface) 55 a of light deflector 55 . The elements including the aperture stop 52 , the collimator lens 53 and the cylindrical lens 54 are those of the first optical system 62 . The luminous flux reflected and deflected by the deflection surface 55 a of the light deflector 55 is then focused by an imaging optical system (fθ lens) 56 operating as the second optical system onto the surface 57 of a photosensitive drum to produce a luminous spot, which is then made to optically scan the surface 57 of the photosensitive drum in the direction of arrow B (main scanning direction) at a uniform rate as the light deflector 55 is driven to rotate in the direction of arrow A. As a result, an image is recorded on the surface 57 of the photosensitive drum which is a recording medium.
In such a light-scanning optical system, generally, a photodetector is arranged for detecting a write-start synchronizing signal immediately before writing the image signal in order to accurately control the write-start position for writing the image signal.
In FIG. 1, reference numeral 58 denotes a bending mirror (to be referred to as “BD mirror” hereinafter) arranged to reflect the luminous flux for detecting the write-start position synchronizing signal to the BD sensor 61 in order to regulate the timing of spotting the scanning start point on the surface 57 of -the photosensitive drum and reference numeral 59 denotes a slit arranged at a position equivalent to the surface 57 of the photosensitive drum 57 . The slit 59 has a width of about 0.5 mm and a luminous flux having a diameter of about 0.1 mm passes therethrough. Reference numeral 60 denotes a BD lens operating as imaging means and arranged to take a role of establishing a conjugate relationship between the BD mirror 58 and the BD sensor 61 . It also takes a role of correcting the inclination of the BD mirror 58 . Reference numeral 61 denotes a photodetector (to be referred to as “BD sensor” hereinafter) operating as write-start position synchronizing signal detecting means.
Thus, the timing of spotting the scanning start point on the surface 57 of the photosensitive drum is regulated by means of the output signal of the BD sensor 61 in FIG. 1 .
Meanwhile, when arranging a light-scanning optical system in the image-forming apparatus main body, the write-start synchronizing signal (to be referred to as “BD signal” hereinafter) may have to be detected at the side opposite to the first optical system 62 relative to the optical axis of the second optical system (fθ lens) as shown in FIG. 2 depending on the positional restrictions due to the configuration of the main body and the arrangement of the electrical equipment. Then, the polygon mirror 55 has to be rotated in the direction opposite to that of FIG. 1 and the scanning luminous spot on the plane to be scanned 57 also has to be moved oppositely. Note that, in FIG. 2, the components same as those of FIG. 1 are denoted respectively by the same reference symbols.
In light-scanning optical systems as shown in FIGS. 1 and 2, generally, the margin between the edge of the luminous flux getting to the opposite ends (point U and point L in FIGS. 1 and 2) of the image and the opposite ends in the longitudinal direction (main scanning direction) of the deflection surface 55 a of the polygon mirror 55 is disregarded for ensuring good optical performance.
FIGS. 3A and 3B are enlarged views of the deflection surface 55 a of the polygon mirror 55 , illustrating the margin. FIG. 3A shows the luminous flux reflected by the polygon mirror 55 to get to the point U. The distance between the marginal end of the luminous flux and the corresponding longitudinal end of the deflection surface 55 a of the polygon mirror 55 is defined as margin ΔU. Similarly, FIG. 3B shows the luminous flux reflected by the polygon mirror 55 to get to the point L. The distance between the marginal end of the luminous flux and the corresponding longitudinal end of the deflection surface 55 a of the polygon mirror 55 is defined as margin ΔL.
In ordinary light-scanning optical systems, the following relationship is normally observed.
ΔU>ΔL
Therefore, if the scanning optical system has to be arranged in a manner as shown in FIG. 2, the BD signal has to be detected on the side where the margin of the deflection surface 55 a of the polygon mirror 55 is scarce. This means that the scanning angle is limited or the diameter of the luminous flux is limited to minimize the scanning luminous spot to a great disadvantage of the performance of the system.
However, all the luminous flux coming from the first optical system 62 does not necessarily have to be reflected by the polygon mirror 55 so long as the luminous flux getting to the BD sensor 61 has a diameter small enough to pass through the slit 60 and provides a certain level of tolerance to the sensitivity of the BD sensor 61 .
Referring to FIG. 4, in known scanning optical systems, it is therefore typically so designed that the polygon mirror 55 is caused to intentionally vignette the luminous flux getting to the BD sensor (not shown) in order to provide a wide scanning luminous spot diameter without vignetting in the effective area of the image, while allowing a wide scanning angle.
However, such known light-scanning optical systems are more often than not accompanied by the problem of printing slippage in the main scanning direction because the quantity of light arriving to the BD sensor fluctuates depending on the deflection surfaces of the polygon mirror due to a possible eccentricity of the axis of rotation of the polygon mirror, uneven accuracy of machining the longitudinal edges of the deflection surfaces of the polygon mirror, the difference in the reflectivity of the films formed by evaporation on the deflection surfaces particularly in areas close to the edges and other factors.
Now, this phenomenon will be discussed by referring to FIGS. 5 and 6. FIG. 5 is a timing chart of a BD signal (BD) and a laser drive signal (LD). Since the polygon mirror is rotating at a constant angular velocity, a BD signal is applied at regular temporal intervals and a laser drive signal is transmitted for a scanning line at predetermined time t 1 after the application of the BD signal for the scanning line. Thus, all the scanning lines are made to have an identical start point. The BD signal is output at time t 0 after the time when the output of the BD sensor gets to a predetermined slice level S as shown in FIG. 6 . Thus, the laser drive signal is transmitted at the predetermined time t 1 after this time for a specific scanning line. If the quantity of light getting to the BD sensor fluctuates depending on the deflection surfaces of the polygon mirror for the above described reasons, the time t 0 can vary as a function of the fluctuations of the quality of light getting to the BD sensor to produce a time lag of At as shown in FIG. 6 . Then, the transmission of the laser drive signal for the scanning lines also shows a time lag of Δt to give rise to the phenomenon of printing slippage in the main scanning direction.
A similar problem arises when such a known light-scanning optical system is realized as multi-beam scanning optical system by using a plurality of light sources (light emitting sections).
For instance, when a popular monolithic 2-beam laser (e.g., multi-beam semiconductor laser) is used as light source, the two light emitting spots are separated at least by a distance as large as about 0.1 mm. If the light emitting spots of the light source are arranged perpendicularly relative to the sub scanning direction, the corresponding focused luminous spots are also separated in the sub scanning direction by more than 0.1 mm on the plane to be scanned. If the resolution of the optical system is 600 DPI, the luminous spots have to be separated in the sub scanning direction by 42.3 μm and then the optical system may require the use of a so-called interlace scanning system, which needs a memory for storing data for several lines to be jumped over to consequently raise the overall cost. The use of a costly memory can be avoided by arranging the two light emitting spots A and B of the light source 71 not perpendicularly but with an angle of θ relative to the sub scanning direction S that provides a distance between the two luminous spots on the plane to be scanned 57 in that direction that matches the resolution of the optical system as shown in FIG. 7 . In FIG. 7, reference symbols 53 and 54 respectively denote a collimator lens and a cylindrical lens while reference symbols 66 and M respectively denote a fθ lens and the main scanning direction.
When the light source 71 is arranged in the above described manner, the two luminous fluxes emitted from the two light emitting spots A and B (laser A having the light emitting spot A and laser B having the light emitting spot B) follows the respective optical paths as shown in FIG. 8 . If the polygon mirror 55 is caused to intentionally vignette the luminous fluxes getting to the BD sensor as in the case of known light-scanning optical systems, the ratio of vignetting the laser A and that of vignetting the laser B of the polygon mirror 55 are inevitably differentiated to consequently differentiate the output of the BD sensor for the laser A and that of the BD sensor for the laser B. Then, as discussed above, there arises the problem of printing slippage in the main scanning direction. If the difference of the outputs of the two BD sensors is constant, this problem may be dissolved by selecting different values for t 1 for laser A and for laser B, taking the time discrepancy of Δt into consideration. However, in reality, the difference of the outputs of the two BD sensors is by no means constant and it is highly difficult to completely eliminate the problem of printing slippage in the main scanning direction because the luminous fluxes are displaced longitudinally relative to the deflection surface of the polygon mirror by a minute distance due to an alignment error of the light source and other possible errors. Note that, in FIG. 8, reference symbols 52 and 53 denotes respectively the aperture stop and the collimator lens, while reference symbols 54 and 55 a denotes respectively the cylindrical lens and the deflection surface.
SUMMARY OF THE INVENTION
In view of the above identified technological problems of the prior art, it is therefore an object of the present invention to provide a light-scanning optical system that is free from the above problems and adapted to realize high definition printing by effectively avoiding any printing slippage in the main scanning direction and an image forming apparatus comprising such a light-scanning optical system.
According to the invention, the above object is achieved by providing a light-scanning optical system comprising:
a light source;
a first optical system for trimming the luminous flux emitted from said light source and imaging it as a linear luminous flux extending in the main scanning direction;
a light deflector having a deflection surface near the imaging position of said first optical system for reflecting and deflecting the incident luminous flux in the main scanning direction for a scanning operation;
a second optical system for imaging said luminous flux reflected and deflected by said light deflector on the plane to be scanned, said second optical system taking a role of establishing a substantially conjugate relationship between the deflection surface of said light deflector and said plane to be scanned;
a photodetector for detecting part of the luminous flux reflected and deflected by said light deflector and generating a write-start position synchronizing signal for controlling the timing of spotting the scanning start point on said plane to be scanned; and
a luminous flux delimiting member arranged on the light path between said light deflector and said photodetector for partly excluding the incident luminous flux en tering the photodetector.
According to the invention, there is also provided a light-scanning optical system comprising:
a light source having a plurality of light emitting sections;
a first optical system for trimming the plurality of luminous fluxes emitted from said light source and imaging each of them as a linear luminous flux extending in the main scanning direction;
a light deflector having a deflection surface near the imaging position of said first optical system for reflecting and deflecting the plurality of incident luminous fluxes in the main scanning direction for a scanning operation;
a second optical system for imaging said plurality of luminous fluxes reflected and deflected by said light deflector in different respective positions on the plane to be scanned, said second optical system taking a role of establishing a substantially conjugate relationship between the deflection surface of said light deflector and said plane to be scanned;
a photodetector for detecting part of the plurality of luminous fluxes reflected and deflected by said light deflector and generating a write start position synchronizing signal for con trolling the timing of spotting the scanning start point on said plane to be scanned; and
a luminous flux delimiting member arranged on the light path between said light deflector and said photodetector for partly excluding the plurality of incident luminous fluxes entering the photodetector.
In another aspect of the invention, there is provided an image forming apparatus comprising:
either of the above defined light-scanning optical systems;
a photosensitive member arranged on the plane to be scanned of said light-scanning optical system;
a developing unit for developing the electrostatic latent image formed on said photosensitive member by scanning the surface of said photosensitive member with a luminous flux into a toner image;
a transfer unit for transferring the developed toner image onto printing paper; and
a fixing unit for fixing the transferred toner image on the printing paper.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a known light-scanning optical system, showing a principal part thereof.
FIG. 2 is a schematic illustration of another known light-scanning optical system, showing a principal part thereof.
FIGS. 3A and 3B are enlarged schematic illustrations of the deflection surfaces of the polygon mirror and its vicinity of the known light-scanning optical system of FIG. 1 or FIG. 2 .
FIG. 4 is a schematic illustration of a known light-scanning optical system adapted to intentionally vignetting the luminous flux arriving to the BD sensor, showing a principal part thereof.
FIG. 5 is a timing chart of a BD signal and a laser drive signal.
FIG. 6 is a graph showing the waveform of a BD signal.
FIG. 7 is a schematic perspective view of a known light-scanning optical system using a multi-beam semiconductor laser, showing a principal part thereof.
FIG. 8 is a schematic illustration of a pair of luminous fluxes emitted from the multi-beam semiconductor laser of the light-scanning optical system of FIG. 7 .
FIG. 9 a schematic cross sectional view of a principal part of the first embodiment of light-scanning optical system according to the invention.
FIG. 10 is an enlarged schematic view of the BD mirror, the mirror holding member and its vicinity of the second embodiment of light-scanning optical system according to the invention.
FIG. 11 is an enlarged schematic view of the BD mirror and its vicinity of the third embodiment of light-scanning optical system according to the invention.
FIG. 12 is a schematic cross sectional view of the fourth embodiment of light-scanning optical system according to the invention and comprising a multi-beam semiconductor laser as light source, showing a principal part thereof.
FIG. 13 is a schematic cross sectional view of an electrophotographic printer comprising a light-scanning optical system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described by referring to the accompanying drawings that illustrate preferred embodiments of the invention.
[Embodiment 1]
FIG. 9 is a schematic cross sectional view of a principal part of the first embodiment of light-scanning optical system according to the invention that can be applied to an image forming apparatus such as a laser beam printer or a digital copying machine.
Referring to FIG. 9, there are shown a light source 1 that may be a semiconductor laser, an aperture stop 2 for trimming the diameter of the luminous flux passing therethrough, a collimator lens 3 for producing a substantially collimated or converged luminous flux out of the luminous flux emitted from the semiconductor laser 1 and a cylindrical lens adapted to exert a certain degree of refractive power in the sub scanning section. Note that the aperture stop 2 , the collimator lens 3 and the cylindrical lens 4 are components of the first optical system 12 of the embodiment.
In FIG. 9, reference symbol 5 denotes a light deflector, which may typically be a polygon mirror (rotary polygon mirror) driven to rotate at a constant rate in the direction of arrow A in FIG. 9 by a drive means such as a polygon motor (not shown).
Reference symbol 6 denotes an imaging optical system (fθ lens) having a characteristic value of fθ and operating as the second optical system. It comprises a spherical lens 6 a having a negative refractive power and a toric lens 6 b having a positive refractive power and adapted to form an image of the luminous flux deflected and reflected by the light deflector 5 and representing image information on the surface 7 of a photosensitive drum that is the plane to be scanned.
Reference symbol 7 denotes the surface of a photosensitive drum (recording medium), which is the plane to be scanned.
Reference symbol 8 denotes a luminous flux delimiting member, which is typically a bending mirror (to be referred to as “BD mirror” hereinafter) for excluding part of the luminous flux for detecting the write-start position synchronizing signal that is used to regulate the timing of spotting the scanning start position on the surface 7 of the photosensitive drum and reflecting the luminous flux to the side of the write-start position synchronizing signal detecting means (which will be described hereinafter). The BD mirror 8 is arranged at the side opposite to the first optical system 12 relative to the optical axis of the second optical system 6 and at the side of the surface 7 of the photosensitive drum of the second optical system 6 .
Reference symbol 9 denotes a slit arranged at a position equivalent to the surface 7 of the photosensitive drum. The slit 9 has a width of about 0.5 mm and the luminous flux of a small spot diameter (which is smaller than that of luminous flux produced by a conventional system and equal to less than 0.1 mm) passes therethrough.
Reference symbol 10 denotes a BD lens operating as imaging means and also for establishing a substantially conjugate relationship between the BD mirror 8 and the write-start position synchronizing signal detecting means 11 , which will be described hereinafter. It also takes a role of correcting the inclination of the BD mirror 8 .
Reference symbol 11 is a photodetector (to be referred to as “BD sensor” hereinafter) operating as write-start position synchronizing signal detecting means. In this embodiment, the timing of spotting the scanning start position for recording an image on the surface 7 of the photosensitive drum is regulated by means of the write-start position synchronizing signal (BD signal) obtained by detecting the output signal of the BD sensor 11 .
In this embodiment, the luminous flux coming from the first optical system 12 is made to strike the deflection surface (reflection surface) 5 a of the light deflector 5 so as to overflow the latter. The part of the incident luminous flux made to overflow the deflection surface 5 a of the light deflector 5 is reflected and deflected by the deflection surface 5 a and enters the BD sensor 11 . The quantity of light overflowing from the deflection surface 5 a of the light deflector 5 is made to be very small relative to the quantity of light delimited by the BD mirror 8 .
The luminous flux optically modulated by and emitted from the semiconductor laser 1 according to the image information given to it is then delimited by the aperture stop 2 in terms of its cross section and transformed into a substantially collimated or converged luminous flux by the collimator lens 3 before striking the cylindrical lens 4 . The luminous flux entering the cylindrical lens 4 is made to leave the latter without any modification in the main scanning section but converged in the sub scanning section to produce a substantially linear image (running longitudinally along the main scanning direction) on the deflection surface 5 a of the light deflector 5 . The luminous flux reflected and deflected by the deflection surface 5 a of the light deflector 5 is then focused by the imaging optical system 6 to produce a luminous spot on the surface 7 of the photosensitive drum, which spot is then made to optically scan the surface 7 of the of photosensitive drum in the direction of arrow B (main scanning direction) at a uniform rate as the light deflector 5 is driven to rotate in the direction of arrow A. As a result, an image is recorded on the surface 7 of the photosensitive drum which is a recording medium.
In the embodiment of light-scanning optical system, part of the luminous flux reflected and deflected by the polygon mirror 5 is reflected again by the BD mirror 8 , made to pass through the slit 9 and led to the BD sensor 11 by way of the BD lens 10 before causing the remaining luminous flux to scan the surface 7 of the photosensitive drum in order to regulate the timing of the scan start position on the surface 7 of the photosensitive drum. The timing of spotting the scan start position for recording the image on the surface 7 of the photosensitive drum is regulated by using the BD signal obtained by detecting the output signal of the BD sensor 11 .
In this embodiment, the luminous flux coming from the first optical system 12 is made to overflow the deflection surface 5 a of the polygon mirror 5 by using a large scanning angle so as to make the latter vignette part of the luminous flux in order to reduce the diameter of the luminous spot. Part of the luminous flux striking the deflection surface 5 a of the polygon mirror 5 is reflected and deflected by the deflection surface 5 a and then reflected by the BD mirror 8 so as to pass through the slit 9 . The luminous flux reflected by the BD mirror 8 has a width smaller than the original width so that only a narrow luminous flux is reflected by the BD mirror 8 and made to pass through the slit 9 . Therefore, the width and hence the quantity of light entering the BD sensor 11 is determined solely by the size (width of the reflection surface) of the BD mirror 8 . Additionally, the quantity of light overflowing the deflection surface 5 a of the light deflector 5 is small relative to the quantity of light delimited by the BD mirror 8 .
With the above described arrangement, the quantity of light arriving to the BD sensor 11 from the deflection surface 5 a of the polygon mirror 5 of this embodiment is uniform for all the deflection surfaces of the polygon mirror 5 so that the BD sensor 11 constantly produces its output without fluctuations. As a result, it can provide high definition printing and effectively avoid any printing slippage in the main scanning direction.
[Embodiment 2]
FIG. 10 is an enlarged schematic view of the BD mirror, the mirror holding member and its vicinity of the second embodiment of light-scanning optical system according to the invention.
This embodiment differs from the above described first embodiment in that the luminous flux delimiting means of this embodiment comprises a BD mirror holding member for holding the BD mirror. Otherwise, this embodiment is identical with the first embodiment particularly in terms of its optical effects.
Referring to FIG. 10, reference symbol 28 denotes the luminous flux delimiting means comprising a BD mirror holding member (BD mirror holder) for holding the BD mirror and delimiting the width of the luminous flux entering the BD sensor (not shown). Reference symbol 18 in FIG. 10 denotes the BD mirror of this embodiment, which is similar to that of FIG. 1 or FIG. 2 .
In this embodiment, the width of the luminous flux and hence the quantity of light entering the BD sensor is substantially determined by the size of the aperture of the BD mirror holder 28 . Additionally, in this embodiment, the quantity of light overflowing the deflection surface 5 a of the light deflector 5 is small relative to the quantity of light delimited by the BD mirror holder 28 .
With the above described arrangement, the quantity of light arriving to the BD sensor 11 from the deflection surface 5 a of the polygon mirror 5 of this embodiment is uniform for all the deflection surfaces of the polygon mirror 5 so that the BD sensor 11 constantly produces its output without fluctuations. As a result, it can provide high definition printing and effectively avoid any printing slippage in the main scanning direction.
Additionally, with this embodiment, any dispersing rays of light reflected by the edges of the BD mirror 18 that can adversely affect the operation of the embodiment are effective blocked by the BD mirror holder 28 .
[Embodiment 3]
FIG. 11 is an enlarged schematic view of the BD mirror and its vicinity of the third embodiment of light-scanning optical system according to the invention. In FIG. 11, the components that are same as those of FIG. 10 are denoted respectively by the same reference symbols.
This embodiment differs from the above described first embodiment only in that the luminous flux delimiting means comprises a partition-like member arranged in the optical housing. Otherwise, this embodiment is identical with the first embodiment particularly in terms of its optical effects.
Referring to FIG. 11, reference symbol 38 denotes the luminous flux delimiting means which is a partition-like member arranged in the optical housing for holding the first optical system, the light deflector, the second optical system and the BD sensor of the embodiment, which are not shown. The partition-like member is located immediately in front of the BD mirror 18 to delimit the luminous flux striking the BD sensor (not shown).
In this embodiment, the width of the luminous flux and hence the quantity of light entering the BD sensor is substantially determined by the size of the aperture of the partition-like member 38 . Additionally, in this embodiment, the quantity of light overflowing the deflection surface 5 a of the light deflector 5 is small relative to the quantity of light delimited by the partition-like member 38 .
With the above described arrangement, the quantity of light arriving to the BD sensor 11 from the deflection surface 5 a of the polygon mirror 5 of this embodiment is uniform for all the deflection surfaces of the polygon mirror 5 so that the BD sensor 11 constantly produces its output without fluctuations. As a result, it can provide high definition printing and effectively avoid any printing slippage in the main scanning direction.
Additionally, with this embodiment, the BD mirror holder can be made to show a simple profile or totally eliminated.
[Embodiment 4]
FIG. 12 is a schematic cross sectional view of the fourth embodiment of light-scanning optical system according to the invention and comprising a multi-beam semiconductor laser as light source, showing a principal part thereof as applied to a laser beam printer or a digital copying machine. In FIG. 12, the components that are same as those of FIG. 9 are denoted respectively by the same reference symbols.
This embodiment differs from the above described first embodiment only in that it comprises a multi-beam semiconductor laser having a plurality of light emitting sections (light emitting spots) as light source and optical elements arranged accordingly. Otherwise, this embodiment is identical with the first embodiment particularly in terms of its optical effects.
Referring to FIG. 12, reference symbol 41 denotes the light source, which is a multi-beam semiconductor laser having a plurality of light emitting sections. In this embodiment, more specifically, the multi-beam semiconductor laser 41 has two light emitting sections arranged with a predetermined angle of θaccording to resolution as described earlier by referring to FIG. 7 so that they are separated from each other along the main scanning direction.
In FIG. 12, reference symbol 46 denotes an imaging optical system (fθ lens) having a characteristic value of fθ and operating as the second optical system. It comprises a single lens having different refractive powers, one for the main scanning direction and the other for the sub scanning direction. Thus, FIG. 12, shows a multi-beam scanning optical system using two beams.
In this embodiment, as in Embodiments 1, 2 and 3 described above, the two luminous fluxes coming from the first optical system 12 are made to overflow the deflection surface 5 a of the polygon mirror 5 so as to make the latter vignette part of the luminous fluxes. While the ratio of the part of the luminous flux vignetted by the polygon mirror 5 to the overall luminous flux may differ between the two luminous fluxes, the size of the BD mirror 8 (the width of the reflection surface) is so selected that it will reflect only part of the luminous flux even showing the greater vignetted ratio. Therefore, the widths of the two luminous fluxes emitted respectively from the two light emitting sections and entering the BD sensor 11 are determined solely by the size (width of the reflection surface) of the BD mirror 8 . Additionally, the quantity of light overflowing the deflection surface 5 a of the light deflector 5 is small relative to the quantity of light delimited by the BD mirror 8 for the two luminous fluxes.
With the above described arrangement, the quantity of light arriving to the BD sensor 11 for accommodating the two light emitting sections of this embodiment is uniform for all the deflection surfaces of the polygon mirror 5 so that the BD sensor 11 constantly produces its output without fluctuations. As a result, it can provide high definition printing and effectively avoid any printing slippage in the main scanning direction.
While the widths and hence the quantities of light of the two luminous fluxes entering the BD sensor 11 of this embodiment are determined solely by the size of the BD mirror 8 , the embodiment is not limited thereto and it may alternatively be determined by the size of the aperture of the BD mirror holding member (BD mirror holder) or the size of the aperture of the partition-like member arranged immediately in front of the BD mirror in the optical housing as described above by referring to Embodiments 2 or 3, whichever appropriate.
Additionally, in each of the above described first through fourth embodiments, the BD mirror, the BD mirror holding member or the partition arranged in the optical housing, whichever appropriate, is arranged at the side of the surface of the photosensitive drum of the second optical system as luminous flux delimiting means (light screening means) for facilitating the separation of the luminous flux arriving to the effective image forming area and the luminous flux entering the BD sensor in order to realize a large scanning angle and effectively utilizing the deflection surface of the polygon mirror.
It may be appreciated that any member that can effectively delimit and partly exclude the luminous flux entering the BD sensor may be used to replace any of the above described luminous flux delimiting members.
FIG. 13 is a schematic cross sectional view of an electrophotographic printer comprising a light-scanning optical system according to the invention. In FIG. 13, reference symbol 100 denotes an light-scanning optical system according to the invention, which may be any of the above described first through fourth embodiments. Reference symbol 101 denotes a photosensitive drum operating as electrostatic latent image carrier, to the surface of which a charging roller 102 is held in contact from above in order to electrically uniformly charge the surface of the drum 101 . A beam of light 103 is made to irradiate and scan the electrically charged surface of the photosensitive drum 101 by an optical scanner 100 at a position downstream relative to the line of contact of the charging roller 102 and the drum 101 in the sense of rotation of the drum 101 .
The beam of light 103 is modulated as a function of the image data given to the printer so that an electrostatic latent image is formed on the surface of the photosensitive drum 101 by irradiating the surface of the drum 101 with the beam of light 103 . The electrostatic latent image is then developed into a toner image by a developing unit 107 arranged downstream relative to the position of irradiation of the beam of light 103 on the drum 101 in the sense of rotation of the drum 101 . The toner image is then transferred onto printing paper 112 by means of a transfer roller 108 disposed vis-a-vis the photosensitive drum 101 at a position located under the drum 101 . While the printing paper 112 is stored in a paper cassette 109 located in front of the photosensitive drum 101 (right to the drum 101 in FIG. 13 ), it may alternatively be fed to the photosensitive drum 101 by hand. A paper feed roller 110 arranged at an end of the paper cassette 109 and a pair of paper transfer rollers 111 arranged behind the feed roller feed the paper 112 in the paper cassette 109 to the delivery path.
The paper 112 now carrying the transferred toner image that is not fixed yet is then moved further to a fixing unit arranged behind the photosensitive drum 101 (left to the drum 101 in FIG. 13 ). The fixing unit comprises a fixing roller 113 containing a fixing heater (not shown) in the inside and a pressurizing roller 114 arranged so as to be pressed against the fixing roller 113 and is adapted to fix the toner image on the paper 112 by heating it, while applying pressure to it by means of the fixing roller 113 and the pressurizing roller 114 . A pair of delivery rollers 116 are arranged behind the fixing roller 113 to deliver the paper carrying thereon the fixed image out of the printer.
The present invention is by no means limited to the above described embodiments, which may be modified or altered appropriately without departing from the scope of the invention as defined by the claims.
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A light-scanning optical system comprises a light source, a first optical system, a light deflector having a deflection surface, a second optical system, a photodetector and a luminous flux delimiting member. A luminous flux emitted from the light source is trimmed and imaged as a linear luminous flux extending in the main scanning direction by the first optical system. The deflection surface of the deflector is arranged near the imaging position of the first optical system so that it reflects and deflects the linear luminous flux for scanning operation. The deflected luminous flux is then imaged on the plane to be scanned by the second optical system that establishes a substantially conjugate relationship between the deflection surface and the plane to be scanned. Part of the deflected luminous flux, in the meantime, is reflected by a bending mirror arranged on the light path between the second optical system and the plane to be scanned, and detected by the photodetector that generates a write-start position synchronizing signal for controlling the timing of spotting the scanning start point on the plane to be scanned. The bending mirror thus operates as the luminous flux delimiting member for the incident luminous flux entering the photodetector. The light source may have a plurality of light emitting sections and in that case, the quantity of light detected by the photodetector is equalized for all the plurality of luminous fluxes emitted from the photodetector.
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This is a division of application Ser. No. 07/820,257, filed on Jan. 14, 1992 U.S. Pat. No. 5,412,139.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a new organophosphate dispersing agent and a thermosetting composition, comprising a thermosetting unsaturated polyester resin containing a monomer which may subsequently be copolymerized with the polyester resin, or an alkyd-, acrylic- or phenolic-type molding resin, a pulverulent mineral filler, and a dispersing agent. The dispersing agent makes it possible to obtain highly-filled thermosetting molding compositions having no yield point and low viscosities under very low shear ratios.
Discussion of the Background
During the fabrication of molded articles from a composition based on thermosetting resins of unsaturated polyester, alkyd, acrylic, or phenolic-type molding resins, in accordance with one of the conventional sheet-molding (sheet molding composition--SMC) and bulk molding (bulk molding composition--BMC) techniques, it becomes increasingly necessary to increase the quantity of mineral filler in order to reduce the cost of the molded articles. It is also necessary to preserve mechanical, thermal, dielectric, and aesthetic properties of the resins, as well as to obtain a viscosity of the mixture which is as low as possible at high and low shear ratios. In fact, the lack of a yield point allows the resin to be easily worked at all stages of the molding operation. In order to add fillers to these resins, the use of conventional organophosphate dispersing agents is well known.
Patent Applications JP 61-101527, JP 62-207337, JP 62-235353 disclose the addition of organophosphates to mixtures containing a maximum of 100 parts filler for 100 parts resin. For greater concentrations of mineral filler ranging up to 65%, U.S. Pat. No. 4,183,843 claims the use of polar esters of phosphoric acid. When used in small proportions, these products reduce the viscosity of the mixture of calcium carbonate and/or aluminum hydroxide and/or titanium dioxide and/or silicon dioxide and/or clay with unsaturated polyester-type resins under high shear ratios. However, the viscosity under very low shear ratios remains very great and there exists a yield point which makes the formulations difficult to handle. Furthermore, it has been observed that the viscosity of the thermosetting composition increases in a directly proportional manner to the quantity of these polar phosphated esters used, resulting in a thickening effect.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a thermosetting molding composition having no yield point and low Brookfield viscosities under high shear ratios and containing a dispersing agent and up to 75% by weight of a pulverulent mineral filler.
A further object of this invention is to provide a new dispersing agent that can be added to a thermosetting composition filled up to 75% by weight without producing a thickening effect.
A further object of this invention is to provide a new dispersing agent that can be added to a highly-filled thermosetting composition without producing a yield point, and without affecting the mechanical, thermal, dielectric, and aesthetic properties of the thermosetting composition.
A further object of the invention is to provide a new dispersing agent that can be added to a highly-filled thermosetting composition without producing a yield point and can be used in sheet-molding composition (SMC) and bulk molding composition (BMC) techniques.
A further object of the invention is to improve the surface state (Low Profile) of articles fabricated using a thermosetting composition containing the dispersing agent according to the invention.
These objects are achieved by preparing a thermosetting composition, comprising:
(a) a thermosetting resin,
(b) a pulverulent mineral filler in a quantity ranging up to 75% by weight of the total weight of the resin and the filler,
(c) an organophosphate dispersing agent, in an amount of 0.3 to 5% by weight of the weight of the filler, having the general formula: ##STR3## where: A is a branched or unbranched polyaryl group,
x and y are whole numbers between 0 and 100 such that x+y is a whole number greater than 40 but not greater than 100, ##STR4## x1 and y1 are whole numbers between 0 and 100 such that x1+y1 is a whole number not greater than 100,
B is a branched or unbranched polyaryl group, or an alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radical, ##STR5## x2 and y2 are whole numbers between 0 and 100 such that x2 +y2 is a whole number not greater than 100,
E is a branched or unbranched polyaryl group, or an alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radical, and R 1 and R 2 may be identical or different.
These objects are further achieved by using an organophosphate dispersing agent for acting on mineral fillers in thermosetting resins, wherein said agent has the following general formula (I): ##STR6## where: A is a branched or unbranched polyaryl group,
x and y are whole numbers between 0 and 100 such that x+y is a whole number greater than 40 but not exceeding 100, ##STR7## x1 and y1 are whole numbers between 0 and 100 such that x1+y1 is a whole number not greater than 100,
B is a branched or unbranched polyaryl group, or an alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radical, ##STR8## x2 and y2 are whole numbers between 0 and 100 such that x2+y2 is a whole number not greater than 100,
E is a branched or unbranched polyaryl group, or an alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radical, and R 1 and R 2 may be identical or different.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIGS. 1-3 show the infrared spectrum of various dispersing agents disclosed herein; and
FIGS. 4 and 5 show the curves for the variation of the Brookfield viscosity in mPa.s at 0.5 R/mn and 100 R/mn as a function of the number of moles of alkylene oxide contained in the general formula (I) of the dispersing agent.
DETAILED DESCRIPTION OF THE INVENTION
The dispersing agent corresponding to general formula (I) preferably contains a branched or unbranched polyaryl group A having molecular weight range between 127 and 2000. B and E, may be branched or unbranched polyaryl groups, or alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radicals, preferably containing up to 18 carbon atoms. The polyaryl group A may be di(phenyl-1-ethyl) phenols, commonly called distyrylphenols, tri(phenyl-1-ethyl) phenols, commonly called tristyrylphenols, and oligomers of polystyrene or styrene copolymer oligomers with another monomer. B and E may be the same as the above-mentioned radicals A and may be lauryl, stearyl, nonyl-phenol, etc. The sum x+y is preferably 50 to 60.
While the prior art discloses polar phosphate ester-type dispersants which are added in quantities of from 0.05% to 1% by weight in relation to the weight of the filler in filled thermosetting composition having a filler content ranging up to 65% of the total weight of the filler and the thermosetting resin, the dispersing agent having the general formula (I) according to the invention is added in a quantity of from 0.3% to 5%, and preferably from 0.5% to 3%, by weight in relation to the weight of the filler. The dispersing agent having the general formula (I) is added while stirring the thermosetting resin just before, just after, or simultaneously with the addition of the pulverulent mineral filler in a quantity ranging up to 75% by weight in relation to the total weight of the resin and of the pulverulent mineral filler.
The thermosetting composition according to the invention comprises a thermosetting resin, a quantity of pulverulent mineral fillers ranging up to 75% by weight of the weight of the resin and the filler, the dispersing agent according to the invention, and optionally, other additives. The composition has no yield point, i.e., it has low viscosity under a very low shear ratio, and has a viscosity less than or equal to that of compositions according to prior art under higher shear ratios.
The thermosetting filled composition may comprise:
(a) a thermosetting resin chosen from among acrylics, phenolic molding compositions, alkyds, unsaturated polyesters produced by the condensation reaction of maleic anhydride, optionally in the presence of phthalic anhydride, and an alkylene glycol or polyalkylene glycol having a low molecular weight, and styrene can be copolymerized with the polyester resins and/or unsaturated polyester resins;
(b) a quantity of up to 75% by weight in relation to the total weight of the resin and the pulverulent mineral filler, of a pulverulent mineral filler chosen from among the mineral salts and/or oxides, such as natural or precipitated calcium carbonate, magnesium carbonate, zinc carbonate, dolomite, calcium sulfate, aluminum hydroxide, metallic oxides such as zinc oxide, iron oxides, titanium oxide, wollastonite, and more particularly chosen from among calcium carbonate, aluminum hydroxide, calcium sulfate, and titanium oxide;
(c) a quantity of between 0.3% and 5% by weight, and preferably from 0.5% to 3% by weight, of the weight of the filler of the organophosphate dispersing agent having the general formula (I); and
(d) optionally, other conventional additives chosen, in particular, from among thermal or photochemical stabilizers, oxidation inhibitors, shrinkage inhibitors, static inhibitors, plasticizers, lubricants, unmolding agents, flame retardants, glass fibers and balls, and mineral thickeners such as magnesium hydroxide.
The thermosetting composition containing the dispersing agent according to the invention is characterized by its Brookfield viscosities under high and low shear ratios, measured using an RVT-type Brookfield viscometer at different rotating speeds of the module. The dispersing agent having the general formula (I) is characterized by its acid value, measured using a titrimetric method in accordance with standard NF T30-402 and by its infrared spectrum produced using the IR 398 infrared spectrophotometer equipped with a 3 600 DATA terminal station marketed by the PERKIN ELMER Corporation.
Other features of the invention will become apparent in the course of the following description of exemplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLE 1
Preparation of the Thermosetting Composition
In a glass crucible of approximately 500 ml equipped with a GRENIER-CHARVET laboratory stirring apparatus, 200 g of an unsaturated polyester resin marketed by WALTER MADER AG under the name CRISTIC 192 LV and having a Brookfield viscosity of 350 mPa.s at 1OR/mn, 20° C. module 3, and 370 mPa.s at 10OR/mn, 20° C. module 3, was added to 2 g of a dispersing agent. The mixture was then homogenized for 30 seconds using the stirring apparatus at a rate of 1,000 R/mn. Next, 200 g of an aluminum hydroxide pulverulent mineral filler, of which 50% of the particles were less than 2.3 μm and all of the particles were less than 50 μm, marketed by the MARTINSWERK company under the name MARTINAL OL 104-C, was added to the mixture of over 10 minutes under agitation while increasing the speed gradually to 2,000 R/mn.
Measurement of the Rheology of the Composition
The composition was kept at 23° C. for 48 hours. After temperature verification, the same module 6 of the RVT-type Brookfield viscometer was used to measure the Brookfield viscosities of the composition obtained under different shear ratios at a temperature of 23° C.
This operating method was carried out for each of the following dispersants:
Test 1
Dispersant according to prior art marketed by ROHM & HAAS under the name TRITON QS-44, having an acid value of I A =294 mg/g according to Standard NF T30-402. The infrared spectrum is shown in FIG. 1.
Test 2
Dispersant according to prior art marketed by PHILIP A. HUNT Company under the name WAYFOS M100, having an acid value of I A =148 mg/g according to Standard NF T30-402. The infrared spectrum is shown in FIG. 1.
Test 3
Dispersant according to prior art marketed by the BYK Company under the name BYK W990, having an acid value of I A =88 mg/g according to Standard NF T30-402. The infrared spectrum is shown in FIG. 1.
Test 4
Dispersant according to the invention, named product 4, composed of a mixture containing 41% of a phosphoric monoester and 59% of a phosphoric diester having general formula (I) , where:
For the monoester: ##STR9## x=48 y=2 R 1 =R 2 =H
For the diester: ##STR10## x=48 y=2 ##STR11## x1=48 y1=2 B=A R 2 =H
An acid value of I A =56 mg/g was determined in accordance with Standard NF T30-402. The infrared spectrum is shown in FIG. 2.
Test 5
Dispersing agent according to the invention, named product 5, composed of a phosphoric monoester having general formula (I), where: ##STR12## x=100 y=0 R 1 =R 2 =H
An acid value of I A =25 mg/g was determined in accordance with Standard NF T30-402. The infrared spectrum is shown in FIG. 2.
Table I presents the Brookfield viscosities measured for each of the above-mentioned compositions, all of which have the same base resin (CRISTIC 192 LV), the same MARTINAL OL-104-C content (50% by weight of the total of the resin and the filler), the same dispersant content (1% by weight of the filler), but as the single variable, the chemical formula of the dispersing agent.
TABLE I__________________________________________________________________________ PRIOR ART INVENTIONTEST NO. 1 2 3 4 5__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type Martinal Martinal Martinal Martinal Martinal OL 104 C OL 104 C OL 104 C OL 104 C OL 104 C Quantity in % by 50% 50% 50% 50% 50% weight of the filler and resin__________________________________________________________________________Dispersant Type Triston Wayfos BYK Product Product QS-44 M100 W990 4 5 Quantity in % by 1% 1% 1% 1% 1% weight of the filler__________________________________________________________________________Brookfield 0.5 R/mn 180,000 182,000 162,000 10,000 14,000viscosity 1 R/mn 106,000 110,000 102,000 10,000 13,000module 6 in 2.5 R/mn 54,800 56,000 54,000 8,800 10,000mPa · s (cP) 5 R/mn 34,000 34,000 34,000 7,200 8,200 10 R/mn 21,600 21,600 21,800 6,200 7,500 20 R/mn 14,200 14,200 14,500 5,250 6,650 50 R/mn 8,540 8,400 8,800 4,300 5,940 100 R/mn 6,700 5,900 6,400 3,900 5,550__________________________________________________________________________
Table I shows that the thermosetting compositions containing the dispersing agent according to the invention have low Brookfield viscosities under low shear ratios (0.5 R/mn to 20 R/mn) and high shear ratios (beginning at 50 R/mn) and have no yield point. The compositions obtained using prior art dispersing agents possess a yield point. Moreover, the compositions containing the dispersing agent according to the invention possess Brookfield viscosities that are lower than those obtained using a prior art dispersing agent at all tested shear ratios.
EXAMPLE 2
Under the same conditions as in Example 1, 400 g of natural calcium carbonate, having particle sizes smaller than 50 μm, 50% of which are smaller than 3.2 μm, and marketed by OMYA, S.A. under the name MILLICARB were added to a mixture of 200 g of an unsaturated polyester resin marketed by WALTER MADER AG under the name CRISTIC 192 LV and 2 g of dispersing agent.
Using the same operating procedure as in Example 1, the Brookfield viscosities of the thermosetting compositions containing the following dispersing agents were measured:
Test 6
Dispersant according to prior art marketed by PHILIP A. HUNT under the name WAYFOS M100, previously used in Test 2.
Test 7
Dispersant according to the invention, called product 4, previously used in test 4.
Test 8
Disperant according to the invention, called product 8, composed of a phosphoric monoester corresponding to general formula (I), where: ##STR13## x=60 y=0 R 1 =R 2 =H
An acid value of I A - 39 mg/g was determined in accordance with Standard NF T30-402. The infrared spectrum is shown in FIG. 2.
Test 9
"Invention limit" dispersant, called product 9, composed of a phosphoric monoester corresponding to general formula (I), where: ##STR14## x=40 y=0 R 1 =R 2 =H
An acid value of I A =55 mg/g was determined in accordance with Standard NF T30-402. The infrared spectrum is shown in FIG. 3.
Test 10
Dispersant according to prior art, called product 10, corresponding to the general formula:
(CH.sub.3 --(CH.sub.2).sub.8).sub.2 --C.sub.6 H.sub.3 --(O--CH.sub.2 --CH.sub.2).sub.50 --OPO.sub.3 H.sub.2
having no polyaryl A radical and having an acid value of I A =55 mg/g. The infrared spectrum is shown in FIG. 1.
Table II presents the Brookfield viscosities for each of the above-mentioned composition, all of which have the same base resin (CRISTIC 192 LV), the same MILLICARB content (66% by weight of the total weight of the resin and filler, the same dispersant content (0.5% by weight of the filler), but as the single variable, the chemical formula of the dispersing agent.
TABLE II__________________________________________________________________________ INVENTION PRIOR PRIOR ART INVENTION LIMIT ART__________________________________________________________________________TEST NO. 6 7 8 9 10__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type Millicarb Millicarb Millicarb Millicarb Millicarb Quantity in % by 66% 66% 66% 66% 66% weight of the filler and resin__________________________________________________________________________Dispersant Type Wayfos Product Product Product Product M100 4 8 9 10 Quantity in % by 0.5% 0.5% 0.5% 0.5% 0.5% weight of the filler__________________________________________________________________________Brookfield 0.5 R/mn 88,000 4,000 4,000 3,600 4,000viscosity 1 R/mn 55,000 4,000 4,000 3,600 4,000module 6 in 2.5 R/mn 31,200 4,480 4,400 4,080 4,480mPa · s (cP) 5 R/mn 22,000 4,800 4,700 4,560 4,960 10 R/mn 16,700 5,240 5,100 5,4440 5,920 20 R/mn 13,750 6,220 6,100 7,250 7,800 50 R/mn 12,100 8,670 8,600 11,300 11,720 100 R/mn 11,300 10,600 10,600 14,500 15,320__________________________________________________________________________
Table II shows that the thermosetting compositions obtained using the dispersing agent according to the invention (Tests 7 and 8) are the only ones which lack a yield point and have minimal viscosities for all tested shear ratios. Although Tests 9 and 10 have no yield point, they have increased viscosities at higher shear ratios. The composition containing the dispersing agent according to the prior art (Test 6) has high viscosities for low shear ratios.
Tests 7, 8, 9, and 10 are different based upon the dispersant used. In Tests 7 and 8, the dispersant contains a polyaryl radical and 50 or 60 units of alkylene oxide. In Test 9, the dispersant contains a polyaryl radical but only has 40 units of ethylene oxide. Similarly, the difference among the dispersants used in Tests 7 and 10 arise from the radical, which is not polyaryl in Test 10, while the number of alkylene oxide groups is identical.
Thus, the dispersants used must have more than 40 units of alkylene polyoxide groups and a polyaryl radical in order to obtain a thermosetting composition without a yield point and with minimal Brookfield viscosities at high shear ratios.
EXAMPLE 3
Thermosetting compositions are prepared under the same conditions and having the same quantities as the compositions in Example 1 except that the dispersants are as follows:
Test 11
Dispersant according to the prior art, marketed by the PHILIP A. HUNT Company under the name WAYFOS M100, previously used in Test 2.
Test 12
Dispersant according to the invention, named product 4, previously used in Tests 4 and 7.
Test 13
Dispersant according to the invention, named product 8, previously used in Test 8.
Test 14
Dispersant according to the invention, named product 5, previously used in Test 5.
Test 15:
"Invention limit" dispersant, named product 15, composed of a mixture or phosphoric mono- and diester corresponding to general formula (I), where:
For the monoester: ##STR15## x=16 y=0 R 1 =R 2 =H
For the diester: ##STR16## x=16 y=0 ##STR17## x1=16 y1=0 B=A R 2 =H
An acid value of I A =60 mg/g was determined in accordance with Standard NF T30-402. The infrared spectrum is shown in FIG. 3.
Test 16
"Invention limit" dispersant, called product 9, previously used in Test 9.
Using the same operating procedures used in Example 1, the viscosities of the thermosetting compositions were measured and are presented in Table III.
TABLE III__________________________________________________________________________ INVENTION PRIOR ART INVENTION LIMIT__________________________________________________________________________TEST NO. 11 12 13 14 15 16__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type Martinal Martinal Martinal Martinal Martinal Martinal OL 104 C OL 104 C OL 104 C OL 104 C OL 104 C OL 104 C Quantity in % 50% 50% 50% 50% 50% 50% by weight of the filler and resin__________________________________________________________________________Disper- Type Wayfos Product Product Product Product Productsant M100 4 8 5 15 9 Quantity in % 1% 1% 1% 1% 1% 1% by weight of the filler__________________________________________________________________________Brookfield 0.5 R/mn 182,000 10,000 4,000* 14,000 20,000 10,000viscosity 1 R/mn 110,000 10,000 4,000* 13,000 20,000 10,000module 6 2.5 R/mn 56,000 8,800 4,000* 10,000 20,000 10,000in 5 R/mn 34,000 7,200 4,250* 8,200 15,000 8,400mPa · s 10 R/mn 21,600 6,200 4,000* 7,500 12,500 7,200(cP) 20 R/mn 14,200 5,250 3,860* 6,650 11,000 6,500 50 R/mn 8,400 4,300 3,640* 5,940 11,000 6,300 100 R/mn 5,900 3,900 3,540* 5,550 9,700 5,900__________________________________________________________________________ *Indicates that the viscosity was measured using module 5, since viscosit was too low to use module 6?
Based on the results in Table III, curves 1 and 2 (illustrated in FIGS. 4 and 5, respectively) were plotted. Curve 1 (FIG. 4) shows the variation of the Brookfield viscosity in mPa.s at 0.5 R/mn as a function of the number of moles of alkylene oxide contained in the general formula (I) of the dispersant. Curve 2 (FIG. 5) shows the variation of the Brookfield viscosity in mPa.s at 100 R/mn as a function of the number of moles of alkylene oxide contained in the general formula (I) of the dispersant. These lines confirm the observation that, when there are more than 40 alkylene oxide groups in the dispersant used, the Brookfield viscosity of the thermosetting composition is very low for low shear ratios and minimal for higher shear ratios, and that the preferred range of the number of alkylene oxide groups contained in the dispersing agent having the general formula (I) is between 50 and 60 groups.
EXAMPLE 4
Under the conditions of Example 1, the proportion of filler added to the mixture composed of resin and dispersant was increased while the proportion of dispersant in relation to the filler was maintained as a constant.
Tests 17 to 22 were prepared using 200 g of unsaturated polyester resin marketed by WALTER MADER AG under the name CRISTIC 192 LV as follows:
Test 17
400 g of calcium carbonate having an average granulometry of 3.2 μm, marketed by OMYA S.A. under the name MILLICARB, and 4 g of the dispersant marketed by the PHILIP A. HUNT Company under the name WAYFOS M100.
Test 18
500 g of the calcium carbonate used in Test 17, and 5 g of the dispersant used in Test 17.
Test 19
600 g of the calcium carbonate used in Test 17, and 6 g of the dispersant used in Test 17.
Test 20
400 g of the calcium carbonate used in Test 17, and 4 g of the dispersant according to the invention, termed product 8, previously used in Test 8.
Test 21
500 g of the calcium carbonate used in Test 17, and 5 g of the dispersant, product 8.
Test 22
600 g of the calcium carbonate used in Test 17, and 6 g of the dispersant, product 8.
Under the operating conditions used in Example 1, the Brookfield viscosities of the thermosetting compositions were measured using modules 6 and 7. The results are presented in Table IV.
TABLE IV__________________________________________________________________________ PRIOR ART INVENTION__________________________________________________________________________TEST NO. 17 18 19 20 21 22__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Quantity in % 66.6% 71.4% 75.0% 66.6% 71.4% 75.0% by weight of the filler and resin__________________________________________________________________________Disper- Type Wayfos Wayfos Wayfos Product Product Productsant M100 M100 M100 8 8 8 Quantity in % 1% 1% 1% 1% 1% 1% by weight of the filler__________________________________________________________________________Brookfield 0.5 R/mn 200,000 512,000 1,176,000 4,000* 10,000* 40,000viscosity 1 R/mn 124,000 296,000 704,000 5,000* 10,000* 40,000module 7 2.5 R/mn 64,000 153,000 392,000 5,600* 11,200* 41,600in 5 R/mn 41,600 101,600 273,600 6,000* 12,000* 44,000mPa · s 10 R/mn 28,400 70,400 204,000 6,300* 13,000* 53,200(cP) 20 R/mn 21,000 52,000 167,600 6,800* 15,300* 78,400 50 R/mn 15,520 38,000 Measurement 8,600* 23,840 Measurement impossible impossible, material material unsuitable unsuitable 100 R/mn 13,240 32,000 idem 11,280 32,000 idem__________________________________________________________________________ *Indicates that the viscosity was measured using module 6, since viscosit was too low to be measured using module 7
Table IV shows that the thermosetting composition according to the invention preserves the absence of a yield point despite the increase in filler content.
EXAMPLE 5
Under the conditions of Example 1, thermosetting compositions were prepared using increasing quantities of the dispersing agent. For 200 g of unsaturated polyester resin marketed by WALTER MADER AG under the name CRISTIC 192LV, and for 400 g of natural calcium carbonate marketed by OMYA, S.A. under the name MILLICARB, 2 g of dispersant were used for Tests 23 and 24, 4 g for Tests 25 and 26, 8 g for Tests 27 and 28, and 20 g for Tests 29 and 30.
Under the operating conditions of Example 1, modules 5, 6, or 7 were used to measure the Brookfield viscosities of the thermosetting compositions thus obtained. Table V, below, shows that the addition of increasing quantities of dispersing agent according to the invention, added in a proportion ranging up to 5% by weight, and preferably 3% by weight, of the filler, allows a lowering of the Brookfield viscosity of the thermosetting composition, while the dispersants according to prior art produce a thickening effect under a low shear ratio (up to 20 R/mn).
This capacity to lower the Brookfield viscosity-makes it possible to chose the desired viscosity for the composition by adjusting the quantity of dispersant to be added.
TABLE V__________________________________________________________________________TEST NO. 23 24 25 26 27 28 29 30__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Quantity 66% 66% 66% 66% 66% 66% 66% 66% in % by weight filler + resin__________________________________________________________________________Disper- Type Wayfos Product Wayfos Product Wayfos Product Wayfos Productsant M100 8 M100 8 M100 8 M100 8 Quantity 0.5% 0.5% 1% 1% 2% 2% 5% 5% in % by weight filler__________________________________________________________________________Brookfield 0.5 R/mn 120,000 5,600* 218,000 5,600* 314,000 5,600* 524,000 8,000*viscosity 1 R/mn 72,000 6,000* 130,000 6,400* 178,000 5,600* 294,000 8,000*module 6 2.5 R/mn 40,400 6,400* 69,600 6,400* 90,000 5,800* 144,000 8,500*in 5 R/mn 27,600 7,000* 46,400 7,000* 56,200 6,000* 86,800 8,600*mPa · s 10 R/mn 23,500 8,200* 32,600 7,640* 37,400 6,100* 58,400 8,600*(cP) 20 R/mn 18,700 10,600* 24,800 8,500* 26,500 6,400* 54,600** 9,500 50 R/mn 17,500** 14,600** 21,200** 12,100** 20,200** 7,100* 32,800** 9,700 100 R/mn 16,800** 16,800** 17,600** 13,200** 15,800** 8,200 24,000** 10,600**__________________________________________________________________________ *Indicates that the measurements were made using module 5, since viscosities were too low for module 6 **Indicates that the measurements were made using module 7, since viscosities were too high for module 6
EXAMPLE 6
Under the conditions of Example 1, thermosetting compositions were prepared using several types of resins. Tests 31 to 33 were conducted using 200 g of acrylic resin, marketed by the I.C.I. company under the name MODAR 826 HT and having a Brookfield viscosity of 220 mPa.s at 10 R/mn (module 4) and of 250 mPa.s at 100 R/mn (module 4) at ambient temperature; 400 g of natural calcium carbonate marketed by OMYA, S.A. under the name of MILLICARB; and 4 g of dispersant. Tests 34 to 36 were conducted with 200 g of an unsaturated polyester resin having a higher molecular weight and a Brookfield viscosity of 2,880 mPa.s at 10 R/mn (module 5) and 2,940 mPa.s at 100 R/mn (module 5) at ambient temperature; 300 g of the same calcium carbonate as previously used; and 4 g of dispersant. Tests 37 and 38 were performed using 200 g of an unsaturated polyester resin distributed by the STRAND GLASS Company under the name CRISTIC 191 LV, whose Brookfield viscosity is 700 mPa.s at 10 R/mn (module 3) and 250 mPa.s at 100 R/mn, (module 3) at ambient temperature; 400 g of the same calcium carbonate as previously used; and 8 g of dispersant.
Once these thermosetting compositions were prepared, the same operating procedure as in Example 1 was implemented in order to measure their Brookfield viscosities, which appear in Table VI, below.
TABLE VI__________________________________________________________________________TEST NO. 31 32 33 34 35 36 37 38__________________________________________________________________________Resin Type Modar Modar Modar Polyester Polyester Polyester Cristic Cristic 826 HT 826 HT 826 HT high mol. high mol. high mol. 191 LV 191 LV weight weight weight__________________________________________________________________________Filler Type Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Millicarb Quantity 66% 66% 66% 60 60 60 66% 66% in % by weight filler + resin__________________________________________________________________________Disper- Type Wayfos Product Product Wayfos Triton Product Wayfos Productsant M100 4 8 M100 QS44 8 M100 8 Quantity 1% 1% 1% 1.3% 1.3% 1.3% 2% 2% in % by weight filler__________________________________________________________________________Brookfield 0.5 R/mn 110,000 10,000 20,000 432,000* 424,000* 32,000* 400,000* 10,000viscosity 1 R/mn 65,000 8,000 16,000 260,000* 260,000* 32,000* 228,000* 13,000module 6 2.5 R/mn 34,000 6,000 10,800 144,000* 134,400* 32,000* 122,000* 13,200in 5 R/mn 22,000 5,400 8,800 96,000* 92,000* 28,800* 81,600* 13,600mPa · s 10 R/mn 14,800 4,900 7,500 68,000* 66,400* 28,800* 56,800* 14,200(cP) 20 R/mn 10,500 4,550 6,550 51,000* 52,000* 29,200* 41,400* 15,400 50 R/mn 7,320 4,280 6,000 36,560* 40,960* 30,240* 30,100* 18,500 100 R/mn 6,020 4,250 5,870 30,000* 34,220* 30,000* 25,100* 23,600*__________________________________________________________________________ *Indicates that the measurements were made using module 7 since viscosities were too high for module 6
Table VI shows that the dispersants according to the invention are effective for various types of resins.
EXAMPLE 7
Under the operating conditions of Example 1, thermosetting compositions were fabricated using two types of fillers. Test 39 was conducted using 300 g of an unsaturated polyester resin marketed by WALTER MADERAG under the name CRISTIC 192 LV; 300 g of titanium dioxide marketed by the THANN & MULHOUSE Company under the name AT1; and 3 g of dispersing agent according to the invention, called product 8. Test 40 was conducted using the same quantities and types of resin and filler as in Test 39, but without the dispersing agent. Test 41 was conducted using 300 g of the same unsaturated polyester resin used in Tests 39 and 40; 400 g of hydrous calcium sulfate having an average granulometry of approximately 15 micrometers; and 2 g of the dispersing agent according to the invention used in Test 39, named product 8. Test 42 was conducted using the types and amounts of resin and filler used in test 41, but without the dispersing agent.
Once these thermosetting compositions were prepared, the operating procedure used in Example 1 was used to measure their Brookfield viscosities, which are provided in Table VII, below.
TABLE VII__________________________________________________________________________TEST NO. 39 40 41 42__________________________________________________________________________Resin Type Cristic Cristic Cristic Cristic 192 LV 192 LV 192 LV 192 LV__________________________________________________________________________Filler Type TiO.sub.2 TiO.sub.2 Calcium Calcium ATT ATT sulfate sulfate Quantity in % 50% 50% 66% 66% by weight of resin + filler__________________________________________________________________________Disper- Type Product Productsant 8 8 Quantity in % 1% 0% 0.5% 0% by weight of filler__________________________________________________________________________Brookfield 0.5 R/mn 10,000 32,000 30,000 200,000viscosity 1 R/mn 8,000 25,000 40,000 130,000module 6 2.5 R/mn 6,800 22,800 53,000 90,000in 5 R/mn 6,000 20,800 57,000 74,000mPa · s 10 R/mn 5,200 18,700 54,600 64,000(cP) 20 R/mn 4,750 16,800 46,600 52,000* 50 R/mn 4,200 13,200 40,400 52,000* 100 R/mn 3,900 9,800* 29,200 Measurement impossible, material unsuitable__________________________________________________________________________ *Indicates that measurements were made using module 7, since viscosities were too high for module 6
Table VII shows that the dispersing agent according to the invention is also effective for pulverulent mineral fillers other than calcium carbonate and aluminum hydroxide, such as titanium oxide and calcium sulfate.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A dispersing agent for use in a thermosetting composition, a thermosetting composition containing said dispersing agent, and application thereof to thermosetting composition having no yield point. The dispersing agent acting on mineral fillers and used in filled acrylic or polyester resin-based thermosetting compositions belongs to the family of organophosphates corresponding to the general formula: ##STR1## where: A is a branched or unbranched polyaryl group,
x and y are whole numbers between 0 and 100 such that x+y is a whole number greater than 40 but not greater than 100, ##STR2## B and E are independently a branched or unbranched polyaryl group, or an alkyl, aryl, arylalkyl, alkylaryl, alkanoyl, or amine radical, and in B and E, and R 1 and R 2 may be identical or different, x1, y1, x2 and y2 are whole numbers, and the sums x1+y1 and x2+y2 are not greater than 100.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for detecting foreign matters that might be present in liquids. More particularly, the present invention relates to a method and apparatus for detecting undesirable small foreign matters that might be present in medical fluids filled in transparent containers such as injection ampoules and vials, which often contain foreign matters like glass chips, small particles, and fibers. The presence of such foreign matters is not desirable for quality, and it is necessary to select defective containers containing foreign matters by testing all the containers filled with medical fluids.
In a conventional method the detection of foreign matters is accomplished as follows: An ampoule to be tested is turned at a high speed and then brought to a standstill quickly. The suspended foreign matters that swirl together with the liquid in the ampoule are illuminated. The beam of light which has passed through the liquid is received by a light detector, and a decrease in light received is regarded as an indication of the presence of foreign matters. In such a method it was difficult to detect foreign matters sensitively with a single photoelectric element as a light detector, because foreign matters to be detected are extremely small as compared with the detection visual field and the difference of photocurrent caused by the presence of foreign matters is also extremely small. Another conventional method in which is used a light detector consisting of many small light sensitive elements equivalent in size to foreign matters and outputs of respective light sensitive elements are scanned, has a fatal drawback that complex electric circuits are required for signal processing and the result of detection is affected by the shape of foreign matters.
In the case of the small light sensitive elements having a light sensitive area equal to or smaller than the projected area of the minimum size of foreign matter particles, sensitive detection can be accomplished because the light sensitive surface is shaded by a foreign matter particle and an extremely great difference occurs in quantity of light received between the shaded elements and the unshaded elements. For instance, a light sensitive area of 100μ×100μ square will be completely shaded by a particle of about 100μ×100μ size, and sensitive detection will be accomplished. However, a long and narrow foreign matter, say 50μ×200μ in size, will not cover the square light sensitive surface completely, although the projected area is the same. Therefore, such a foreign matter may not be detected.
Another conventional method that detects diffused reflection from foreign matters cannot discriminate foreign matters of different sizes because the ratio of reflection varies depending on the kinds of foreign matters.
In the present invention which has been made to overcome the above-mentioned drawbacks, the light sensitive surface of the light detector is divided into a multiplicity of small sections measuring 0.01 mm 2 to 1 mm 2 so that each light sensitive element generates an output signal proportional in magnitude to the projected area of foreign matters, and detection is accomplished by comparing the output signal with the reference value.
Foreign matters vary in shape, and typical shapes are particle and fiber. Foreign matters of fibrous shape generally measure 20μ in diameter and more than ten times the diameter in length. Thus, a particle measuring 100μ×100μ has the same projected area as a fiber measuring 20μ×500μ. If the limit of detection is to be set up for particles measuring 100μ×100μ and fibers measuring 20μ in diameter (or 500μ in length), the light sensitive surface of the detector should be divided into sections measuring 500μ×500μ (0.25 mm 2 ). By measuring the quantity of received light with each section of the divided light sensitive surface, it is possible to obtain an output signal proportional to the projected area of foreign matter regardless of its shape--particle, fiber, and others, and to obtain output signals having a sufficient S/N ratio, without mistaken detection due to small particles inherent to medical fluids.
According to a preferred embodiment of this invention, the light sensitive surface of the light detector is provided with a bundle of optical fibers connected to photoelectric elements in such a manner that each divided section of the light sensitive surface corresponds to each photoelectric element. Thus, the individual sections of the light sensitive surface are substantially continuous and there is no dead zone which might result in failure of detection.
In addition, photoelectric converting elements such as phototransistors, photodiodes, and photocells may be staggered directly on the light sensitive surface without using optical fibers, so that foreign matters suspended in the swirling liquid are detected by either row of the detecting elements. Such arrangement eliminates any dead zone.
In continuous and automatic detection the visual field of detection should be changed according to the size of ampoules to be tested, and this is accomplished by replacing the light receiver or by covering optically or mechanically a part of the light receiver. Such operation, however, needs skill, and a simple and certain method has been searched for.
According to the present invention the visual field for detection is changed as follows: The output signals from the group of small light sensitive elements are compared with the preset reference values to produce an output. Thus obtained output is then introduced into the detection visual field selector circuit that controls the number of small light sensitive elements to be used according to the size of objects to be detected.
The detection visual field selector circuit is a circuit to select a proper number of small light sensitive elements to be used according to the change of visual field relative to the size of objects to be detected. More particularly, it is so designed as to make presetting by means of a selector circuit according to the size of objects to be detected so that the number of small light sensitive elements to be used corresponds to the size of detection visual field. This is accomplished by the built-in matrix circuit such as diode matrix circuit and wired OR-circuit. Thus, it is possible to obtain by simple operation necessary and sufficient outputs from the output signals generated by the small light sensitive elements through the comparators. And the visual field thus changed is extremely accurate.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a method to detect sensitively and easily foreign matters based on their projected areas regardless of their configuration.
Another object of the invention is to provide an apparatus which has no dead zone in the light sensitive area of the light detector.
A further object of the invention is to provide an apparatus to change simply and accurately the detection visual field according to the size of objects to be detected.
Other and further objects and features of the invention will be apparent from the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of apparatus suitable for carrying out several embodiments of the present invention.
FIG. 2 is an enlarged sectional view of the turntable in FIG. 1.
FIG. 3 is a block diagram to illustrate the operation of the apparatus according to the invention.
FIGS. 4a and 4b are perspective views of different examples of the light detector.
FIG. 5 is a front view of another example of the light detector.
FIG. 6 is a block diagram to illustrate the apparatus according to the invention which is provided with a detection visual field selector circuit.
FIG. 7a is a perspective view of an example in which the light detector is arranged not only in vertical direction but in horizontal direction corresponding to the bottom of ampoules to be detected.
FIG. 7b is a block diagram to illustrate the action of the arrangement as shown in FIG. 7a.
DETAILED DESCRIPTION
Apparatus suitable for carrying out several embodiments of the present invention is described referring to FIGS. 1 and 2, wherein there is shown a hopper (10). Ampoules (11), which are objects to be detected, stored in the hopper (10) are fed one by one intermittently to a turntable (14) by feed star wheels (12) and (13) which mesh each other. The turntable (14) rotates intermittently by 90 degrees together with a head pressing cap (16) about the axis of rotation (15).
At position A, as the ampoule (11) is fed to a rotating seat (17) on the turntable (14), the head pressing cap (16) comes down to hold the ampoule (11). As the ampoule (11) is transferred to position B, a cam (18) rotates and a roller (19) goes down to actuate an arm (20) about a fulcrum (20), causing a disk clutch (22) to be engaged by a leaf spring (not shown) and connected to the rotating seat (17). Thus, the rotation of a motor (23) is transmitted through a belt (24) to turn the ampoule at a high speed. As the cam (18) rotates further to lift the roller (19), the clutch (22) is disengaged and, at the same time, a brake (25) is applied to stop rotation quickly. Subsequently, the ampoule (11) is transferred to detection position C by the intermittent rotation of the turntable (14).
At position C, the ampoule (11) is at a standstill, but the liquid and foreign matters in it continue to rotate. The ampoule (11) is illuminated by light (1) emitted from a light source (26) through a condenser lens (27) and a slit (28). The beam of light which has passed the liquid is focussed by a focussing lens (29) on a photodetector (30) which is described later. The photodetector (30) issues an output signal which is delayed for a prescribed time by a delay circuit and then actuates a solenoid for selection. As the ampoule (11), which has undergone detection, is further brought by intermittent rotation of the turntable (14) to position D, the head pressing cap (16) lifts and disengages. Thus, the ampoule (11) is discharged from the turntable (14) by a discharge wheel (31) of the selector unit. A selector lever (32) is flipped by the solenoid actuated according to the selection signal, and the ampoule (11) is received in a reject hopper (33) or acceptance hopper (34).
We will describe below the above-mentioned detecting device and the computing and processing circuit connected thereto referring to FIGS. 3, 4a, and 4b, wherein there are shown the light source (26), the condenser lens (27), the ampoule (11), the rotating seat (17), the focusing lens (29), and the photodetector (30). The light sensitive surface of the photodetector (30) consists of microphotoreceivers (35) of prescribed area arranged vertically. More particularly, optical fibers (36) about 10μ in diameter are bundled in such a manner that their ends form the light receiving surface in the vertical frame of 500μ width, as shown in FIG. 4a. The bundle of the optical fibers is divided at intervals of 500μ so that the microphotoreceivers (35), each of which has an area of 500μ×500μ=0.25 mm 2 , are formed. The bundle of optical fibers (36) forming the microphotoreceiver (35) is optically connected to photoelectric elements (37). The optical fibers are made of glass fibers, and the photoelectric elements are selected from phototransistors, photodiodes, and photocells. The shape may be square as shown in FIG. 4 a or circular as shown in FIG. 4b.
The number of the microphotoreceivers (35) to be arranged vertically is determined so that the detection visual field covers the height from the liquid surface to the bottom of the ampoule (11). For instance, if 2-ml ampoules having detection visual field of 25 mm are to be detected, the bundle of the optical fibers (36) should be divided into 50 sections, each measuring 500μ, so that 50 units of microphotoreceivers (35) are arranged vertically.
In the above-mentioned example, 50 units of microphotoreceivers (35), each measuring 0.25 mm 2 , are arranged vertically. However, for detection of ampoules of 1 ml to about 20 ml, it is desirable to arrange 20 to 120 units of microphotoreceivers (35), each measuring 0.01 mm 2 to 1 mm 2 in area. It goes without saying that a greater number of microphotoreceivers (35) should be used for detection of vials as large as 500 ml. There is substantially no boundary that makes a dead zone between any two microphotoreceivers (35), and this eliminates failure of detection.
The output signals from the photoelectric elements (37) are applied to the corresponding operational amplifiers (38 1 ), (38 2 ) . . . (38 n ), which are of differential input type having variable resistors (39 1 ), (39 2 ) . . . (39 n ) connected thereto to make uniform their DC output level when there is variation in sensitivity among the photoelectric elements (37). The output signals from the operational amplifiers (38 1 ), (38 2 ) . . . (38 n ) have their DC components removed by capacitors (40 1 ), (40 2 ) . . . (40 n ) that block the flow of direct current but permit the AC components to pass which are generated only when there are foreign matters in proportion to the size of the foreign matters. Such AC components pass through the capacitors and reach comparators (41 1 ), (41 2 ) . . . (41 n ), to which are applied a reference voltage for comparison from a reference voltage setting circuit (42) through a selector switch (43) so that outputs are generated from the comparators only when the signal voltage from the capacitors (40 1 ), (40 2 ) . . . (40 n ) is greater than the reference voltage from the setting circuit (42). The reference voltage for comparison can be switched in multiple steps by means of the selector switch (43). The lower the reference voltage, the higher the sensitivity for detecting foreign matters of smaller size. Conversely, the higher the reference voltage, the lower the sensitivity for detecting foreign matters. The reference voltage can be changed by the selector switch (43) and also by the variable resistor continuously.
The output signals from the comparators (41 1 ), (41 2 ) . . . (41 n ) are applied to an OR-gate which gives a defective detection signal when any one of the comparators issues a detection signal for foreign matters. The defective detection signal is applied to a solenoid (47) through a signal delay circuit (45) and an amplifier (46) so that the selector lever (32) in FIG. 1 is flipped in either direction to select defective ampoules. The selector lever may be actuated by a proper electro-mechanical force converter such as an air valve and electro-magnetic clutch.
In experiments with an embodiment in which the light sensitive surface of the photodetector (30) is divided into sections of microphotoreceivers (35), each measuring 500μ×500μ, the detection result as shown in Table 1 was obtained.
Samples to be judged as acceptable are designated as group A (A 1 and A 2 ), and samples to be judged as defective are designated as group B (B 1 and B 2 ). The rate of detection is defined as the rate of samples which were judged as defective.
______________________________________ Projected area Shape______________________________________Group AA.sub.1 0.4 × 10.sup.3 (μ.sup.2) or less 20μ × 20μ or lessA.sub.2 0.4 × 10.sup.3 (μ.sup.2) 20μ × 20μGroup BB.sub.1 10 × 10.sup.3 (μ.sup.2) 20μ × 500μB.sub.2 10 × 10.sup.3 (μ.sup.2) 100μ × 100μ______________________________________
TABLE 1______________________________________Sample Detection Rate (%)______________________________________A.sub.1 0A.sub.2 0B.sub.1 99.5B.sub.2 99.9______________________________________
On the other hand, the following results were obtained when a 1024-bit self-scanning diode array in which 1024 units of light sensitive elements measuring 25.4μ×12.7μ are arranged at intervals of 12.7μ was used as the photodetector and when the light sensitive surface divided into five sections measuring 5 mm=5 mm was used as shown in FIGS. 4a and 4b.
TABLE 2______________________________________Light sensitive Detection Rateelements Diode array 5 mm × 5 mm elementsSensitivity Low High Low High______________________________________SamplesA.sub.1 0.5% 50% 0% 30%A.sub.2 0.9% 70% 0% 33%B.sub.1 61% 98% 13% 50%B.sub.2 75% 99% 15% 55%______________________________________ Low level: less than 1% for group A? High Level: more than 90% for group B?
As shown in Table 2, in the case where a diode array was used, if the detection rate for group A is held below 1%, the detection rate for group B is decreased to about 70%, and if the detection rate for group B is held above 90%, the detection rate for group A is increased to 50-70%. However, in the case where a little greater light sensitive elements were used, the sensitivity is insufficient and group A and group B are not separated completely.
In contrast to this, the method according to the present invention provides sure separation of group A and group B as shown in Table 1.
The limit for separation can be adjusted in a small range by varying the reference voltage for comparison. Adjustment to a large extent can be made by selecting an optimum light receiving area for each section of the microphotoreceivers (35) consitituting the photodetector (30) in the range of 0.01 mm 2 to 1 mm 2 . It is also possible to set the relative ratio of the projected area of foreign matters to the microphotoreceivers (35) in the same manner as mentioned above by changing the magnification of the focussing lens (29). More simply, it is possible to change the sensitivity level by placing a shading mask on one part of the microphotoreceivers (35), although the linearity of output signals with respect to foreign matters is decreased. In this case the shading mask may be placed in front of the focussing lens, but preferably it should be placed in front of the microphotoreceivers (35) so that a sharp image is formed on the light sinsitive surface.
FIG. 5 illustrates another embodiment of this invention in which light is received directly by the photodetector without using optical fibers. Square phototransistors measuring 1 mm×1 mm are used as the microphotoreceivers (35) constituting the photodetector (30). The phototransistors are spaced at intervals of 0.5 mm and one row is displaced by half a pitch from another row, so that an image of foreign matter of fibrous shape measuring 20μ×500μ will be caught by one section in either row. This eliminates failure of detection due to dead zone between elements. Thus, this embodiment provides the same result as was obtained with the embodiment in which optical fibers are used as shown in FIGS. 4a and 4b. Foreign matters of fibrous shape give various projected images depending on their movement. Therefore, the projected area of foreign matters varies if each section of the microphotoreceivers (35) is of rectangular shape having extremely different side lengths. However, if each unit of the microphotoreceivers is of square shape, it is possible to measure the size of foreign matters accurately because the entire projected image is given regardless of position of fibrous foreign matters. Thus, each unit should preferably be square.
Referring to FIG. 6, we will describe the operating and processing circuit provided with the detection visual field selector circuit to change the detection visual field according to the size of ampoules to be inspected. In FIG. 6, there are shown the light source (26), the condenser lens (27), ampoules of different sizes (11 1 ), (11 2 ), (11 3 ), the focussing lens (29), and the photodetector (30). The light sensitive surface of the photodetector (30) consists of a multiplicity of the microphotoreceivers (35) arranged in one or more rows. The number of units to be arranged vertically is determined according to the maximum size of ampoules to be inspected. For inspection of ampoules (11 1 ), (11 2 ), (11 3 ) of 1 ml, 2 ml, and 3 ml, 60 units are arranged vertically so that the range from the liquid surface to the bottom of the 3-ml ampoule (11 3 ) is covered, and 40 units cover the 2-ml ampoule (11 2 ) and 30 units cover the 1-ml ampoule (11 1 ). The microphotoreceivers (35.sub. 1), (35 2 ) . . . (35 60 ) are connected to the corresponding photoelectric elements (37 1 ), (37 2 ) . . . (37 60 ), the operational amplifiers (38 1 ), (38 2 ) . . . (38 60 ), the capacitors (40 1 ), (40 2 ) . . . (40 60 ), and the comparators (41 1 ), (41 2 ) . . . (41 60 ) consecutively. The output signals from the comparators (41 1 ), (41 2 ) . . . (41 60 ) are applied to the inspection visual field selector circuit (48) which is made up of diode matrix circuits so that a number of the microphotoreceivers (35 1 ), (35 2 ) . . . (35 60 ) to be employed as the inspection visual field is changed according to the size of ampoules (11) to be inspected, is controlled. For inspection of 3-ml ampoules (11 3 ) all of 60 microphotoreceivers (35 1 ), (35 2 ) . . . (35 60 ) are used and the OR-gate (49) consisting of diodes (49 1 ), (49 2 ) . . . (49 60 ) is connected. Similarly, for inspection of 2-ml ampoules (11 2 ) the OR-gate (50) consisting of diodes (50 1 ), (50 2 ) . . . (50 40 ) is connected to 40 microphotoreceivers (35 1 ), (35 2 ) . . . (35 40 ). Further, for inspection of 1-ml ampoules (11 1 ), the OR-gate (51) consisting of diodes (51 1 ), (51 2 ) . . . (51 30 ) is connected to 30 microphotoreceivers (35 1 ), (35 2 ) . . . (35 30 ). The respective OR-gates (49), (50), and (51) are connected to the delay circuit (45), the amplifier (46), and the solenoid (47), as in FIG. 3, through the selector circuit (52) having terminals (49 0 ), (50 0 ), (51 0 ), and (52 0 ).
For inspection of 3-ml ampoules (11 3 ) the common terminal (52 0 ) of the selector circuit (52) is connected to the terminal (49 0 ) of the OR-gate (49) and output signals from all of 60 microphotoreceivers (35 1 ), (35 2 ) . . . (35 60 ) function effectively. Thus, the inspection visual field selector circuit (48) issues outputs regardless of signals for detection of defectives. Likewise, for inspection of 2-ml ampoules (11 2 ) the common terminal (52 0 ) of the selector circuit (52) is connected to the terminal (50 0 ) of the OR-gate (50) and output signals from 40 microphotoreceivers (35 1 ), (35 2 ) . . . (35 40 ) function effectively, with output signals from the remaining 20 microphotoreceivers (35 41 ) . . . (35 60 ) being cut off. For inspection of 1-ml ampoules (11 1 ), output signals from 30 microphotoreceivers (35 1 ), (35 2 ) . . . (35 30 ) function effectively, with the remaining output signals being cut off. Thus, it is possible to change easily and accurately without any skill the inspection visual field by switching operation of the selector circuit (52) alone. It is expected that the present invention will improve the accuracy and efficiency of selection in the automatic inspection apparatus of this kind.
In FIG. 6 which illustrates inspection of ampoules of 1 ml, 2 ml, and 3 ml sizes the inspection visual field selector circuit (48) and the selector circuit (52) are designed for switching for these three sizes. However, it should be understood that modification can be made easily so that switching is accomplished according to various sizes of ampoules.
In the embodiment as shown in FIG. 6 the microphotoreceivers (35 1 ), (35 2 ) . . . (35 60 ) are arranged vertically. In FIG. 7a the microphotoreceivers are arranged horizontally at the position corresponding to the bottom of the ampoule, in addition to the vertically arranged ones. Such arrangement will permit complete detection of heavy foreign matters such as glass chips that tend to settle on the bottom. In FIG. 7a the microphotoreceivers (35 1 ), (35 2 ) . . . (35 60 ) are arranged vertically in one or more rows along the approximate center line of the ampoule (11) and the microphotoreceivers (35 m ) . . . (35 1 ) . . . (35 n ) are arranged horizontally in one or more rows along the bottom of the ampoule (11). As shown in FIG. 7b the horizontally arranged microphotoreceivers (35 m ) . . . (35 1 ) . . . (35 n ) are connected through respective photoelectric elements to the operational amplifiers (38 m ) . . . (38 1 ) . . . (38 n ), the capacitors (40 m ) . . . (40 1 ) . . . (40 n ), and the comparators (41 m ) . . . (41 1 ) . . . (41 n ). To the output side of these comparators are connected the diode array (49 m ) . . . (49 n ), (50 p ) . . . (50 q ), and (51 x ) . . . (51 y ) corresponding to the widths of ampoules (11 3 ), (11 2 ), and (11 1 ). These diodes, together with the diodes for the vertical row, constitute the inspection visual field selector circuit (48).
In such construction, it is possible to change the inspection visual field according to the width of ampoules as well as the height of ampoules, by switching the OR-gates (49), (50), and (51) through the selector circuit (52). Thus, heavy foreign matters such as glass chips that tend to settle on the bottom of the ampolue can be detected completely.
Instead of the matrix circuits constituting the visual field selector circuit (48), wired OR-circuits can be used for the same effect.
In the above-mentioned embodiment the inspection visual fields for the vertical row and horizontal row are switched synchronously, but a different arrangement is possible that permits separate switching of the vertical row and horizontal row. Such arrangement will permit inspection of more different sizes of ampoules.
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Method and apparatus for detecting foreign matters in liquids comprising the steps of turning at a high speed a transparent container filled with a liquid, bringing the container to a standstill quickly permitting suspended foreign matters to swirl with the liquid, illuminating the liquid and foreign matters causing the transmitted light to be received by a light detector consisting of a multiplicity of small light sensitive elements measuring 0.01 mm 2 -1 mm 2 and capable of providing output signals proportional to the projected area of foreign matters, and rejecting defective containers that give output signals exceeding the reference value. The small light sensitive elements are connected to the detection visual field selector circuits so that the detection visual field can be changed by selecting a proper number of the small light sensitive elements to be employed according to the size of object to be detected.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. provisional patent application No. 60/319,048 filed Dec. 28, 2001, the disclosure of which is hereby expressly incorporated by reference in its entirety for purposes of disclosure.
FIELD OF THE INVENTION
The present invention relates to an analysis method and a computerized system for detection and prediction of pattern(s) in data that quantifies details or characteristics of a person (personal data). The resulting pattern(s) can be used to characterize the personal data, and with increased knowledge, refine efficiency in predictions about the person and specific characteristics will be enabled, especially, but not exclusively, with respect to medical therapy.
BACKGROUND OF THE INVENTION
Patients who suffer from some psychological syndromes have different movement patterns than a group of people without psychological syndromes. Patient movements can be measured together with other patient data. If the patient's psychological syndrome can be characterized by measured patient data and the use of an objective analysis method, it would be possible to observe the effect of applied medical therapies. Such analysis method would be very useful.
U.S. Pat. No. 5,810,747 describes an interactive intervention training system used for monitoring a patient suffering from neurological disorders of movement or a subject seeking to improve skill performance and assisting their training. A patient (or trainee) station is used in interactive training. The patient (or trainee) station includes a computer. A supervisor station is used by, for example, a medical or other professional. The patient (or trainee) station and the supervisor station can communicate with each other, for example, over the Internet or over a LAN. The patient (or trainee) station may be located remotely or locally with respect to the supervisor station. Sensors collect physiological information and physical information from the patient or subject while the patient or subject is undergoing training. This information is provided to the supervisor station. It may be summarized and displayed to the patient/subject and/or the supervisor. The patient/subject and the supervisor can communicate with each other, for example, via video, in real time. An expert system and neural network determine a goal to be achieved during training. There may be more than one patient (or trainee) station, thus allowing the supervisor to supervise a number of patients/subjects concurrently.
Another known technique is illustrated in FIG. 1 ; OPTAx, delivered by OPTAx SYSTEMS, Inc. Continuous Performance Test (CPT) is a fifteen min test to measure inattention and impulsivity. The patient 11 executes the test himself on a computer 12 , while the patient's head motions are measured with a camera. The camera finds the head position by tracking a marker 13 that is fitted on the patient's head. Motion data and CPT data are sent to a central system 14 after finalizing the entire test. Test results are calculated on the central system. The results are compiled to a report, which is sent back to a physician. The physician uses the report as one instrument to treat the patient, for example, through the prescription of medication.
A number of new techniques have been described in Proc. of the 7 th IEEE Int. Conf. On Image Processing, Sep. 10-13, 2000, Vol. 2, P. 435-438 intended to enhance the performance of a video analysis system, free from motion markers and complicated setup procedures. The system is used for purposes of quantitatively identifying gait abnormalities in static human posture analysis. Visual features are determined from still frame images out of the entire walking sequence. The features are used as a guide to train a neural network in an attempt to assist clinicians in demagnetizing patients with neurological disorders.
The application of digital image processing and pattern recognition techniques are described in Real Time Imaging , Vol. 5, No. 4 (August 1999) p. 253-269 for assisting in diagnosing neurological disorders. In medical practices, the posture and movement of human subject through his/her gait cycle contains information that is used by experienced clinicians to determine the mental health of a patient. This is achieved by processing, extracting and classifying joint angle information from images of a human subject's gait. Joint angles and swing distances obtained from normal and patient subjects are used in training and verifying classifications using feed-forward neural network and a fuzzy clustering algorithm.
In U.S. Pat. No. 6,090,044, a system for diagnosing medical conditions, such as low back pain (LBP), is described whereby a neural network is trained by presentation of large amounts of clinical data and diagnostic outcomes. Following training, the system is able to produce the diagnosis from the clinical data. By comparison, the present invention may be useful in diagnosing LBP in one embodiment, but there are other applications for the present invention both in the medical fields and in other fields. The instant intelligent diagnostic system is less expensive and more accurate than conventional diagnostic methods, and has the unique capability to improve its accuracy over time as more data is analyzed.
According to WO0064347, a pattern is determined of the neck movement of a subject. The head/body movement of the subject is recorded with markers placed on the shoulders and on the head and which therefore move with the subject. The locus curve of each marker in three-dimensional space is then determined in dependence on the time and it is stored as a data set. The neck movement is isolated from the head and torso movements by determining the difference between the average of the two locus curves that represent the shoulder movements and the locus curve representing the head movement. The pattern of movement established on the cranio-corpo-graphy is evaluated and analyzed using a data-processing device. The method is particularly suitable for determining the presence and the severity of an injury to the cervical spine as a result of whiplash caused by a traffic accident.
SUMMARY OF THE INVENTION
It is an object of one of the preferred embodiments of the present invention to provide a computer system and an analysis method that distinguishes a personal characteristic, such as a disorder, and preferably, disorders related to some special type of psychological syndrome. Amongst others, the advantages of this embodiment of the invention involve fast, accurate and classified decision and automatic storage of relevant data. The results involve providing more accurate and correct amounts of drugs, allowing the finding/predicting of sub-groups of patients that are especially responsive to medication and the like.
For these reasons the present invention includes a computerized system having an interface arrangement for interfacing a data source that delivers data related to motion of a person. A memory arrangement is provided for storing the data and a processor is provided for processing the data. An included artificial neural network (ANN) uses the processor and acts as a means for collecting a second set of data from the person or subject. A means for calculating one or several parameters distinctive of various features of the person is included, as is a means for feeding the parameter values to the ANN trained to recognize the various features or characteristics. Most preferably, the features include psychological syndromes, however, other analysis may also be conducted. In one embodiment, the ANN is trained with data collected from one or several persons being under influence of drugs. Preferably, the ANN includes a number of nodes representing sets of training data. The system may include means for use of Linear Predictive Coding (LPC) to analyze the parameter values fed to the ANN. According to one embodiment, the data source is a camera. Most preferably, the ANN is a Kohonen type ANN.
The invention also relates to a method for the detection of a characteristic of a person employing an artificial neural network (ANN) in which motion data are analyzed and which includes measuring motion data on the person or subject; collecting other measured data from the person; calculating one or several parameters distinctive of various characteristics; feeding the parameter values to an ANN trained to recognize various characteristics, and analyzing the parameter values in the neural network. According to most preferred embodiments, the characteristics include at least one psychological syndrome. The parameters include one or several of the following: the variance of distance, the variance of CPT variables, the residual signal defined as difference between the input signal and a smoothed version of the same, an estimate of immobility duration, and one or more parameters suited to detect periodicity in the one or more of the input signals.
The invention also relates to a method for the detection of patients with psychological syndrome employing an artificial neural network (ANN) in which motion data are analyzed and which include: measuring motion data on a patient; collecting other measured data from the patient; calculating one or several parameters distinctive of various psychological syndromes; feeding the parameter values to an ANN trained to recognize various psychological syndromes, and analyzing the parameter values in the neural network. The parameters exemplarily include one or more of the following: the variance of distance, the variance of CPT variables, the residual signal defined as difference between the input signal and a smoothed version of the same, an estimate of immobility duration, and one or more parameters suited to detect periodicity in the one or more of the input signals. Preferably, the ANN is trained with data collected from patients being under influence of drugs. According to one embodiment, the ANN has a number of nodes representing sets of training data. Most preferably, the ANN is a Kohonen-map type ANN. The method also includes the use of linear predictive coding (LPC) to analyze the parameter values fed to the ANN. The parameters are used for optimal correlation between parameter distance and conceptual distance. Preferably, the psychological syndrome is ADHD.
Further objects of the invention will be evident from the following description of the invention, the attached drawings illustrating an exemplary and preferred embodiment, the detailed description thereof, and the appended claims.
DESCRIPTION OF THE DRAWINGS
The invention will be described in the following with reference to attached exemplary drawings, in which:
FIG. 1 is a schematic representation of a known system;
FIG. 2 is a schematic representation of a system configured according to the present invention;
FIG. 3 is a block diagram illustrating certain functional features of the present invention;
FIG. 4 is an exemplary depiction of a vector illustration; and
FIG. 5 is an exemplary depiction of a map response illustration.
DETAILED DESCRIPTION
To simplify the description of the present invention, the following definitions are used which are based on a system for patient analyses; however, the invention is not limited to such a system:
Model
To distinguish between different signal patterns, a model is used to characterize typical qualities and features of the patient data. The model parameters are chosen with the aim to be as distinct, unambiguous and informative as possible. The set of parameters shall reflect the typical signal patterns.
In addition, to be sensitive to psychological syndrome characteristics, it is important that the parameters shall be insensitive to features irrelevant to the task.
EventDistanceLimit:
Minimum distance (eucledian) traveled before it is considered to be a movement.
For example: EventDistanceLimit=1 mm
Microevent:
From any point on the movement trajectory, a Microevent is said to occur when the first following point along the trajectoria is reached, where the Eucledian distance between the two points exceeds EventDistanceLim.
Feature Vector
The values of the model parameters (see FIG. 4 ) are compiled to form a vector, below named the feature vector. For each subset of patient data, the values of the feature vector are extracted.
Prior to the extraction of parameter values, the signal mean is separate for some signals. The mean will vary with patients and/or hardware and may not contain useful information. The mean is therefore removed in those cases. Each k-dimensional feature vector can be regarded as one point in a k-dimensional signal-space.
Training
An Artificial Neural Network (ANN) is iteratively trained to organize groups or clusters of feature vectors with similar properties. The self-organizing process, known as Self-Organizing Feature Map (SOFM), for example as described in T. Kohonen's Phonetic typewriter for Finnish and Japanese , has shown great capability of performing this task.
The number of clusters is defined prior to the training and is determined by the required resolution of the ANN. The training is initiated by a set of (for example M) clusters, randomly positioned in the k-dimensional signal-space.
Compiling the feature vectors from a large number of patients forms the database used for training. During the training, each input feature vector is compared to each cluster to find the one with best resemblance to the input vector. This cluster is voted winner, and is adjusted towards the input vector. In addition, all other clusters within a neighborhood to the winner in another domain, the so-called map-space, are adjusted towards the input vector. The map-space is usually of low dimension containing a node for each cluster in the signal-space. The nodes are arranged in hexagonal or a square lattice, and the Euclidean distance between them defines their internal relation. A node's neighborhood is usually defined by a neighborhood function and contains the set all nodes in the beginning of the training whereas only a few (or none) are considered neighbors at the end. The further away a node is from the winner in the map-space, the less the corresponding cluster in the signal-space is adjusted towards the input vector. Thus, all adjustments are done in the signal-space, while the rules of adjustments are defined in the map-space.
The training time is predetermined and an annealing function is used to “freeze” down the system causing only small adjustments at the end of the training. The neighborhood function creates correlation between the signal-space distance and the map-space distance allowing classification to be performed in the (low dimensional) map-space, rather than in the more complicated signal-space.
The method described above is known as “unsupervised learning”, that is, there is no need to use classified data in the training procedure described above.
When the ANN is readily trained, the clusters will represent features of the input signal including normal and various types of psychological syndrome characteristics.
The response (output) of the ANN is proportional to the signal distance between the input signal and all the clusters (see FIG. 5 ). Often, this output is of less interest in the case of classification. The output is instead used to find the node with best resemblance to a classified input. This is known as the labeling phase in the design of the ANN. Features with known qualities are presented for the ANN, the output is observed and the node giving the highest output is labeled with the presented feature. The actual output thereafter is the label rather than the response value.
The set of clusters are now stored and can then be used in the analysis in runtime mode. Patient data is analyzed exactly the same way as done in the training phase to extract the values of the parameters used in the model, for example, the feature vector. The vector is then presented to the network, which will produce the output label (classification).
In summary, the present invention, in its primary embodiments, is based on the understanding that an analysis of patient data with an Artificial Neural Network (ANN) can successfully be used to distinguish between patients with psychological syndromes and normal patients.
Thus, the present invention provides an Analysis Method (AM) in which patient data, consisting of motion data and other data measured from the patient, is used for calculation of a number of parameters. Patient data are collected from a large number of patients and the data is used to train ANN to teach the system the variation ranges of the parameters. The result from the ANN is obtained as a low-dimensional chart in which each set of patient data is represented by a trajectory. A trajectory for a normal patient looks very different from that for a patient with psychological syndromes.
In particular, an exemplary method performed according to the present invention includes a selection from the following steps:
Measuring motion data such as position of the patient or a part of the patient's body as a function of time; Collecting other measured data from the patient; Calculating one or several parameters distinctive of patients with psychological syndrome; Feeding the parameter values to the artificial neural network trained to recognize psychological syndrome characteristics; and Analyzing the parameter values in the neural network.
An exemplary and preferred embodiment of a system 20 configured according to the present invention is illustrated in FIG. 2 in which a computer unit or other training arrangement 22 , a central unit 24 connected to a database 25 and comprising AM 26 with an ANN, a camera unit 27 and an interface means (not shown) for communication between various parts are incorporated. The person, patient, or other subject is provided with a marker 23 . The central unit is a conventional computer comprising memory, interface, drivers, storage means, and the like. For the purpose of the invention, especially for ADHD, the marker is placed on the head of the person to be analyzed and the motion of the head is analyzed.
The Artificial Neural Network (ANN) 26 is preferably trained with data collected from a large number of patients 21 . The data is collected from patients differing in many aspects: sex, age, medical drugs, movement pattern, type of psychological syndrome, and the like. The parameter values can be analyzed using a Linear Predictive Coding.
The collected data form a primary database 25 . During the training of the artificial neural network, the data is quantified under formation of a small secondary dedicated database, which is used in AM. Thus, according to the present invention, a dedicated secondary database obtained from a primary database comprising data collected from a large number of persons is used in AM. Most specially, the invention offers a new approach as the patients are analyzed and data is collected under the influence of drugs, which is compared to a first collected (system training) data. The patients are analyzed using a reaction test and by analyzing movement patterns, especially movement of the patient's head that is preferably tracked using a detectable arrangement such as a marker. The approach of testing a patient under influence of drugs is thus unique for the invention.
Moreover, the performance of the patient can be measured while analyzing the movement pattern. That is, the performance of the patient can be measured utilizing a switch that can be set between on and off positions, thereby giving a reaction time. The performance test can be conducted by providing a patient with very tedious and monotonous tasks or tests so that the characteristic capacities of a patient are exposed. For example, two different images can be shown in random order, whereby the person to be analyzed must activate the switch for one image and not activate the switch for the other image. The reaction time, number of correct and wrong decisions, and movement pattern can be measured during the test. The result of the test can be used as a basis for a screening report.
The system can also generate a treatment report that is specially arranged to objectively group different types of psychological syndromes, most preferably for ADHD related syndromes. The groups are completely based on the objective measurement data. Some groups react positively to a drug and some in a negative way, thus the test under drug influence. Through grouping the patients, it is possible to diagnose correct treatment. It is also possible to measure the accuracy of a drug dose.
In the system, the ANN includes a number of nodes representing sets of training data. Each node reflects a state or an incident (feature). Neighboring nodes represent incidents of similar features. In the same way as in training, a feature vector is extracted for each subset of data. The Euclidean distance from the feature vector to each node is calculated. The node in closest proximity to the vector is associated with it. Sequences of incident vectors are followed as sequences of nodes in the artificial neural network. It can be said that a sequence of nodes is the response from the network. Thus, a trajectory in the structure of the network (response) is followed rather than in the parameter space. The fact that the dimension of the network more often is smaller than the parameter space is of advantage, since the calculation thereby is simplified. The response from the network forms the basis for distinguishing between patients with psychological syndrome and normal patients.
The ANN 26 is based on a self-organizing process, known as Self-Organizing Feature Map (SOFM). This type of ANN is preferable to use in this application compared to the other types of ANN, for example MLP neural networks, due to the fact that there is no need for supervised training. The use of unsupervised training makes the training easier to handle large amount of data, less labor intensive and objective. After the training is finalized, the output of the ANN can be labeled with a small amount of classified data. An additional advantage with SOFM ANN is that neighboring nodes in the ANN output represents similar features of the input signal. This implies that the output can be interpreted as a continuum (c.f. soft decision) rather than on-off (c.f. hard decision).
The result from the ANN is presented to competent persons (e.g. physician) by mail, e-mail, through Internet, displayed on a display and the like.
Further variations of the present invention are disclosed in the following description of a preferred embodiment.
EXAMPLE 1
Application on Patient Data
Equipment: Measuring system from OPTAx, a PC with software based on this analysis method.
Patients: X patients aged from YEARS a to YEARS b, suffering from the psychological syndrome, ADHD, and Y normal patients.
Measurement: The patient was set up with a device for measuring the patient motion during a continuous performance task (CPT). Motion coordinates and data from the CPT were collected. The measuring time was 15 minutes. Motion data was sampled at 50 Hz, and performance data at 0.5 Hz.
EXAMPLE 2
Implementation
Data Acquisition
Referring to FIG. 3 , assume that the input signal(s) is a digitized version of the measured signal(s). Each signal is sampled at a certain rate, giving a sequence of samples according to:
x i , i=0,1, . . . ,N
Pre-Processing
To reduce the influence of individual patient variations and to facilitate classification stability, some signals should pass a device to remove the signal mean. Any kind of steep edge high-pass filter can be employed.
Parameters
A window is used to calculate parameters on a subset of the data at a time. The window is then slid over the entire measurement. The parameters extracted may be one or more of (but not limited to) the following.
The variance of distance, d, which is defined as
1
N
-
1
∑
i
=
1
N
(
d
i
-
d
_
)
2
,
where the distance, d, is defined as the Euclidean distance between two consecutive sample points of motion data, N the number of samples of the complete measurement, and d =1/N·Σ i=1 N d i , i.e. the mean movement per sample in meters.
The variance of CPT variables such as latency defined as
1
N
-
1
∑
i
=
1
N
(
t
i
-
t
_
)
2
,
where the latency, t, is the delay or reaction time, and t =1/N·Σ i=1 N t i , i.e. the mean latency per sample in milliseconds.
The residual signal defined as difference between the input signal and a smoothed version of the same. An estimate of immobility duration. One or more parameters suited to detect periodicity in the one or more of the input signals.
Feature Map Geometry and Definitions
Let the M k-dimensional map nodes be denoted
m i , i= 0 , . . . ,M− 1.
Most often, the nodes are arranged in a square (2-dimensional) grid. The distance between two map nodes i and j, is denoted D i,j and defined as the squared Euclidean distance (L 2 norm) between them in the map-space.
D i,j =L 2 ( m i ,m j ).
This measure is used in the neighborhood function.
Let the input feature vector, representing sample x n be denoted y n . Furthermore, let the map response in node i for feature n, S i,n , be defined as:
S i,n =e −(d i,n 2 /k)
where the signal-space distance d i,n 2 , is defined as
d
i
,
n
2
=
∑
l
=
1
k
w
l
(
y
l
n
-
m
l
i
)
2
and w i is some suitable weight function.
Annealing Function
The task of the annealing function is to obtain equilibrium at the end of the training. The principle is that large adjustments are allowed in the beginning of the training whereas only small (or zero) adjustments are allowed at the end. How the decrease is incorporated is not critical. Linear, exponential, and even pulsating decay schedules are proposed in the literature.
Initialization
Traditionally, all data driven clustering schemes, including ANNs, employ random positioning of clusters in the signal-space, by assigning (small) random numbers to the parameters. The actual values are not important as long as they are not identical. The ordering of the clusters is also at random.
Training
The iterative algorithm adjusts all clusters after each input feature vector, y n , presented. The direction of the adjustment is towards y n , and how much is determined partly by the annealing function, partly by the neighborhood function. The adjustment formulae for cluster m i at time instant t+1 is:
m i ( t+ 1)= m i ( t )+γ i ( t )·( y n −m i ( t )), i =0 , . . . M −1
where
γ k ( t )=ƒ( t )· g ( t )
and ƒ(t) is the annealing function and g(t) is the neighborhood function. Various suitable functions are discussed in P. Knagenhjelm's A recursive design method for Robust Vector Quantization.
Other parameters used can be, but need not to be limited to:
Microevents
The number of position changes greater than EventDistanceLim.
Immobility duration
The average time between Microevents.
Temporal scaling
Measures the distribution of Immobility duration.
Event Distance
Euclidian distance sampled at Microevents.
Euclidian Distance
Euclidian distance sampled at system sampling rate.
Area
Total area (in mm2) covered during the test period.
AreaTrend
A measure of how the covered area varies over test time. The area is measured in three or more sub-intervals. The values are used to fit a curve describing the area evolution. The curve fit may be, for example, polynomial or exponential.
Fractal
A measure of trajectoria complexity.
Latency
Reaction time, i.e. time between target presentation and response.
Commission Latency
As above, but measured at commission errors, i.e. at button presses without target present.
LatencyVariation
Standard deviation of Latency.
Coefficient of Variation
C.O.V=100*LatencyVariation/Latency
Commission Errors
Measures rate of incorrect (switch) button presses.
Omission Errors
Measures rate of incorrect non-presses.
MultiResponse
Measures multiple responses to a single target.
The invention is not limited to the illustrated and described embodiments. It should be appreciated that variations and modifications may occur and still be within the scope of the attached claims.
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Method and arrangement for providing a computerized system having an interface arrangement for interfacing a data source. The data source delivering data related to motion of a person, a memory arrangement for storing said data, a processor for processing the data, an artificial neural network (ANN) using the processor, means for collecting a second set of data from the person, means for calculating one or several parameters distinctive of various features of said person, and means for feeding the parameter values to the ANN trained to recognize the various features.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel alternate copolymers comprising an isopentenyl compound as one constituent.
2. Description of the Related Art
The carbon-carbon double bond of isopentenyl compounds is so low in reactivity that they do not homopolymerize by radical polymerization. Accordingly, few studies have been made on the polymerization of the compounds except that the copolymerization among isopentenyl alcohol or prenyl alcohol and unsaturated carboxylic acids of salts thereof has been proposed only in Japanese Laid-open Patent Application Nos. 59-108010 and 59-102496.
The copolymers obtained by the above processes have a compositional ratio of the isopentenyl alcohol or prenyl alcohol of 15 to 33 mole% and are not alternate copolymers.
An object of the invention is to provide novel alternate copolymers having isopentenyl compounds as one constituent.
Other objects, features and advantages of the invention will become apparent from the following description.
SUMMARY OF THE INVENTION
We have found that isopentenyl compounds whose reactivity has been considered to be very low undergo alternate copolymerization in high efficiency in the presence of specific unsaturated compounds and radical initiators. The present invention is accomplished based on the above finding. More particularly, the present invention provides an alternate copolymer which consists essentially of structural units [I] based on an isopentenyl compound of the following formula (A) or (B) ##STR1## in which R 1 represents a hydrogen atom, an alkyl group with or without an ether bond, an acryl group, a cycloalkyl group, an aralkyl group or an acyl group, or ##STR2## in which R 2 is an alkyl group with or without an ether bond, a cycloalkyl group, an aryl group or an aralkyl group, and structural units [II] based on an unsaturated compound selected from the group consisting of maleic anhydride, dialkyl maleates, maleimides, dialkyl fumarates, unsaturated nitriles, and acrylic esters.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the above formula (A) representing the isopentenyl compound, R 1 represents, as defined above, a hydrogen atom, an alkyl group with or without an ether bond, an aryl group, a cycloalkyl group, an aralkyl group or an acyl group. The alkyl group includes, for example, a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group and the like, and has thus preferably from 1 to 6 carbon atoms. The alkyl group having an ether bond includes, for example, a methoxymethyl group, a methoxyethyl group, an ethoxymethyl group, an ethoxyethyl group, a propoxymethyl group, a propoxyethyl group, a butoxymethyl group, a butoxyethyl group, a pentoxymethyl group, a pentoxyethyl group, an isopentenoxymethyl group, an isopentenoxyethyl group, and the like. Examples of the aryl group include a phenyl group, a tolyl group, a xylyl group and the like. The cycloalkyl group includes, for example, a cyclopentyl group, a cyclohexyl group or the like. The aralkyl group includes, for example, a benzyl group, a 1-phenylethyl group, a 2-phenylethyl group, a 3-phenylpropyl group or the like. Examples of the acyl group include a formyl group, an acetyl group, a propionyl group, a butyryl group, a valeryl group, a hexanoyl group, a 2-ethylhexanoyl group, a heptanoyl group, an octanoyl group, a nonanoyl group, a decanoyl group, a undecanoyl group, a dodecanoyl group, a cyclohexanoyl group, a methylcyclohexanoyl group and the like. The acyl group has favorably from 1 to 12 carbon atoms.
In the general formula (B), R 2 represents an alkyl group with or without an ether bond, a cycloalkyl group, an aryl group or an aralkyl group. Examples of the alkyl group include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group, a hexyl group and the like, and are preferably those which have from 1 to 6 carbon atoms. The alkyl group having an ether bond includes, for example, a methoxymethyl group, a methoxyethyl group, an ethoxymethyl group, an ethoxyethyl group, a propoxymethyl group, a propoxyethyl group, a butoxymethyl group, a butoxyethyl group, a pentoxymethyl group, a pentoxyethyl group, an isopentenoxymethyl group, an isopentenoxyethyl group and the like. The cycloalkyl group includes, for example, a cyclopentyl group, a cyclohexyl group or the like. The aryl group is, for example, a phenyl group, a tolyl group, a xylyl group or the like. The aralkyl group includes, for example, a benzyl group, a 1-phenylethyl group, a 2-phenylethyl group, a 3-phenylpropyl group or the like.
Specific examples of the isopentenyl compounds of the general formula (A) include: isopentenyl alcohol; isopentenyl ethers such as isopentenyl methyl ether, isopentenyl ethyl ether, isopentenyl propyl ether, isopentenyl butyl ether, isopentenyl amyl ether, isopentenyl hexyl ether, isopentenyl cyclohexyl ether, isopentenyl cyclopentenyl ether, isopentenyl benzyl ether, isopentenyl phenyl ether and the like; and esters such as isopentenyl formate, isopentenyl acetate, isopentenyl propionate, isopentenyl butyrate, isopentenyl valerate, isopentenyl caprylate, isopentenyl caprate, isopentenyl pelargonate, isopentenyl undecylate, isopentenyl laurate, isopentenyl benzoate, isopentenyl cyclohexylcarbonate, isopentenyl phenylacetate, isopentenyl benzylacetate, and the like. Specific examples of the isopentenyl compounds (B) include methyl prenyl ether, ethyl prenyl ether, propyl prenyl ether, butyl prenyl ether, amyl prenyl ether, isoamylprenyl ether, hexyl prenyl ether, cyclohexyl prenyl ether, cyclopentyl prenyl ether, benzyl prenyl ether, phenyl prenyl ether and the like.
The unsaturated compounds which are capable of forming alternate copolymers in combination with the above-indicated isopentenyl compounds are: maleic anhydride; maleimides such as maleimide, N-methylmaleimide, N-ethylmaleimide, N-(carboxylphenyl)maleimide, N-propylmaleimide, N-butylmaleimide, N-phenylmaleimide, N-(sulfophenyl)maleimide and the like; dialkyl maleates such as dimethyl maleate, diethyl maleate, dipropyl maleate, dibutyl maleate, dihexyl maleate, dioctyl maleate and the like; dialkyl fumarates such as dimethyl fumarate, diethyl fumarate, dipropyl fumarate, dibutyl fumarate, dihexyl fumarate, dioctyl fumarate and the like; acrylic esters such as methyl acrylate, ethyl acrylate, propyl acrylate, methyl 2-chloroacrylate, methyl 2-fluoroacrylate, ethyl 2-fluoroacrylate and the like; and unsaturated nitriles such as acrylonitrile, 2-chloroacrylonitrile, 2-cyanoacrylonitrile and the like.
The alternate copolymers of the invention should preferably have an average molecular weight of about 3,000 to 300,000.
The isopentenyl compound of the general formula (A) or (B) can be copolymerized with the unsaturated compound by known techniques. For instance, there may be used solution polymerization in organic solvent, emulsion or suspension polymerization in water, or solution, suspension or emulsion polymerization in a mixed solvent of a water-soluble organic solvent and water. Alternatively, since the isopentenyl compound does not polymerize by itself, solution polymerization using large excess of the compound as a monomer and solvent is possible. From the standpoint of the reactivity, reaction procedures and treatment for the reaction mixture, it is preferred that the isopentenyl compound is used in excess, partly as a solvent. For the copolymerization reaction, a radical initiator such as an azo compound or organic peroxide may be used as a polymerization initiator especially in an organic solvent or in a solution polymerization using an isopentenyl compound as a solvent. For polymerization in water, persulfates, hydrogen peroxide and the like are used. For the polymerization in a mixed solvent of a water-soluble organic solvent and water, the above-indicated polymerization initiators are suitably used.
The polymerization temperature is not critical and should preferably be a temperature at which the polymerization initiator used decomposes quickly.
The formation of a 1:1 alternate copolymer by the above reaction has been confirmed from elementary analysis, IR absorption spectrum, NMR spectrum and the like. These analyses reveal that the copolymers have, respectively, a 1:1 composition irrespective of the mixing ration between two ingredients.
The alternate copolymers of this invention consist of monomers having a hydroxyl group, an ester group or an acid anhydride group and are easily soluble in chemically inactive and commonly used solvents, so that they could be subjected to intra- or inter-molecular reaction to give crosslinked polymers and high performanced polymers. Especially, since alternate copolymers containing maleic anhydride as comonomer have a highly reactive acid anhydride group in the polymer, they readily react with compounds having a nucleophilic functional group such as a hydroxyl group, an amino group, a mercapto group, an epoxy group, an isocyanate group or the like, thereby forming a covalent bond. Alternatively, the maleic anhydride units contained in the copolymers may form an ionic bond with various metal ionic compoounds. The alternate copolymers of the invention can be imparted with various characteristic properties by combination of the structural units (I) and (II). Thus, the copolymers have thus wide utility as polymeric carriers, polymeric surface treating agents, highly water-absorbing resins, ion-exchange resins, medical materials, anti-clouding agents, scale inhibitors, dispersants, adhesives, sizing agents, materials for separation membranes, electronic materials, photoresist materials and the like.
The present invention will now be described in more detail with reference to the following examples.
In the following examples, molecular weight expresses Mw. Mw and Mw/Mn were obtained by calculation from the results of GPC method using polystyrene as a standard, and copolymerization composition ratio was obtained by calculation on the basis of 1 H-NMR data.
EXAMPLES 1-9
Comonomers indicated in Table 1 were each dissolved in isopentenyl acetate (IPAc) and azobisisobutyronitrile (1.5 mole% based on the comonomer) was provided as an initiator, followed by polymerization at 60° C. for a given time. After completion of the reaction, the polymerization solution was added to a poor solvent with stirring to permit the resultant polymer to precipitate. The yields and analytical data of the copolymers such as elemental analysis, IR, NMR and monomer composition are shown in Table 1 and 2.
TABLE 1__________________________________________________________________________Ex- Polymn. Yield Compn. Ratioam- Amount IPA.sub.c Time Solv. for of Polymer Elementary Anal. .sup.(1)(2) IPA.sub.c : Como-ple of comonomer (mmol) (Hrs.) re-pptn. (g) (%) C H N Cl --Mw nomer__________________________________________________________________________1 maleic anhydridc 83 5 cyclohexane 1.26 73.5 58.67 6.36 0.03 -- 86400 50.2:49.8 0.744 g (7.6 mmol) (58.40) (6.24) (0) --2 diethyl maleate 64 96 cyclohexane 1.53 19.7 60.32 8.32 0.16 -- 7200 51.5:48.5 4.459 g (25.9 mmol) (59.98) (8.05) (0) --3 N--ethylmaleimide 79 5 cyclohexane 1.67 86.2 61.66 7.79 5.55 -- 150000 50.4:49.6 0.95 g (7.6 mmol) (61.16) (8.29) (5.49) --4 N--phenylmaleimide 82 41 diethyl 6.45 93.9 67.86 6.11 4.90 -- 190000 48.0:52.0 3.943 g (22.8 mmol) ether (67.76) (6.35) (4.65) --5 diethyl fumarate 82 41 cyclohexane 5.06 72.4 59.68 8.18 0.06 -- 25000 48.2:51.8 4.019 g (23.3 mmol) (59.98) (8.05) (0) --6 methyl acrylate 84 42 cyclohexane 1.21 72.5 62.23 8.78 0.26 -- 27000 46.5:53.5 0.67 g (7.8 mmol) (61.66) (8.47) (0) --7 acrylonitrile 84 42 cyclohexane 0.84 57.4 66.45 8.58 8.21 -- 4700 51.6:48.4 0.43 g (8.1 mmol) (66.27) (8.34) (7.73) --8 2-chloroacrylnitrile 83 16 cyclohexane 0.930 15.5 57.17 6.83 7.65 17.00 5600 51.7:48.3 2.44 g (27.9 mmol) (55.69) (6.54) (6.49) (16.44)9 dioctyl fumarate 82.5 24 ethanol 4.14 38.1 69.11 10.71 0.04 -- 75000 45.4:54.6 7.91 g (23.2 mmol) (71.19) (10.57) (0) --__________________________________________________________________________ .sup.(1) (): theoretical value for a 1:1 alternate copolymer .sup.(2) Nitrogen is resulted from azobisisobutyronitrile used as radical initiator.
TABLE 2__________________________________________________________________________ExampleComonomers i.r. .sup.1 HNMR__________________________________________________________________________1 maleic anhydride 1775, 1850 cm.sup.-1 : CO stretching, 1735 cm.sup.-1 : CO stretching 1230 cm.sup.-1 : CO stretching ##STR3##2 diethyl maleate 1720, 1735 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching ##STR4##3 Nethylmaleimide 1685, 1700, 1735 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching ##STR5##4 Nphenylmaleimide 1705, 1720, 1735 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching, 1595 cm.sup.-1 : phenyl group, skeletal vibration ##STR6##5 diethyl fumarate 1725, 1740 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching ##STR7##6 methyl acrylate 1730, 1720 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching ##STR8##7 acrylonitrile ##STR9## ##STR10##8 2-chloroacrylonitrile 2230 cm.sup.-1 : CN stretching 1730 cm.sup.-1 : CO stretching 1228 cm.sup.-1 : CO stretching ##STR11##9 dioctyl fumarate 1720, 1730 cm.sup.-1 : CO stretching, 1230 cm.sup.-1 : CO stretching ##STR12##__________________________________________________________________________
EXAMPLES 10-12
0.055 moles of each of various isopentenyl carboxylates indicated in Table 3 and 0.05 moles of maleic anhydride were copolymerized, using azobisisobutyronitrile (0.6 mole% based on the maleic anhydride) as an initiator, in 56.3 g of a mixed solvent of ethyl acetate/tertiary butanol (75/25) at 65° C. for a given time. After completion of the eaction, the polymerization solution was added to a poor solvent in which the resultant polymer was precipitated. The results are summarized in Table 3 and the results of IR and NMR analyses are shown in Table 5. The solubility of the copolymers obtained in Examples 10, 11 and 12 together with that of the copolymer obtained in Example 1 was examined at room temperature. The results are shown in Table 6.
TABLE 3__________________________________________________________________________ Polymn. Copolymn. Compn. ratioEx- Isopentenyl Solv. for Time Solv. for Yield Elementary Anal..sup.(1)(2) isopentenyl carboxylate: maleicample carboxylate Polymn. (Hrs.) re-pptn. (%) C H N --Mw anhydride__________________________________________________________________________10 isopentenyl ethylacetate/ 8 cyclohexane/ 65.5 61.22 7.26 0.01 27200 48.9:51.1 butyrate t-butanol benzene (61.42) (7.09) (75/25) (1/1)11 isopentenyl ethylacetate/ 5.5 cyclohexane 26.1 64.17 8.24 0.09 17500 50.0:50.0 n-caprylate t-butanol (65.81) (8.39) (75/25)12 isopentenyl ethylacetate/ 5 t-butanol 54.1 68.15 9.57 0.06 103300 50.0:50.0 laurate t-butanol (68.85) (9.27) (75/25)__________________________________________________________________________ .sup.(1) (): theoretical value for a 1:1 alternate copolymer .sup.(2) Nitrogen is resulted from azobisisobutyronitrile used as radical initiator.
EXAMPLES 13-14
Methyl prenyl ether or methyl isopentenyl ether were polymerized with maleic anhydride, using azobisisobutyronitrile as an initiator (0.06 mole% based on the maleic anhydride) at 65° C. for 5 hours under conditions indicated in Table 4. The resultant polymer precipitated as a powder as the polymerization proceeded. After completion of the reaction, the powder was dissolved in acetone and then the solution was added to cyclohexanone to allow the resultant polymer to precipitate. The results are shown in Table 4 and 5.
TABLE 4__________________________________________________________________________ Copolymn. Compn.Isopentenyl Maleic Elementary ratio isopentenylcompound anhydride Solv. for Solv. for Yield Anal..sup.(2) --Mw compound: maleicExample(moles) (moles) Polymn. re-pptn. (%) C H (--Mw/--Mn) anhydride__________________________________________________________________________13 methyl prenyl 0.05 -- cyclohexane 23.5 59.32 7.14 5200 48.7:51.3ether.sup.(1) (60.61) (7.07) (1.39)(0.5)14 methyl 0.05 ethylacetate/ cyclohexane 76.7 58.59 6.92 2800 51.2:48.8isopentenyl ether t-butanol (60.61) (7.07) (1.49)(0.055) (75/25)__________________________________________________________________________ .sup.(1) Methyl prenyl ether was used in excess as a monomer and solvent. .sup.(2) (): theoretical value for a 1:1 alternate copolymer
TABLE 5__________________________________________________________________________IsopentenylExamplecompound i.r. .sup.1 HNMR__________________________________________________________________________10 isopentenyl butyrate ##STR13## ##STR14##11 isopentenyl caprylate ##STR15## ##STR16##12 isopentenyl laurate ##STR17## ##STR18##13 methyl prenyl ether ##STR19## ##STR20##14 methyl isopentenyl ether ##STR21## ##STR22##__________________________________________________________________________
TABLE 6__________________________________________________________________________ Copolymers obtained in Examples Example Example ExampleSolvent 1 10 11 Example 12__________________________________________________________________________acetone O O O Omethyl ethyl ketone O O O Omethyl isobutyl X O O Oketonecyclohexanone O O O Oisophorone O O O Odiethyl ether X X X Xtetrahydrofuran O O O O1,4-dioxane O O O Oglyme X O O Odiglyme X O O Oethyl acetate X O O Obutyl acetate X O O Oethyl cellosolve X O O Oacetatetoluene X X O Obenzene X X O ODMF O O O ODMSO O O O Otertiary butyl X X X Xalcohol__________________________________________________________________________ O: soluble X: insoluble
EXAMPLE 15
0.972 g (5.7 mmols) of N-phenylmaleimide was dissolved in 10.62 g (83 mmols) of isopentenyl alcohol, to which azobisisobutyronitrile (0.05 mole% based on the N-phenylmaleimide), followed by polymerization at 60° C. for 24 hours. After completion of the polymerization, 20 ml of dimethylformamide was added so as to make a homogeneous solution, followed by precipitation in diethyl ether to obtain 1.34 g of a polymer (polymer yield of 78%).
Elementary analysis C: 67.89% (69.48); H: 6.20% (6.56); N: 5.41% (5.40). (): theoretical value for a 1:1 alternate copolymer.
I.R. 3450 cm -1 (broad): O--H stretching, 1700 cm -1 : C═O stretching, 1595 cm -1 : skeletal vibration of the phenyl group
1 H-NMR 7.15-7.60 ppm phenyl, 1.2-1.5 ppm ##STR23##
Copolymerization composition ratio: (isopentenyl alcohol/N-phenyl maleimide)=44.2/55.8 Mw=69600
EXAMPLE 16
12.75 g (99.6 moles) of isopentenyl acetate, 20 ml of a chlorobenzene solution of vinylidene cyanide (containing 3.0 g (38.4 mmols) of vinylidene cyanide) and 20 mg of azobisisobutyronitrile were charged into a glass ampoule and allowed to stand at a temperature of 60° C. for 24 hours. Thereafter, the resultant precipitate was washed with xylene to obtain 2.5 g of an alternate copolymer (yield 33.8%).
Elementary analysis: C=63.49%; H=6.40%; N=15.48%; (64.06); (6.84); (15.58); (): theoretical vaue for a 1:1 substrate copolymer.
I.R. 1720 cm -1 : C═O, 1225 cm -1 : C--O.
1 H-NMR 4.27 ppm ##STR24## 2.5-2.7 ppm ##STR25##
Copolymerization composition ratio: (isopentenyl acetate/vinylidene cyanide)=52.9/47.1
Mw=3200
REFERENCE 1
10.5 g (8.19×10 -2 moles) of isopentenyl acetate and 20 mg of azobisisobutyronitrile were charged into a glass ampoule, and allowed to stand at 60° C. for 48 hours. The resultant reaction solution was added to cyclohexane, but any precipitate did not formed.
EXAMPLE 17
14.08 g (0.11 moles) of isopentenyl acetate and 9.8 g (0.1 mole) of maleic anhydride were added to 112.6 g of a mixed solvent of ethyl acetate/tertiary butanol (75/25), to which 0.1 g (0.6 mole% based on the maleic anhydride) of azobisisobutyronitrile was added under agitation, followed by reaction at 60°-63° C. for 5 hours. After completion of the reaction, the resultant polymer formed a block. After breakage of the block, the broken polymer was removed by filtration, washed and dried to obtain 9.4 g (yield 41.6%) of a powder. The filtrate was subjected to analysis of residual monomers by gas chromatography and alkaline titration. As a result, it was found that the conversion of the isopentenyl acetate was 39.5% and the conversion of the maleic anhydride was 41.9%. The elementary analysis of the polymer revealed C: 57.92% (58.41%) and H: 61.7% (6.19%), these values being substantially coincident with the theoretical as an alternate copolymer. 0.5 g of the polymer and 0.18 g of sodium hydroxide were added to 50 g of methanol and heated under reflux for 3 hours. The resultant solution was poured into a 0.3N sulfuric acid aqueous solution for neutralization to cause the polymer to precipitate, followed by removal by filtration, washing and drying. The resultant polymer was subjected to analysis with an infrared spectrophotometer, revealing that the ester group and the acid anhydride group were, respectively, converted into a hydroxyl group (ν O--H : 3500 cm -1 ) and a carboxyl group (ν C ═O : 1720 cm -1 ). In addition, good results were obtained with respect to the elementary analysis. ##STR26##
C: 53.93% (53.47%); H: 6.48% (6.93%); (): theoretical value for a 1:1 alternate copolymer.
EXAMPLE 18
342 g of ethyl acetate, 112.8 g (0.42 moles) of isopentenyl laurate, 39.2 g (0.40 moles) of maleic anhydride and 0.66 g (1 mole% based on the maleic anhydride) of azobisisobutyronitrile were charged into a 1 liter autoclave equipped with an agitator and agitated for 30 minutes. After the atmosphere of the solution was substituted with nitrogen at room temperature, the solution was maintained at 65° C. for 5 hours.
After completion of the polymerization, the inner liquid was taken out and the solvent was distilled off by means of a rotary evaporator, the resultant polymer was dried in vacuum at 40° C. to obtain 142.1 g of an alternate copolymer of the isopentenyl laurate and the maleic anhydride (polymer yield of 97% based on the charged maleic anhydride, Mw=105,000, Mw/Mn=2.3). From the NMR data, it was confirmed that the polymer was an alternate copolymer of isopentenyl laurate and maleic anhydride at 1:1.
EXAMPLE 19
The procedure of Example 18 was repeated except that 101.0 g (0.42 moles) of isopentenyl caprate was used instead of the isopentenyl laurate, thereby 132.0 g of an alternate copolymer of isopentenyl caprate and maleic anhydride was obtained (polymer yield of 97.5% based on the charged maleic anhydride, Me=94,000, Mw/Mn=2.1). From the NMR data, it was confirmed that the copolymer was an alternate copolymer if isopentenyl caprate and maleic anhydride at 1:1.
APPLICATION 1
The copolymers obtained in Examples 18 and 19 were subjected to a performance test as a water-soluble hot-melt adhesive. The polymers were each extruded at a maximum temperature of 200° C. to give a 0.2 mm thick sheet. The sheet was interposed between aluminum plates, each having a size of 50 mm×25 mm (adhesion area of 25 mm×25 mm) and pressed at a temperature of 210° C. under a pressure of 5 kg/cm 2 , thereby the aluminum plates were bonded together.
The tensile strength of the bonded plates was measured with a tensile tester (Instron Company) under the condition of a pulling speed of 50 mm/minute to give the following results.
Copolymer: Adhesion Force;
Polymer of Example 18: 34 kg/cm 2 ;
Polymer of Example 19: 18 kg/cm 2 .
When the two types of the bonded aluminum plates were each immersed in a 0.1N sodium hydroxide aqueous solution at 80° C., the copolymers were dissolved to permit the aluminum plates to be readily separated. This means that the copolymers have the properties as a water-soluble hot-melt adhesive.
APPLICATION 2
The copolymer obtained in Example 18 was evaluated as a water-absorbing resin.
73.3 g (0.2 moles) of a powder of the polymer and 11.2 g of sodium hydroxide (0.7 equivalent quantities to maleic anhydride units) were agitated in 200 g of ethanol at 65° C. for 3 hours, followed by filtration and drying to obtain a powder of the Na salt of the copolymer. Equal weight of the Na salt of the copolymer and hot-melt type polyvinyl alcohol were blended with a kneader (Brabender Company) at 110° C. The resultant compound was pressed under conditions of 180° C. and 50 kg/cm 2 for 10 minutes to obtain a piece of sheet having 1 mm thickness. The thus obtained sheet was subjected to heat treatment at 150° C. for 1 hour for crosslinking reaction between the carboxyl groups and the hydroxyl groups and resulted in insolubilization in water. Thereafter, the sheet was immersed in distilled water at room temperature for 1 hour and subjected to water-absorbing test to obtain water-absorption factor of 8. This means that the copolymer serves as a water-absorbing resin.
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Novel alternate copolymers consisting of isopentenyl compounds having a specific structure and certain types of unsaturated compounds are provided.
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BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to an electrochemical element and a method of manufacturing the same, specifically to an electrochemical element with improved energy density comprising multiply stacked electrochemical cells and a method of manufacturing the same.
(b) Description of the Related Art
There has been growing interest on energy storage technology. The applicable field of the battery has been expanded to cellular phones, camcorders and notebook computers with recent addition of electric vehicles into this list. Such expansion has led to increased research and development of batteries with visible outcomes. In this respect, researches on electrochemical elements are one of the fields that have been receiving much attention, among which rechargeable battery is the central field of interest. Recent developments have turned its way to designing new batteries and electrodes to improve capacity and specific energy.
Among the secondary batteries being used, lithium ion battery developed in the 1990s has become increasingly popular because it has higher operating voltage and energy density compared to Ni—MH, Ni—Cd, and sulfuric acid-lead batteries that use aqueous solution electrolyte. These lithium ion batteries, however, have safety problems resulting from the use of organic electrolyte, which causes the batteries to be flammable and explosive. Also, lithium ion has the weakness of having difficult manufacturing process. Recent lithium ion polymer batteries have overcome such shortcomings of the lithium ion batteries and are anticipated to become the batteries of the next generation. These lithium ion polymer batteries, however, have relatively low capacity compared to lithium ion batteries and have especially insufficient discharging capacity at low temperatures; and thus, need to be improved.
The capacity of the batteries is in proportion to the amount of the electrode active materials. Thus, it is extremely important to design a cell structure that can be filled with as much quantities of electrode materials as possible within the limited space of the battery package. The most widely known and used type of cell structure is a jellyroll shaped structure used in a cylindrical or a prismatic battery. Such a structure is prepared by a process of coating and pressing active electrode material onto a metal foil which is used as a current collector, followed by cutting it into a shape of a strip having predetermined width and length, and then separating the anode and cathode using the separator film, and then winding it into a spiral form. Such a jellyroll structure is widely used for manufacturing cylindrical batteries. This structure, however, has small radius of curvature at the center portion of the spiral, which often results in extreme stresses at the bending surface of the electrode, often causing exfoliation of the electrode. This facilitates the deposition of lithium metal at the center portion of the electrode during the repeated charge and discharge of the battery, which may shorten the lifespan of the battery while degrading the safety of the battery.
Generally, the widely known and used method of manufacturing a thin prismatic shaped battery comprises aforesaid process of winding the spiral shaped jelly roll into an oval shape and then compressing it, followed by inserting it into a rectangular container. This method is not free from aforesaid problems of reduced lifespan and safety, but rather has increased problems caused by the decrease in the radius of curvature due to the oval shape. Also, the problem of reduced performance is greater because manufacturing a tight spiral structure is inherently impossible. Furthermore, discrepancy of the oval shape of the jelly role and the rectangular shape of the container reduces the rate of utilized volume. This is known to reduce approximately 20% of the weight energy density and 25% of the volume energy density when the container is taken into account. In reality, a prismatic lithium ion battery is reported to have lower capacity density and specific energy compared to a cylindrical one.
Recently, various patents and technologies proposing to solve the problems of the spiral jelly roll type structure and providing cell structures suitable for a prismatic container are being published. These proposals, however, only provides partial solution to the problems or causes other problems more difficult to solve so that they have not become a practical solution. For example, U.S. Pat. No. 5,552,239 describes a process of first placing and laminating a separator layer or polymer electrolyte between the cathode and anode, then cutting it into a form of a strip with predetermined length and width, followed by gradually folding a cell having an anode/separator layer/cathode layered structure into a square form. The inventors of the present invention have tried to replicate such a process but have found out that it was difficult to manufacture the cells for such a use. The laminated cells were so stiff that it was difficult to fold and when it was folded by exerting force, the problem arose in the folded area because it was fractured in a manner similar to the jellyroll typed cells.
In fan-folding method described in U.S. Pat. No. 5,300,373, the pressure and stresses at the inner layer of the abruptly bending portion are transferred to the outer layer and diverged so that twisting and stretching occur, finally resulting in a “dog bone” shaped cell. Thus, the problems of exfoliations, cracks, crumbles or snapping, encountered in jelly role type structure also occur frequently. Also, the cells with this structure are inherently prone to snapping; and therefore, the possibility of making a practically applicable battery is very low.
Meanwhile, U.S. Pat. No. 5,498,489 attempted to solve and improve such problems in the bending portions. It provides a fundamental way of avoiding exfoliation of the electrodes by leaving out the electrodes at the folding portions and providing connections only through the use of current collectors and separator layers or polymer electrolyte portions. But, there is difficulty in composing such a cell. Furthermore, too much current collectors are used and the structure wastes too much electrolyte. Thus, the structure is not very practical because it has many inefficient factors.
SUMMARY OF THE INVENTION
It is an objective of the present invention to provide an electrochemical element comprising electrochemical cells which are multiply stacked, wherein it is easy to manufacture, and has a structure making efficient use of the space available and a method of manufacturing the same while considering the prior art.
It is another objective of the present invention to provide an electrochemical element and a method of manufacturing the same that can maximize the content of the active electrode material and can be manufactured easily.
These and other objectives may be achieved by an electrochemical element comprising electrochemical cells which are multiply stacked, said electrochemical cells formed by stacking full cells having a cathode, a separator layer, and an anode sequentially as a basic unit, and a separator film interposed between each stacked full cell wherein,
said separator film has a unit length which is determined to wrap the electrochemical cells, and folds outward every unit length to fold each electrochemical cell in a Z-shape starting from the electrochemical cell of a first spot to the electrochemical cell of the last spot continuously while the remaining separator film wraps an outer portion of the stacked cell.
Also, the present invention provides a method of manufacturing an electrochemical element using the full cell comprising the steps of,
a) placing a full cell on and below the separator film continuously or alternately;
b) laminating said placed full cells and said separator film of a); and
c) folding outward said laminated full cells and said separator film of b) to the full cell adjacent next to the first full cell to fold each full cell in a Z-shape and wrapping the remaining separator film round an outer portion of the stacked full cell at least once so that each full cell is stacked.
Furthermore, the present invention provides an electrochemical element comprising electrochemical cells which are multiply stacked, said electrochemical cells formed by stacking,
i) a bicell having a cathode; a separator layer; an anode; another separator layer; and another cathode sequentially as a basic unit; or
ii) a bicell having an anode; a separator layer; a cathode; another separator layer; and another anode sequentially as a basic unit;
and a separator film interposed between each stacked bicells wherein,
said separator film has a unit length which is determined to wrap the electrochemical cells, and folds outward every unit length to fold each electrochemical cell in a Z-shape starting from the electrochemical cell of a first spot to the electrochemical cell of the last spot continuously while the remaining separator film wraps an outer portion of the stacked cell.
Still furthermore, the present invention provides a method of manufacturing an electrochemical element using the bicell comprising the steps of
a) placing a bicell on and below the separator film continuously or alternately;
b) laminating said placed bicells and said separator film of a); and
c) folding outward said laminated bicells and said separator film of b) to the bicell adjacent next to the first bicell to fold each bicell in a Z-shape and wrapping the remaining separator film round an outer portion of the stacked bicell at least once so that each bicell is stacked.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a layered structure of a full cell comprising a both-side coated cathode, an anode and a separator layer.
FIG. 2 shows a layered structure of the cell where multiple full cells are stacked and a separator film is interposed between stacked cells.
FIG. 3 shows a layered structure of a cell comprising multiply stacked full cells having a single side of an outermost electrode of an outermost full cell coated and left as a foil, and having a separator film interposed between the full cells.
FIG. 4A shows a layered structure of a bicell where a middle layer is an anode and both outer sides are cathodes.
FIG. 4B shows a layered structure of a bicell where a middle layer is a cathode and both outer sides are anodes.
FIG. 5 shows a layered structure of a cell where two types of bicells are alternately stacked with an interposed separator film between the bicells.
FIG. 6 shows a layered structure of a cell comprising bicells having a single side of an outermost electrode of an outermost bicell coated and left as a foil and two types of bicells are alternately stacked having a separator film interposed between the full cells.
FIGS. 7A-7B are development figures of a battery where full cells are sequentially placed on a cut separator film and then laminated so that the full cells are accurately aligned for stacking.
FIG. 8 is a graph showing a charging and discharging characteristic of the electrochemical element according to the present invention.
FIGS. 9A-9B are development figures of a battery where full cells are sequentially placed on a cut separator film and then laminated so that the full cells are accurately aligned for stacking.
FIGS. 10A-10B are development figures of a battery where bicells are sequentially placed on a cut separator film and then laminated so that the bicells are accurately aligned for stacking.
FIG. 11 shows a cycle characteristic of an electrochemical element according to the present invention.
FIGS. 12A-12B are development figures of battery where bicells are sequentially placed on a cut separator film and then laminated so that the bicells are accurately aligned for stacking.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be discussed in detail with reference to the figures.
[Function]
The present invention provides a cell structure and a method for the preparation thereof which is more convenient to manufacture and uses space more efficiently compared to conventional cells. The present invention provides a unique but a simple way of maximizing the content of electrode active material in a prismatic battery while solving various shortcomings of various conventional cell structures discussed above. In principle, the present invention does not make avail of longitudinally cut electrodes used for spiral winding or folding, but rather uses the method of stacking electrodes cut in a predetermined form.
The electrochemical cells according to the present invention are stacked with a full cell or a bicell as a basic unit.
The full cell of the present invention has a structure where a layered construction of a cathode 7 , an anode 8 and a separator layer 15 is cut into a regular shape and regular size and then stacked as shown in FIG. 1 . All the electrodes use current collectors 11 and 12 coated with electrode active material 13 and 14 on both sides. Such a structure is treated as a single unit cell to constitute a battery by stacking. For such a purpose, the electrodes and the separator films must be fixed to each other. For example, in a lithium rechargeable cell, the main component of the cathodic material 14 is lithium intercalation materials such as lithium manganese oxide, lithium cobalt oxide, lithium nickel oxide or a complex oxide formed from a combination of aforesaid oxides, said cathodic material coated on the cathode current collector 12 , that is, a foil prepared from aluminum, nickel, or a combination thereof to form a cathode 8 . Also the main component of the anodic material 13 is lithium metal or lithium alloy, and lithium intercalation materials such as carbon, petroleum coke, activated carbon, graphite or other carbons, said anode material 13 coated on anode current collector 11 , that is, a foil prepared from copper, gold, nickel, copper alloy or a combination thereof to form an anode 7 .
The separator layer 15 includes a micro-porous polyethylene film, a micro-porous polypropylene film, or a multi-layer film prepared by a combination thereof, or a polymer film for solid polymer electrolyte or gel-type polymer electrolyte such as polyvinylidene fluoride, polyethylene oxide, polyacrylonitrile or polyvinylidene fluoride hexafluoropropylene copolymer. Furthermore, it is very efficient to use a polymer film for polymer electrolyte including a primary micro-porous polymer layer and a secondary gelling polymer layer of polyvinylidene fluoride-chlorotrifluoroethylene copolymer described in Korean Patent Application No. 99-57312. An important feature needed for the separator layer 15 is a bonding characteristic from laminating for constituting a unit cell which is a full cell.
The unit structure of the full cell 17 shown in FIG. 1 is composed of a cathode, a separator layer, and an anode sequentially. The separator layer 15 is naturally placed in the center of the cell. A plurality of these unit cells can be stacked in a number desired to implement a battery with practical capacity. For example, FIG. 2 shows five full cells sequentially stacked. The way of interposing a polymer separator layer or a polymer separator film having micro porous for polymer electrolyte is extremely important as explained above. FIG. 2 shows a way of interposing a separator layer 15 according to the present invention.
The full cells 17 of the present invention are stacked by folding the longitudinally cut separator film 19 in a Z-shape starting from a full cell and then stacked one by one. Such a structure becomes a very efficient structure because the outer active coating material not used within a unit cell is shared with opposite electrode active coating material of another adjacent unit cell. The separator film 19 is finished by fixing a tape 27 after finishing the folding and wrapping once around the full cells. Furthermore, the finishing can use thermo-fusing besides taping. That is, the separator film itself is fixed and bonded by heat-sealing which carry out bring a thermo-welding machine, a hot plate, or etc into contact with the separator film. The number of full cells to be stacked is determined according to the desired capacity of the finished battery.
In the present invention, the structure 44 of FIG. 2 has another meaning. According to the experience of the inventors of the present invention, the surfaces between the separator films such as film for polymer electrolyte film or the polymer separator layer and electrodes are important. When the battery is actually used after injecting liquid electrolyte and packaging, it is subject to numerous charging and discharging cycle. When the contact of the surface is not constantly maintained and becomes unstable, the performance of the battery drops suddenly and actual capacity of the battery decreases. According to the structure of the battery, this effect can be shown from the beginning or can be revealed as time passes by. Therefore, there is a need to exert pressure to constantly maintain the surfaces. The present invention provides a new cell structure and method of assembling as a way of maintaining the pressure while fundamentally solving above problem. In this context, FIG. 2 has another meaning.
As can be seen in structure 44 of FIG. 2, a way of stacking the unit cells of full cells while folding the separator film 19 in a Z-shape efficiently uses the electrodes between the full cells. Pressure formed by wrapping the full cells once around after the folding presses surfaces between the polymer film of the polymer electrolyte or the polymer separator layer and the electrodes formed by all the cells. A final finishing using a tape 27 is a measure to constantly maintain such a pressure, which allows stable and constant contact between the surfaces.
A different material or same material of polymer separator layer or polymer film for polymer electrolyte can be used for a separator layer 15 and separator film 19 . The separator layer 15 must have bonding characteristic from laminating to constitute a unit cell which is a full cell, but the separator film 19 does not need to have such a characteristic because it is possible to fold the full cells 17 by the separator film 19 for assembling. But, for another type of assembling using a cell structure as shown in structure 44 of FIG. 2, it is preferable to use the separator film 19 that also has the bonding characteristic. In this respect, it may be most appropriate to use the polymer film for polymer electrolyte as a separator film 19 comprising a first micro-porous polymer layer and a second gelling polymer layer of polyvinylidene fluoride-chlorotrifluoroethylene copolymer for the battery according to the present invention. When the new polymer film is used as the separator film 19 , there can be a large variety of assembling method in structure 44 of FIG. 2 . That is, every full cell 17 has two possible directions, that is the upper direction and the lower direction for bonding to the separator film 19 . If there are five full cells as in FIG. 2, there can be 2 5 kinds of ways of assembling. In such a method, after the separator film 19 is spread in a longitudinal direction, full cells are disposed in upper or lower side of the separator film 29 according to any of the 2 5 ways, and then laminated followed by simply folding in a Z-shape and wrapping once around. This method advantageously facilitates the assembling process of designing and disposing of full cells.
FIG. 3 shows structure 45 which eliminates the unused outermost active electrode material from the structure 44 of FIG. 2 so that the structure has the maximum space efficiency. When another full cell 17 ′ is defined as a full cell structure having one electrode coated on both sides and the other electrode coated on a single side, structure 45 of FIG. 3 adopts such a full cell 17 ′ so that the outermost active electrode material not used is left as a foil as shown in structure 44 of FIG. 2 . This results in the additional decrease in the thickness without losing the capacity so that the space efficiency is increased furthermore. But, when the stacked cells are increased, it does not show much difference in space utilization efficiency compared to the structure 44 of FIG. 2 . Nevertheless, structure 45 of FIG. 3 is effective in a very thin layer card typed battery recently being discussed.
In the present invention, when a plurality of bicells is stacked as a unit cell, the space efficient cell structure is applied in a manner identical to the above method. For such a purpose, two types of bicells 23 and 24 are respectively defined both of which uses a both-side coated electrode as shown in FIGS. 4 a and 4 b . The bicell 23 has an anode placed in the middle and cathodes placed in both outer sides whereas the bicell 24 has a cathode placed in the middle and anodes placed in both outer sides. The usable active electrode material and polymer separator layer or polymer film for polymer electrolyte as a separator layer 15 is same in detail as discussed above in the full cells.
The structure 46 of FIG. 5 shows a way of constituting a battery using two types of bicells as basic unit cells. When the bicell 23 and 24 are alternately stacked, and aforementioned polymer separator layer or separator film 19 such as polymer film for polymer electrolyte are inserted between the bicells in a Z-shape folding manner, the outer active coating material not used within a bicell is naturally shared with an opposite polarity of another type of adjacent bicell, forming a new full cell which has a very efficient structure. As can be seen in structure 46 of FIG. 5, if the separator films 19 are interposed continuously between the cells and the bicells are alternately stacked, the polarity of the battery is naturally formed without discrepancy. The outermost stacked bicell of the battery can be either bicell 23 or bicell 24 , the only difference being whether the unused electrode material is an anode or a cathode. The proportion of such unused electrodes decreases as the number of stacks increases and for electrode with a practical thickness, only has little influence. In other structure 46 , the way and structure of inserting the separator film 19 is identical to those of full cell in every detail and the separator film 19 and tape 27 functioning under such a structure also has the same meaning.
FIG. 6 shows a structure 47 eliminating the outermost active electrode material from the structure 46 of FIG. 5 so that the structure has a maximum space efficiency. When the primes(′) denote structures where only one out of two outer electrodes of the bicell is left as the foil, a structure stacking a bicell 23 ′ as the outermost bicell of the battery (it does not matter whether the outermost bicell is bicell 23 ′ or bicell 24 ′) as in structure 47 of FIG. 6 leaves the unused portion of the outermost active electrode material as the foil so that the thickness is further reduced not losing the space efficiency. This allows the merit of directly being related to the space efficiency. When the layers of bicells being stacked increase, it does not show much difference from structure 46 of FIG. 5 in terms of the space efficiency. In a thin layer card typed battery, however, the structure of stacked cell 47 of FIG. 6 is effective.
The battery structure provided in the present invention is very effective for a prismatic battery. Generally, liquid electrolyte is injected when packaging. For such a purpose, aluminum prismatic can or an aluminum laminate film can be used as a container. The liquid electrolyte is a salt of A + B − dissolved or dissociated in an organic solvent wherein the A + comprises an alkaline metal cation such as Li + , Na + , or K + or combination thereof, the B − comprises an anion PF 6 − , BF 4 − , Cl − , Br − , I − , ClO 4 − , ASF 6 − , CH 3 CO 2 − , CF 3 SO 3 − , N(CF 3 SO 2 ) 2 − or C(CF 2 SO 2 ) 3 − or combination thereof and the organic solvent comprises propylene carbonate(PC), ethylene carbonate(EC), diethyl carbonate(DEC), dimethyl carbonate(DMC), dipropyl carbonate(DPC), dimethyl sulfoxide, acetonitrile, dimethoxyethane, diethoxyethane, tetrahydrofurane, N-methyl-2-pyrrolidone(NMP), ethylmethyl carbonate(EMC), or γ-butyrolactone or combination thereof. Unlike a jelly roll of a lithium ion battery, the constituents of the battery according to the present invention have a form coinciding with the form of the quadrilateral container so that there will be no unused space within the container. Therefore, the energy density of the battery can be greatly increased to implement a highly integrated battery having maximized spatial efficiency of active materials.
The electrochemical element of the present invention can be applied to the various fields such as supercapacitors, ultracapacitors, primary batteries, secondary batteries, fuel cells, sensors, electrolysis devices, electrochemical reactors, and etc, besides lithium secondary batteries.
The present invention will be explained in detail with reference to the examples. These examples, however, should not in any sense be interpreted as limiting the scope of the present invention.
EXAMPLES
Example 1
Preparing a Stacked Cell Where a Full Cell is a Basic Unit
(Preparing a Cathode)
LiCoO 2 :carbon black:PVDF, of which the weight ratio was 95:2.5:2.5, was dispersed in NMP in order to prepare slurry, and then the slurry was coated on an aluminum foil. After sufficiently drying at 130° C., the cathode was prepared by pressing.
A cathode of the full cell was prepared by coating the slurry on both sides of aluminum foil. That is, the cathode has a cathodic material coated on both sides of the aluminum cathode current collector. The thickness of the both-side coated cathode was 140 μm.
(Preparing an Anode)
Graphite:acetylene black:PVDF, of which the weight ratio was 93:1:6, was dispersed in NMP in order to prepare slurry, and then the slurry was coated on a copper foil. After sufficiently drying at 130° C., the anode was prepared by pressing.
An anode of the full cell was prepared by coating the slurry on both sides of copper foil. That is, the anode has an anodic material coated on both sides of the copper anode current collector. The thickness of the both-side coated anode was 135 μm.
(Preparing a Separator Layer; a Separator Film; a Polymer Film for Polymer Electrolyte)
A multi-layer polymer film was prepared wherein polypropylene film having a microporous structure and a thickness of 16 μm was a first polymer separator layer and polyvinylidene fluoride-chlorotrifluoroethylene copolymer 32008 (Solvay) was a second gelling polymer. 6 g of the 32008 was added to 194 g of acetone and stirred at 50° C. After 1 hour, the completely dissolved transparent 32008 solution was coated on the polypropylene first polymer separator layer by a dip coating process. The thickness of coated 32008 was 1 μm and the thickness of the final multi-layered polymer film was 18 μm. Here, a same material was used for the separator layer and the separator film.
(Preparing a Full Cell)
Seven full cells 17 of FIG. 1 were prepared by cutting the cathode having cathodic material coated on both sides of a cathode current collector to the size of 2.9 cm×4.3 cm of rectangle, except for the area where a tab was to be formed (the area where a tab was to be formed should not be coated with electrode material), cutting the anode having anodic material coated on both sides of an anode current collector to the size of 3.0 cm×4.4 cm of rectangle, except the area where a tab was to be formed (the area where a tab was to be formed should not be coated with electrode material), cutting a multi-layered polymer film prepared in a manner mentioned above to the size of 3.1 cm×4.5 cm, interposing the above film between the anode and the cathode, and passing it through a roll laminator of 100° C. to laminate the electrodes and the separator layer.
(Stacking Full Cells)
After preparing the polymer film 19 for the polymer electrolyte manufactured as above by cutting longitudinally, the seven full cells were disposed alternately on and below the separator film 19 as shown in FIG. 7 a . FIG. 7 b is a drawing showing the side of FIG. 7 a . The gaps between each cell were spaced equally but enough that the cells could be stacked and separated by the separator film in a Z-shape. The polarity of the tab was disposed as in FIGS. 7 a and 7 b so that it coincided with the polarities of the neighboring full cells. That is, the direction of the electrodes of the first full cells placed on and below the separator film 19 was disposed in the sequence of cathode and then the anode, and the direction of the electrodes of the second full cell and next full cells was disposed alternately below and on the separator film in the reverse order.
The polymer film 19 having the full cells placed thereon was passed through a roll laminator so that the full cells were bonded on and below the polymer film 19 .
The bonded full cell 17 of the first spot was folded into a Z-shape. After the folding was finished, the remaining separator film 19 wrapped the outer side of the stacked full cells once and was fixed and secured tightly by a tape 27 .
(Preparing a Battery)
The full cell stacked battery prepared as above was placed within the aluminum laminate package. Then the liquid electrolyte comprising 1:2 weight ratio of EC/EMC of 1 M LiPF 6 was injected and packaged.
(Evaluation)
Using the charging and discharging experiment, the evaluation of the cycle characteristic of the battery is shown in FIG. 8 . Reference numeral 102 shows the cycle characteristic of the manufactured battery where 0.2C is charged and 0.2 C is discharged.
Example 2
Preparing a Stacked Cell Where a Full Cell is a Basic Unit
(Preparing a Cathode)
Each cathode was prepared in a manner identical to the example 1.
(Preparing an Anode)
Each anode was prepared in a manner identical to the example 1.
(Preparing a Separator Layer; a Separator Film; a Polymer Film for Polymer Electrolyte)
Each separator layer and polymer film for polymer electrolyte for separator film was prepared in a manner identical to the example 1.
(Preparing a Full Cell)
The eight full cells 17 of FIG. 1 were prepared by passing through a roll laminator of 100° C. to laminate the electrodes and the separator layer as in example 1.
(Stacking Full Cells)
After preparing the polymer film 19 for the polymer electrolyte manufactured as above by cutting longitudinally, the eight full cells were disposed on or below the separator film 19 as shown in FIG. 9 a . FIG. 9 b is a drawing showing the side of FIG. 9 a . The gaps between each cell were spaced equally but enough that the cells could be stacked and separated by the separator film in a Z-shape where the distance was the addition of width and thickness of the full cell. The polarity of the tab was disposed as in FIGS. 9 a and 9 b so that it coincided with the polarities of the neighboring full cells. That is, the direction of the electrodes of the first full cells placed on and below the separator film 19 was disposed in the sequence of cathode and then the anode identically, and the direction of the electrodes of the second full cell and next full cells was disposed below and on the separator film 19 in the reverse order.
The polymer film 19 having the full cells placed thereon was passed through a roll laminator so that the full cells were bonded on and below the polymer film 19 .
The bonded full cell 17 of the first spot was folded into a Z-shape. After the folding was finished, the remaining separator film 19 wrapped the outer side of the stacked full cells once and was fixed and secured tightly by a tape 27 .
(Preparing a Battery)
The full cell stacked battery prepared as above was placed within the aluminum laminate package. Then the liquid electrolyte comprising 1:2 weight ratio of EC/EMC of 1 M LiPF 6 was injected and packaged.
(Evaluation)
Using the charging and discharging experiment, the evaluation of the cycle characteristic of the battery is shown in FIG. 8 . Reference numeral 103 shows the cycle characteristic of the manufactured battery where 0.2C is charged and 0.2 C is discharged.
Example 3
Preparing a Stacked Cell Where a Bicell is a Basic Unit
(Preparing a Cathode)
Each cathode was prepared according to the method same as the above example 1.
A cathode of the bicell was prepared by coating the slurry on both sides of aluminum foil. That is, the cathode has a cathodic material coated on both sides of the aluminum cathode current collector. The thickness of the both-side coated cathode was 140 μm.
(Preparing an Anode)
Each anode was prepared according to the method same as the above example 1.
An anode of the bicell was prepared by coating the slurry on both sides of copper foil. That is, the anode has an anodic material coated on both sides of the copper anode current collector. The thickness of the both-side coated anode was 135 μm.
(Preparing a Separator Layer; a Separator Film; a Polymer Film for Polymer Electrolyte)
The separator layers, separator films, and polymer film for polymer electrolyte were prepared in a manner identical to the example 1.
(Preparing a Bicell)
The cathode having aforesaid cathodic material coated on both sides of the cathode current collector was cut to the size of 2.9 cm×4.3 cm of rectangle, except for the area where a tab was to be formed. The anode having anodic material coated on both sides of the anode current collector was cut to the size of 3.0 cm×4.4 cm of rectangle, except for the area where a tab was to be formed.
Four bicells 23 of FIG. 4 a were prepared by placing both-side coated anode in the middle and the both-side coated cathodes at both outer sides, placing a multi-layered polymer film prepared according to the aforesaid manner which was cut into the size of 3.1 cm×4.5 cm between each anode and each cathode, and passing it through a roll laminator of 100° C. to thermofuse the electrodes and the separator layer. Other bicells, that is, three bicells 24 of FIG. 4 b were prepared by placing the both-side coated cathode in the middle and the both-side coated anodes at both outer sides, placing a multi-layered polymer film prepared according to the aforesaid manner which was cut into the size of 3.1 cm×4.5 cm between each anode and each cathode, and passing it through a roll laminator of 100° C. to laminate the electrodes and the separator layer.
(Stacking Bicells)
After preparing the polymer film 19 for the polymer electrolyte manufactured as above by cutting longitudinally, four bicells 23 and three bicells 24 prepared as above were placed on the separator film 19 and below the film respectively. FIG. 10 b is a drawing showing the side of FIG. 10 a . The gaps between each cell were spaced equally but enough that the cells could be stacked and separated by the separator film in a Z-shape. The polarity of the tab was disposed as in FIGS. 10 a and 10 b so that it coincided with the polarities of the neighboring bicells. That is, the direction of the electrodes of the first bicell placed on the separator film 19 was disposed in the sequence of cathode and then the anode, and the direction of the electrodes of the second bicell and next bicells was disposed alternately below and on the separator film 19 in the reverse order.
The polymer film 19 having the bicells placed thereon was passed through a roll laminator so that the bicells were bonded on and below the polymer film 19 .
The bonded bicell 23 of the first spot was folded into a Z-shape. After the folding was finished, the remaining separator film 19 wrapped the outer side of the stacked bicells once and was fixed and secured tightly by a tape 27 .
(Preparing a Battery)
The stacked bicell battery prepared as above was placed within the aluminum laminate package. Then the liquid electrolyte comprising 1:2 of EC/EMC of 1 M LiPF 6 was injected and packaged.
(Evaluation)
Using the charging and discharging experiment, the evaluation of the cycle characteristic of the battery is shown in FIG. 11 . Reference numeral 104 shows the cycle characteristic of the manufactured battery where 0.2C is charged and discharged at first and second time followed by 0.5C charges/1C discharges from the third time from which it is illustrated on the graph.
Example 4
Preparing a Stacked Cell Where a Bicell is a Basic Unit
(Preparing a Cathode)
Each cathode was prepared according to the method same as the above example 1.
(Preparing an Anode)
Each anode was prepared according to the method same as the above example 1.
(Preparing a Separator Layer; a Separator Film; a Polymer Film for Polymer Electrolyte)
The separator layers and separator film, that is, polymer film for polymer electrolyte were prepared in a manner identical to the example 1.
(Preparing a Bicell)
Four bicells 23 and four bicells 24 were prepared as in example 3.
(Stacking Bicells)
After preparing the polymer film 19 for the polymer electrolyte manufactured as above by cutting longitudinally, four bicells 23 and four bicells 24 prepared as above were placed on the same location of the separator film 19 with the bicell 24 upper side and the bicell 24 lower side so that the bicell 23 and the bicell 24 were placed alternately as shown in FIG. 12 a . FIG. 12 b is a drawing showing the side of FIG. 12 a . The gaps between each cell were spaced equally but enough that the cells could be stacked and separated by the separator film in a Z-shape where the distance was the addition of width and thickness of the bicell. The polarity of the tab was disposed as in FIGS. 12 a and 12 b so that it coincided with the polarities of the neighboring bicells. That is, the direction of the electrodes of the first bicells placed on and below the separator film 19 was disposed in the sequence of cathode and then the anode identically, and the direction of the electrodes of the second bicell and next bicells was disposed below and on the separator film 19 in the reverse order.
The polymer film 19 having the bicells placed thereon was passed through a roll laminator so that the biceps were bonded on and below the polymer film 19 .
The bonded bicell 17 of the first spot was folded into a Z-shape. After the folding was finished, the remaining separator film 19 wrapped the outer side of the stacked bicells once and was fixed and secured tightly by a tape 27 .
(Preparing a Battery)
The stacked bicell battery prepared as above was placed within the aluminum laminate package. Then the liquid electrolyte comprising 1:2 of EC/EMC of 1 M LiPF 6 was injected and packaged.
(Evaluation)
Using the charging and discharging experiment, the evaluation of the cycle characteristic of the battery is shown in FIG. 11 . Reference numeral 105 shows the cycle characteristic of the manufactured battery where 0.2C is charged and discharged at first and second time followed by 0.5C charges/1C discharges from the third time from which it is illustrated on the graph.
The electrochemical element according to the present invention multiply stacked with full cells or bicells as a unit cell is easy to manufacture, has a structure which uses the space available efficiently, and can especially maximize the content of the active electrode material so that a highly integrated battery can be implemented.
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The present invention relates to an electrochemical element, specifically an electrochemical element with improved energy density comprising stacked electrochemical cells.
In order to achieve such objects, the present invention provides an electrochemical element comprising electrochemical cells which are multiply stacked, said electrochemical cells formed by stacking full cells or bicells having a cathode, a separator layer, and an anode sequentially as a basic unit, and a separator film interposed between each stacked cell wherein, said separator film has a unit length which is determined to wrap the electrochemical cells, and folds outward every unit length to fold each electrochemical cell in a Z-shape starting from the electrochemical cell of a first spot to the electrochemical cell of the last spot continuously while the remaining separator film wraps an outer portion of the stacked cell and a method for manufacturing the same.
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RELATED APPLICATION
Priority is claimed under 35 U.S.C. 119(e) from the Provisional Application, Serial No. 60/002454, filed on Aug. 16, 1995, and of same title and inventors Qin Kong, the present inventor and Mr. Richard May. Mr. May is not an inventor of any of the claims of this application.
FIELD OF THE INVENTION
The present invention relates generally to devices for controlling the light intensity output of a fluorescent light. In particular the present invention relates to systems where the light intensity is dimmed or reduced from full output to accommodate the user's specific tolerances such that viewing of items entails less glare and fewer shadowed or dark areas within the viewers sight.
BACKGROUND OF THE INVENTION
Fluorescent lights are by their nature non-linear. That is, a reduction in electrical energy to a fluorescent lamp does not cause a corresponding reduction in light intensity out from the lamp. Indeed there will be a point where the lamp extinguishes even though there is electrical energy being supplied to the lamp. Herein lamp is defined as the fluorescent tube or bulb.
There have been prior attempts to control the lumen or light intensity output from a fluorescent lamp. One such attempt is found in U.S. Pat. No. 5,345,150, entitled REGULATING LIGHT INTENSITY BY MEANS OF MAGNETIC CORE MULTIPLE WINDINGS, which issued Sep. 6, 1994 to Biegel and is assigned to Stocker & Yale, Inc. This invention discloses a variable inductor formed by two windings on a common core. The current through one winding (the control winding) affects the degree of saturation of the core. The inductance of the second winding is directly affected by the degree of saturation and so the second winding inductance. The second winding inductance directly influences the current and so the lumen output of the lamp connected to the second winding.
Another device for controlling the lumen output of a fluorescent lamp is found in U.S. Pat. No. 4,855,646, entitled FLUORESCENT ILLUMINATOR WITH INVERTER POWER SUPPLY, which issued on Aug. 8, 1989 to Peckitt et al. and assigned to Techni-Quip Corp. This invention discloses apparatus to vary the lumen output between two or more lumen levels. Apparatus is disclosed with a relatively fixed AC voltage amplitude and frequency. Control is exercised by adjusting the lamp current by changing the impedance of the circuitry (and so the current) connecting the power source to the lamp.
Another fluorescent dimmer is described in a user's guide, ML 4831, from Micro Linear published on Jul. 7, 1994. This guide is incorporated by reference herein as though laid out in full. The Guide describes a theory of operation and circuitry for a Dimmable Electronic Ballast that is particularly suitable for driving T8 and T12--types of fluorescent lamps. Other fluorescent lamps may also be driven from the described circuitry. This circuit uses a feedback loop where the frequency of the lamp current is changed in accordance to the amount of dimming selected. When the frequency is increased the load impedance presented by the lamp and associated circuitry increases (an inductive dominated load for these frequencies) resulting in lower lamp current and less output light. The operation is to sample the lamp current, convert the sampled current into a voltage and use the voltage to drive inverter stages at different frequencies. The operation is from about 30K Hz to 50K Hz. The inverter output is converted into the lamp current by the driving transformer and other associated circuitry. However, as the light output is diminished there will be a threshold where the lamp will be extinguished and will not restart. The Micro Linear circuitry is optimized for T8 and T12 types of fluorescent lamps and the performance of this circuitry will usually be unsatisfactory for other types of lamps. On page four of the User's Guide operation with other types of fluorescent lamps is discussed. Changing turns ratios on transformers and changing circuit values are suggested. But, these suggestions are aimed at increasing voltages or matching impedances or to affect pre-heat of the lamps. A limitation of the Microlinear circuitry when dimming is that the feedback loop used to control the fluorescent lamp is slow. The loop bandwidth is about 160 Hz. FIG. 1 shows the lamp current for the Micro Linear circuitry under dimming conditions where the lamp current occurs as peaks separated by about 5 milliseconds. The light output under such driving conditions has a noticeable flicker, and the dimming range of the lamp is limited. Moreover, for more non-linear lamps the dimming range is limited to less than 50%.
As discussed above, it has been found that operation of the Micro Linear circuitry is limited when driving a fluorescent lamp that is more non-linear than the T8 or T12 type lamps. For example, a T5 lamp extinguishes at or about 50% dimming. This limited dimming range is usually unsatisfactory. The suggestions in the Users Guide do not help.
Also, these and other prior art inventions are inefficient in their use of electrical components. The transformers and variable inductors and capacitors must be arranged and configured for the higher power outputs and, thus, must be larger than needed for the lower power outputs.
An object of this invention is to provide a feedback arrangement for dimming a very non-linear fluorescent lamp with a manual setting, and where the power rating and size of the electrical components are more optimum over the range of different lumen outputs. Another object is to provide an extended range of dimming for fluorescent lamp and, especially, lamps more non-linear than the T8 and T12 lamps.
It is another object of the present invention to provide a lamp dimmer operating where there is no perceived flicker to the user's eye at dimmed lamp light levels.
SUMMARY OF THE INVENTION
The foregoing objects are met in circuitry that allows the light output to be reduced to about 10% of full output for fluorescent lamps that have significantly more non-linear characteristics. The circuitry includes a feedback loop where the loop speed is substantially increased over prior art circuits. This increased speed allows dimming control of the non-linear T5 fluorescent lamp to well below 30% of full light output. There is a significant advantage of controlling the dimming of these non-linear lamps over a wide dimming range. There are physical configurations where a non-linear lamp, like the T5, can only be used, and the ability to dim such a lamp provides a significant performance advantage over non-dimmable arrangements. A feedback loop exists with a settable desired lumen or light intensity output. The actual lamp current is compared to the current represented by the desired setting thus generating an error signal. The feedback loop acts to reduce the error signal forcing the lamp current and so the light output to the desired level.
The feedback apparatus for controlling the lumen output of the fluorescent light lamp includes an inverter for generating a controlled frequency current through the lamp, means for sensing the current in said lamp, adjusting means for setting a lumen output level for said lamp, means for comparing said current to said setting to form an error signal, responsive to said error signal, feedback means to vary said inverter frequency to change said current such that the lumen output of the lamp changes in a manner corresponding to said setting. Increasing the loop speed of the feedback circuitry to provide higher frequency operations allow the lamp to be dimmed to lower than 30% but not be extinguished. This phenomenon was not known or understood in the prior art, and there is no suggestions of the limitation of the loop speed as a factor in dimming of fluorescent lamps. In a preferred embodiment, the feedback loop frequency has been modified to provide a faster feedback loop speed than previously suggested so that the lamp dimming can range down to less than 30%. If other stray capacitance is eliminated the dimming can range down to about 10% or even lower.
Other preferred embodiments may use variable inductors and/or saturable transformers and other variable impedance components where the change in impedance causes a change in the lamp current.
In a preferred embodiment, a switch that changes the light output from 100% to 50% will often cause a fluorescent lamp to extinguish. One reason not suggested or understood by the prior art was that the feedback loop speed was too slow. In such an instance, the lamp current being sampled is reduced precipitously but the frequency of the lamp current signal has not changed. When the feedback loop speed is slow, the feedback error signal (as defined and used in classic feedback circuitry) exists for the time needed for the loop speed to achieve its steady state operating point. During this transition the lamp current is reduced to the point of extinction and may remains off for most of the loop delay time. But, when a fast feed back loop exists the time that the lamp is off is much smaller in the same ratio as the quicker loop speed. In effect in the prior art designs will cause current pulses in the lamp separated by the feedback delay time when the lamp is off. This operation causes flicker and a reduced dimming range for the lamp.
The present invention provides for a fast feedback loop where there is no noticeable flicker and the dimming range of the lamp is extended.
In a preferred embodiment a dimmable electronic ballast circuit, the ML4831 from Micro Linear, has been found to be unsuitable for driving a T5 or other such non-linear lamp. The ML4831 dimmer design is pointed at T12 and T8 fluorescent lamps which are relatively linear. These lamps require a high starting voltage and a large working current. However, in the present design a T5 lamp is used which exhibits very non-linear characteristics compared to the T12 and T8 lamps. In particular with the T5 lamp, dimming the light output below 50% is difficult, and the ML4831 continuous current source is not useful. In order to dim a T5 lamp the current source is discontinuous such that the new operating point is quickly achieved, and the quickness is effective in keeping the lamp lit.
Other objects, features and advantages will be apparent from the following detailed description of preferred embodiments thereof taken in conjunction with the accompanying drawing in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of prior art circuitry lamp current at dimmed light levels;
FIG. 2A is a circuit diagram;
FIG. 2B is a voltage/current graph of the non-linear nature of fluorescent lamps;
FIG. 2C is a graph of the lamp current of the present invention at dimmed light levels;
FIG. 3 is a circuit block diagram of a feedback control circuit; and
FIG. 4 is a circuit diagram made in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 3, 120 VAC power is supplied to an AC to DC converter 2. The DC output is fed to a frequency converter 4 which has a control input 6. The range of frequencies is from about 30K Hz to 50K Hz. The output of the frequency converter 4 is fed to a resonant circuit and current limiter 8. The output of the current limiter 8 is an AC current that drives the lamp 10. The Resonant block 8 looks inductive at the frequencies involved
The lamp current is fed back 12 to a control circuit 14. The control circuit outputs the signal 6 which controls the frequency of the frequency converter 4. Another input to the control circuit is a dimming setting 16. When the light is to be dimmed the setting 16 is changed and which results in a higher frequency output from the frequency converter. The higher frequency signal results in less lamp current since the resonant circuit 8 looks inductive thereby providing a higher impedance at the higher frequencies and thus less current.
In the present invention the loop speed, that is the time required for a signal to traverse the loop from the frequency converter to the resonant circuit to the lamp to the control circuit and back to the frequency converter requires about 50 microseconds. By contrast the loop speed of the prior art Micro Linear circuit is about 5 milliseconds having a bandwidth of about 160 Hz. The impact of this delay is that the DC to frequency converter outputs a higher frequency and therefor less current to the lamp for a time of about 5 milliseconds. If the current level is near the extinguishing threshold of the lamp, the light will be off for the 5 milliseconds. The feedback system ultimately responds and, depending upon the dimming required and other circuit parameters as are known in the art of feedback circuitry, the voltage will rise above the voltage discharge threshold and light the lamp again. The result is graph of FIG. 1, where the peaks occur 5 milliseconds apart and where the lamp is lighted only during these peaks. Noticeable flickering of the light occurs under these conditions. As discussed previously, the time where the lamp is off allows the cathode to cool which has the erratic effect of changing the voltage discharge threshold.
Any reduction in the 5 millisecond of the feedback loop circuitry is advantageous regarding range of dimming and flicker. In another preferred embodiments, feedback speeds of 0.5 milliseconds and 50 microseconds and less can be used to advantage.
In a corresponding manner, using bandwidth rather than speed as a parameter, increases in the feedback loop frequency is advantageous, and loop frequencies exceeding 160 Hz, and frequencies of 1.6 kHz, and 16 kHz have been used to advantage.
FIG. 2C shows the effect of a higher frequency feedback circuit where the response is about 50 microseconds. In this representation of the present invention the time between discharge of the lamp is small and the cooling of the cathode will be more uniform allowing the dimming to occur in a more uniform manner over a larger range of dimming and with no flickering.
FIG. 2B shows the voltage current profile for a typical fluorescent lamp and the combination of a lamp and the resistive element as shown in FIG. 2A. With reference to FIG. 2B, the line Vr is the resistive voltage drop with current which is, obviously, linear, and the curve Vab is the sum of the drops across the resistor and the lamp. Of note is the negative resistance part of the curve VNEG1 where a cold discharge cathode lamp lights. As the cathode heats up the negative resistance portion changes to the curve marked VNEG2--hot cathode discharge. Under hot cathode conditions where Vab is reduced to reduce light output there will be a point where the applied voltage Vab will not reach the discharge peak A and the lamp will be permanently off. Before this point there will be an operating condition where the applied voltage is low and the lamp is off more than it is on. In this condition the cathode will cool raising the discharge threshold and causing erratic operation and eventual extinguishing of the lamp. This previously described operation is exacerbated when the feedback loop speed is slow. In the Micro Linear circuitry and Users Manual operates with a feedback loop speed that allows cathode cooling an associated erratic lamp operation. This is a limitation of slow feedback circuitry for controlling fluorescent lamp dimming.
The present invention teaches a feedback circuit that is one hundred times faster than that described in the Micro Linear application note. The unrecognized advantage of this faster feedback loop is that the cathode will not cool down allowing the operation at low lamp currents to be more predictable and controllable. Thus the hot cathode characteristic will allow lower light output than the cold cathode since the hot cathode will operate in the area marked 52 while the colder cathode use will be in the area marked 54.
FIG. 1 shows the current at low light with the slow Micro Linear circuit, and the graph of FIG. 2C shows the current with the faster feedback loop. Here there is only 50 microseconds where the lamp current is low and the lamp un-lighted. There is a peak of current every 50 microseconds which provides for flicker free operation and maintains the cathode at a high temperature so that the erratic nature of the lamp with a cooling cathode is avoided until much lower current levels are reached.
FIG. 4 shows the circuit of a preferred embodiment. 220 VAC 30 is input to a rectifying circuit 32 that provides a DC voltage to a totem pole MOSFETs Q1 and Q2. The transformer T1 and the related circuitry D25, R3, C18, R7 and d4 drives the MOSFETs producing an AC voltage with a frequency range from about 10K Hz to about 50K Hz. This signal is transferred to the lamp via the transformer T2 and C22 which provide the main resonant circuit. C16 is a DC blocking capacitor that provides a high voltage when at resonance. T4 is an isolation transformer that couples the high voltage to the lamp for ignition. C14 is another blocking capacitor to avoid the rectifying effect of the lamp itself. A winding on t2 leading to R3, D26, D6, R1, C6, and c2 provide power to IC1. T4, D10, and R35 convert current to voltage. This circuit produces a voltage signal proportional to the lamp current. D19, D21 and C5 are the lamp failure detecting circuit.
V1 is a varistor that protects the circuitry from high voltage spikes. Rectifying diodes D5, D7, D8, and D9 convert the AC signal to DC.
D22 is an anti-flickering diode. When power turned off if the voltage to IC1 is allowed to gradually fall off to ground there will be a flickering in the lamp. The filter capacitor voltage on C7 will not power IC1 (via R32) since D22 blocks the voltage on C7.
IC1 is the Micro Linear ML 4831 electronic Ballast Controller IC. In the Micro Linear Users Guide this chip is used in a dimming configuration which is significantly different from the circuit of the FIG. 4. The circuit changes between the circuitry of FIG. 4 and the Micro Linear circuits increase the loop speed by a factor of 100 in a preferred embodiment. The Micro Linear Users Guide is hereby incorporated herein by reference as though laid out in full. In particular, in the ML 4831 circuit CKT #1, there are several capacitors connecting to pins 1-4 and pin 18, In the inventive circuit of FIG. 4 these pins are grounded thereby eliminating five capacitors. In addition, in the ML 4831 CKT# 1, there are several resistors connecting to pin 5, and all of these resistors are in the 5 to 10K ohm range and higher. In FIG. 4 this resistor is changed to 10 ohms These are the changes that increase the loop speed by a factor of 100 in this preferred embodiment.
It will now be apparent to those skilled in the art that other embodiments, improvements, details and uses can be made consistent with the letter and spirit of the foregoing disclosure and within the scope of this patent, which is limited only by the following claims, construed in accordance with the patent law, including the doctrine of equivalents.
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An electronic drive for fluorescent lamps that includes a feedback loop arrangement where a lumen or intensity setting is compared to the lamp current and the frequency of an inverter is changed to bring the lumen output of the lamp to a level that matches the setting. The bandwidth of the feedback loop is great enough such that the time delay around the feedback loop is faster than prior art designs, and is preferably about 50 microseconds. This fast feedback loop provides the advantage that fluorescent lamps, and especially the more non-linear fluorescent lamps, can to be dimmed down to 10-30% of normal full scale lumen output without extinguishing. The faster feedback loop also prevents flicker when as the lamp is dimmed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/757,575 (Docket: CNTR.2582), filed on Feb. 1, 2013, which is herein incorporated by reference for all intents and purposes.
[0002] U.S. patent application Ser. No. 13/757,575 is a continuation of U.S. Nonprovisional patent application Ser. No. 13/747,038 (Docket: CNTR.2539), filed on Jan. 22, 2013.
[0003] This application is related to the following co-pending U.S. Patent Applications, each of which has a common assignee and common inventors.
[0000]
FILING
Ser. No.
DATE
TITLE
—
—
SOURCE SYNCHRONOUS DATA STROBE
(CNTR.2539-C1)
MISALIGNMENT COMPENSATION MECHANISM
—
—
SOURCE SYNCHRONOUS DATA STROBE
(CNTR.2539-C2)
MISALIGNMENT COMPENSATION MECHANISM
13/747,140
Jan. 22, 2013
APPARATUS AND METHOD FOR DYNAMIC
(CNTR.2540)
ALIGNMENT OF SOURCE SYNCHRONOUS BUS
SIGNALS
13/747,187
Jan. 22, 2013
SOURCE SYNCHRONOUS BUS SIGNAL ALIGNMENT
(CNTR.2576)
COMPENSATION MECHANISM
—
Feb. 1, 2013
APPARATUS AND METHOD FOR AUTOMATICALLY
(CNTR.2581)
ALIGNING DATA SIGNALS AND STROBE SIGNALS
ON A SOURCE SYNCRHONOUS BUS
—
—
APPARATUS AND METHOD FOR AUTOMATICALLY
(CNTR.2581-C1)
ALIGNING DATA SIGNALS AND STROBE SIGNALS
ON A SOURCE SYNCRHONOUS BUS
—
—
APPARATUS AND METHOD FOR AUTOMATICALLY
(CNTR.2581-C2)
ALIGNING DATA SIGNALS AND STROBE SIGNALS
ON A SOURCE SYNCRHONOUS BUS
—
—
APPARATUS AND METHOD FOR DYNAMICALLY
(CNTR.2582-C1)
ALIGNED SOURCE SYNCHRONOUS RECEIVER
BACKGROUND OF THE INVENTION
[0004] Field of the Invention
[0005] This invention relates in general to the field of microelectronics, and more particularly to an apparatus and method for synchronizing and clocks and data related to the transmission and reception of source synchronous signals.
[0006] Description of the Related Art
[0007] A present day computer system employs a source synchronous system bus to provide for exchange of data between bus agents, such as between a microprocessor and a memory hub. A “source synchronous” bus protocol allows for the transfer of data at very high bus speeds. Source synchronous protocols operate on the principle that a transmitting bus agent places data out on the bus for a fixed time period and asserts or switches a “strobe” signal corresponding to the data to indicate to a receiving bus agent that the data is valid. Both data signals and their corresponding strobe are routed over the bus along equal propagation paths (both physically and electromagnetically), thus enabling a receiver to be relatively certain that when switching of the corresponding strobe is detected, data is valid on the data signals. For purposes of the present invention, a bus agent may be any electronic element that utilizes source synchronous signaling for the transfer of data to/from another bus agent over a source synchronous bus. Exemplary bus agents may be, but are not limited to, central processing units (CPUs), microprocessors, memory controllers, memory hubs, chipsets, and graphics controllers. The source synchronous bus may also be known as a system bus, a front side bus, or a back side bus. Bus agents may be individually packaged, disposed on a motherboard, and interconnected by conductive traces on the motherboard. Additionally, a plurality of bus agents may be disposed within the same package that is mounted to a motherboard, where the plurality of bus agents may be individual dies within the package or they may be integrated into the same integrated circuit die and are interconnected via traces on the die.
[0008] Yet, source synchronous data strobes and data signals are subject to error for a number of different reasons. These inaccuracies may be the result of uncontrollable design margins, fabrication tolerances, or environmental factors such as voltage or temperature. In most cases, it is desired that a strobe signal switch precisely halfway through a data validity period so that there is equal set up and hold time for the data as seen at the receiver. However, inaccuracies resulting from the above factors may result in skewing of the data signals and/or their strobes such that reception conditions are not optimum. Consequently, operating frequency of associated devices is limited.
[0009] Another source of error may be caused by distribution of a strobe signal within a receiving device. While system designers go to great lengths to ensure that a strobe and its associated data signals are routed along the same propagation path on a system board (or, motherboard), it is well known that once the strobe enters the receiving device, it must be distributed to all of the internal synchronous receivers that are associated with that strobe. Some techniques for distributing a strobe signal to internal receivers simply adds propagation lengths that are required to route the strobe to the internal receivers, which may add delay over that of the data signals, thereby skewing the phase of the synchronous transmission. More recent mechanisms for strobe distribution also introduce buffering of the disturbed strobe signals, thereby skewing the phase of the synchronous transmission even more.
[0010] Therefore, what is needed are apparatus and methods that compensate for misalignment of signals and strobes on a source synchronous data bus, thus allowing optimization of a device's operating frequency.
[0011] What is also needed is a technique that allows the signals on a synchronous bus to be optimized for reception by modifying the phase alignment of a data strobe and its corresponding data signals.
[0012] What is furthermore needed is an automatic mechanism that allows the phase alignment of a data strobe and its associated data signals to be dynamically optimized at a receiving device.
[0013] What is moreover needed is an apparatus that is programmable at the motherboard level to compensate for fabrication and design inaccuracies, voltage variations, and temperature variations in an automated signal alignment mechanism.
[0014] What is additionally needed is a synchronous receiver that automatically compensates for misalignment of signals on a source synchronous data bus.
SUMMARY OF THE INVENTION
[0015] The present invention, among other applications, is directed to solving the above-noted problems and addresses other problems, disadvantages, and limitations of the prior art. In addition, the present invention provides a superior technique for automatically and dynamically optimizing the phase alignment of data signals and associated strobes that are received over a source synchronous bus. In one embodiment, an apparatus is provided that compensates for misalignment on a synchronous data bus, the apparatus includes a replica radial distribution element, a bit lag control element, and a synchronous lag receiver. The replica radial distribution element is configured to receive a first signal, and is configured to generate a second signal, where the replica radial distribution element comprises replicated propagation path lengths, loads, and buffering of a radial distribution network for a strobe. The bit lag control element is configured to measure, when an update signal is asserted, a propagation time beginning with assertion of the first signal and ending with assertion of the second signal, and is configured to generate a value on a lag bus that indicates the propagation time. The bit lag control element has delay lock control and a gray encoder. The delay lock control is configured to select one of a plurality of successively delayed versions of the first signal that coincides with the assertion of the second signal, where the delay lock control selects the one of a plurality of successively delayed versions of the first signal by incrementing and decrementing bus states of select inputs on a second mux, and where the plurality of successively delayed versions of the first signal comprises inputs to the mux. The gray encoder is configured to gray encode the propagation time to generate the value on the lag bus. The synchronous lag receiver is configured to receive one of a plurality of radially distributed strobes and a data bit, and is configured to delay registering of the data bit by the propagation time. The synchronous lag receiver includes a first plurality of matched inverters, a first mux, and a bit receiver. The first plurality of matched inverters is configured to generate successively delayed versions of the data bit. The first mux is coupled to the first plurality of matched inverters, and is configured to receive the value on the lag bus, and is configured to select one of the successively delayed versions of the data bit that corresponds to the value. The bit receiver is configured to receive the one of the successively delayed versions of the data bit and one of a plurality of radially distributed strobe signals, and is configured to register the state of the one of the successively delayed versions of the data bit upon assertion of the one of a plurality of radially distributed strobe signals.
[0016] In one aspect, the present invention contemplates an apparatus that compensates for misalignment on a synchronous data bus. The apparatus includes a microprocessor. The microprocessor has a replica radial distribution element, a bit lag control element, and a synchronous lag receiver. The replica radial distribution element is configured to receive a first signal, and is configured to generate a second signal, where the replica radial distribution element comprises replicated propagation path lengths, loads, and buffering of a radial distribution network for a strobe. The bit lag control element is configured to measure, when an update signal is asserted, a propagation time beginning with assertion of the first signal and ending with assertion of the second signal, and is configured to generate a value on a lag bus that indicates the propagation time. The bit lag control element has delay lock control and a gray encoder. The delay lock control is configured to select one of a plurality of successively delayed versions of the first signal that coincides with the assertion of the second signal, where the delay lock control selects the one of a plurality of successively delayed versions of the first signal by incrementing and decrementing bus states of select inputs on a second mux, and where the plurality of successively delayed versions of the first signal comprises inputs to the mux. The gray encoder is configured to gray encode the propagation time to generate the value on the lag bus. The synchronous lag receiver is configured to receive one of a plurality of radially distributed strobes and a data bit, and is configured to delay registering of the data bit by the propagation time. The synchronous lag receiver includes a first plurality of matched inverters, a first mux, and a bit receiver. The first plurality of matched inverters is configured to generate successively delayed versions of the data bit. The first mux is coupled to the first plurality of matched inverters, and is configured to receive the value on the lag bus, and is configured to select one of the successively delayed versions of the data bit that corresponds to the value. The bit receiver is configured to receive the one of the successively delayed versions of the data bit and one of a plurality of radially distributed strobe signals, and is configured to register the state of the one of the successively delayed versions of the data bit upon assertion of the one of a plurality of radially distributed strobe signals.
[0017] Another aspect of the present invention comprehends a method that compensates for misalignment on a synchronous data bus. The method includes: replicating propagation path lengths, loads, and buffering of a radial distribution network for a strobe; receiving a first signal, and generating a second signal by employing the replicated propagation path lengths, loads, and buffering; when an update signal is asserted, when an update signal is asserted, measuring a propagation time beginning with assertion of the first signal and ending with assertion of the second signal by selecting one of a plurality of successively delayed versions of the first signal that coincides with the assertion of the second signal, wherein said selecting comprises incrementing and decrementing bus states of select inputs on a mux, wherein the plurality of successively delayed versions of the first signal comprises inputs to the mux; gray encoding a value on a lag bus that indicates the propagation time; and receiving one of a plurality of radially distributed strobes and a data bit, and delaying registering of the data bit by the propagation time. The receiving includes generating successively delayed versions of the data bit; receiving the value on the lag bus, and selecting one of the successively delayed versions of the data bit that corresponds to the value; and registering the state of the one of the successively delayed versions of the data bit upon assertion of one of a plurality of radially distributed strobe signals.
[0018] Regarding industrial applicability, the present invention is implemented within a MICROPROCESSOR which may be used in a general purpose or special purpose computing device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects, features, and advantages of the present invention will become better understood with regard to the following description, and accompanying drawings where:
[0020] FIG. 1 is a block diagram illustrating a present day system wherein source synchronous data is transmitted and received;
[0021] FIG. 2 is a timing diagram depicting two source synchronous signaling scenarios that may occur in the present day system of FIG. 1 : one scenario in which a data strobe in a receiving device is in synchronization with associated data, and a second scenario in which the data strobe and the associated data are unsynchronized.
[0022] FIG. 3 is a block diagram featuring an apparatus for automated local synchronous signals alignment according to the present invention;
[0023] FIG. 4 is a block diagram showing an apparatus for automated dynamic synchronous signals alignment according to the present invention;
[0024] FIG. 5 is a block diagram one embodiment of a bit lag control element according to the present invention;
[0025] FIG. 6 is a block diagram showing a fuse-adjustable bit lag control element according to the present invention;
[0026] FIG. 7 is a block diagram illustrating a JTAG-adjustable bit lag control element according to the present invention;
[0027] FIG. 8 is a block diagram depicting a synchronous lag receiver according to the present invention; and
[0028] FIG. 9 is a block diagram detailing a precision delay element according to the present invention.
DETAILED DESCRIPTION
[0029] Exemplary and illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification, for those skilled in the art will appreciate that in the development of any such actual embodiment, numerous implementation-specific decisions are made to achieve specific goals, such as compliance with system-related and business related constraints, which vary from one implementation to another. Furthermore, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Various modifications to the preferred embodiment will be apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described herein, but is to be accorded the widest scope consistent with the principles and novel features herein disclosed.
[0030] The present invention will now be described with reference to the attached figures. Various structures, systems and devices are schematically depicted in the drawings for purposes of explanation only and so as to not obscure the present invention with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present invention. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
[0031] In view of the above background discussion on source synchronous signaling and associated techniques employed within present day devices for the transmission and reception of data, a discussion of the disadvantages and limitations of the present day techniques be discussed with reference to FIGS. 1-2 . Following this, a discussion of the present invention will be presented with reference to FIGS. 3-9 . The present invention overcomes these limitations and disadvantages by providing mechanisms that allow for the detection of the precise lag of a data strobe from associated data group bits in a receiving device and also techniques for delaying those associated data group bits in corresponding receivers thereby providing for correction of strobe and data misalignment caused by any of a number of reasons, thus enabling throughput to be optimized between the a transmitting device and a receiving device.
[0032] Turning to FIG. 1 , a block diagram is presented illustrating a present day computer system 100 where two or more bus agents 101 exchange data over a source synchronous system bus 102 . The bus agents 101 may be any element or elements of the computer system 100 that are employed to transmit or receive data via the bus 102 , as is alluded to above. The source synchronous bus 102 may be known by other names as well including, but not limited to, a system bus, a front side bus, and a back side bus.
[0033] As one skilled in the art will appreciate, a typical present day bus agent 101 may be embodied as, but not limited to, a microprocessor or central processing unit (CPU), a memory hub or memory controller, a chipset, a master or slave peripheral device, a direct memory access unit, a graphics controller, or another type of bus interface unit. In broad terms, to transfer data, one of the bus agents 101 will drive a subset of the signals on the bus 102 while another of the bus agents 101 detects and receives the driven signals, thus capturing the data that is represented by the states of one or more of the subset of the signals on the bus 102 . One or more of the bus agents 101 may be devices each disposed on an individual integrated circuit die and encapsulated in a device package, where the device package is disposed on a motherboard (or “system board”) by conventional means, and where the system bus 102 is disposed as metal traces (or “lands”) on the motherboard. Alternatively, two or more of the bus agents 101 may be devices each disposed on an individual integrated circuit die, where two or more of the integrated circuit die are disposed on a substrate and encapsulated in a single device package, and where the bus 102 is disposed as metal traces on the substrate, and where the single device package is disposed on a motherboard and is coupled to other device packages on the motherboard via interconnecting metal traces on the motherboard, where those interconnecting metal traces include the bus 102 . Furthermore, two or more of the bus agents 101 may be disposed on a single integrated circuit die that is encapsulated in a device package that is disposed on a motherboard, where the system bus 102 comprises metal traces on the single integrated circuit die to interconnect the two or more bus agents 101 , and also as metal traces on the motherboard to interconnect the device package housing the single integrated circuit die to other device packages disposed on the motherboard.
[0034] There are a number of different bus protocols provided for in the present day art for transferring data between two bus agents 101 , and it is beyond the scope of this application to include a detailed description of these various techniques. It is sufficient for purposes of the present application to appreciate that the “data” which is communicated between two or more bus agents 101 during a bus transaction may include, but is not limited to, address information, data that is associated with one or more addresses, control information, or status information. Regardless of the type of data that is communicated over the bus 102 , it is germane to this application that more and more present day computer systems 100 are employing a particular type of bus protocols commonly known as “source synchronous” protocols, to affect the transfer of data at very high bus speeds. In contrast to prior art sampled data bus protocols, source synchronous protocols operate on the principle that a transmitting bus agent 101 places data out on the bus 102 for a fixed time period (i.e., “setup time”) and asserts a “strobe” signal corresponding to the data to indicate to a receiving bus agent 101 that the data is valid. The transmitting bus agent 101 holds the data on the bus 102 for an amount of time (i.e., “hold time”) approximately equal to the setup time so that a receiving bus agent 101 can detect the state of the date prior to assertion of the strobe signal and to latch the data subsequent to assertion of the strobe signal. One skilled in the art will appreciate that the propagation path, to include physical and electromagnetic parameters, of one set of data and corresponding strobe signals, at very high transfer speeds, may very well be quite different from the propagation path that is associated with another set of signals on the bus, whether that propagation path is from the transmitting device to another receiving device or whether the propagation path is from the transmitting bus agent 101 to the same receiving bus agent 101 , but corresponds to another data group and the group's associated strobe signal. In particular, propagation delay, bus impedance, and electromagnetic characteristics of a propagation path affect the times (i.e., the setup and hold times) at which the data signals are stable, (i.e., “valid”) for reception by the receiving bus agent 101 . It is for this reason that source synchronous bus protocols are now prominent in the market of fielded devices. In a typical configuration, a data strobe that is associated with a corresponding set (or “group”) of data signals is purposely routed along the same propagation path as the set of data signals, and thus the strobe sees the same propagation characteristics as the data signals themselves. If the strobe is asserted during the period in which the data is valid (preferably such that setup and hold times are approximately equal), when the receiving bus agent 101 detects a valid transition of the strobe, it is relatively certain that the data signals will be valid as well.
[0035] To more particularly describe the interaction of signals on a source synchronous bus, attention is now directed to FIG. 2 , where is a timing diagram 200 is presented depicting two source synchronous signaling scenarios that may occur in the present day system of FIG. 1 : one scenario in which a data strobe in a receiving device is in synchronization with associated data, and a second scenario in which the data strobe and the associated data are unsynchronized. The diagram 200 shows interaction of signals within an exemplary data signal group for performing the data phase of an 8-byte burst bus transaction. For clarity, assertion of signals is shown in the diagram 200 as a logic low level, although one skilled in the art will appreciate that assertion can as well be indicated by a logic high level, or by toggling between a high and low levels. Cycles of a differential bus clock BCLK[1:0] are shown across the top of the timing diagram 200 . For an x86-compatible microprocessor, the bus clock BCLK[1:0] is distributed to all bus agents in order to facilitate synchronization of transactions between the bus agents.
[0036] A source synchronous protocol provides for a 16-bit data bus D[15:0] that supports transfer during the data phase of an 8-byte cache line over two cycles of the bus clock BCLK[1:0] through the employment of source synchronous data strobe signals DSTBPB 0 , DSTBNB 0 . The transfer of one byte over the 16-bit data bus D[15:0] is known as a beat, and 4 beats 1 - 4 , 5 - 8 are transferred during each cycle of the bus clock BCLK[1:0]. The data bus signals D[15:0] and their corresponding strobe signals DSTBPB 0 , DSTBNB 0 are routed along the same propagation path to individual bit receivers for each of the bits in D[15:0]. The falling edges of data strobe DSTBPB 0 are used to indicate validity of words 1 , 3 , 5 , and 7 on D[15:0]. The falling edges of data strobe DSTBNB 0 are used to indicate validity of words 2 , 4 , 6 , and 8 on D[15:0]. Note that the frequency of the data strobe signals DSTBPB 0 , DSTBNB 0 is twice that of the bus clock BCLK[1:0] and that the two strobes DSTBPB 0 , DSTBNB 0 exhibit a relative ½-cycle lag in phase. Consequently, the exemplary bus protocol supports transfer of four sets (i.e., beats) of data during a single bus clock cycle. The signals noted above are presented to teach aspects of the present invention, and for clarity sake bus interactions are simplified, however, as one skilled in the art will appreciate, the bus could be expanded to support any number of bits.
[0037] As one skilled in the art will acknowledge, a transmitting bus agent (e.g., microprocessor, chipset, or other bus agent) places its data D[15:0] on the bus and then asserts a corresponding data strobe DSTBPB 0 , DSTBNB 0 to indicate validity of the data, preferably halfway through the validity period of the data so that setup and hold times are approximately equal. Hence, in contrast to older, sampled data/address buses, where data was placed on the bus and held for a sampling period, the present synchronous bus mechanisms strobe data out over bus subgroups in a plurality of bursts, where the validity of each burst is indicated by the state of the corresponding strobe DSTBPB 0 , DSTBNB 0 , and since the corresponding strobe DSTBPB 0 , DSTBNB 0 is routed along the same propagation path as its associated data signals D[15:0], it is virtually certain that when a receiver detects assertion of the data strobe DSTBPB 0 , DSTBNB 0 , the associated data D[15:0] will be valid.
[0038] From the perspective of a receiving bus agent, assertions of the data/address strobes DSTBPB 0 , DSTBNB 0 appear to be indeterminate with respect to assertions of the bus clock BCLK#, but as alluded to above, the period for each of the data strobes DSTBPB 0 , DSTBNB 0 is equal to approximately one-half of the period of the bus clock BCLK#. As previously noted, the timing of data and strobe transitions is indeed a function of the bus clock frequency, but at a receiving bus agent the switching of any given data strobe seems, for all intents and purposes, to be asynchronous to the bus clock BCLK[1:0]. This is because there is a fixed, but unknown, phase difference between the bus clock BCLK[1:0] and transitions of the data subgroup signals and corresponding data strobes as the bus clock may BCLK[1:0] have traversed a different propagation path between a clock generator and the receiving bus agent.
[0039] Note that the transitions of D[15:0] and associated strobes DSTBPB 0 , DSTBNB 0 in a first scenario 201 appear to be in phase with the transitions of BCLK[1:0] while the transitions of D[15:0] and associated strobes DSTBPB 0 , DSTBNB 0 in a second scenario 202 appear to have no phase relationship with BCLK[1:0] whatsoever. These differences may be due to that manner in which a transmitting bus agent transfers data over the bus, or it may be due to a different propagation path length for the data bus D[15:0] relative to BCLK[1:0], or it may be due to both transmitter characteristics and propagation path lengths.
[0040] As long as the data signals within the bus D[15:0] are received approximately in proper phase with their corresponding strobe signals DSTBPB 0 , DSTBNB 0 , because setup and hold times are approximately equal, effective data transfer can be accomplished at very high bus speeds. This is the case illustrated the first scenario 201 . Note that at time T 1 , from the perspective of the receiving bus agent, DSTBPB 0 is asserted halfway through the period when burst 1 is valid on the bus, thus enabling optimum conditions for reception of the burst 1 . Likewise, at time T 2 , from the perspective of the receiving bus agent DSTBNB 0 is asserted halfway through the period when burst 4 is valid on the bus, thus enabling optimum conditions for reception of the burst 4 .
[0041] The conditions in the first scenario 201 , although desirable, are not realistic. This is because at the high speeds corresponding to a present day synchronous data bus, even the propagation paths and corresponding loads within a receiving device affect the relative skew of each of the data bits D[15:0] and their corresponding strobe signals DSTBPB 0 , DSTBNB 0 . In prior art designs, data bit signals and strobe signals were routed using brute force techniques such that the signals and strobes incurred the least amount of propagation path delay and loading that was possible on a die. And because each bit was individually routed to its receiver, the phase difference between data bit and strobe signal varied from receiver to receiver.
[0042] Because these individual propagation paths differ internal to a receiving device, designers often utilize a radial distribution scheme for the strobe where an equivalent propagation path (including loads and buffering) is applied to every distributed strobe signal. The result is that the phase lag between every data bit within the subgroup and their respective distributed strobe signal, as seen at a bit receiver, is approximately equal. Thus, radial distribution introduces phase lags into distributed strobe signals so that each of the receivers within a data group see the same amount of lag in their respective strobe signal relative to their corresponding data bit. Radial distribution schemes are very useful from a design standpoint because every data bit in a group sees the same phase lag for its corresponding strobe. However, the present inventors have observed that radial distribution limits the operating frequency of a device as a result of the lag that is introduced into the strobe signals. That is, setup times are much longer than hold times, which limits overall operating frequency.
[0043] This case is what is depicted for in the second scenario 202 for D[15:0], which for purposes of illustrating an extreme case, renders its associated data bit receivers inoperable. That is, because DSTBPB 0 and DSTBNB 0 are distributed to data bit receivers for bits D[15:0] within the receiving bus agent according to a radial distribution scheme, the amount of lag introduced into the distributed strobes causes the distributed strobes to be asserted when the data bits D[15:0] are no longer valid. Clearly, this is undesirable. Consider that at time T 3 , from the perspective of the bit receivers, DSTBPB 0 is asserted when burst 5 is no longer valid on the bus, thus precluding any chance for reception of the burst 5 . Likewise note that at time T 4 , DSTBNB 0 is asserted when burst 8 is no longer valid on the bus, thus precluding any chance for reception of the burst 8 .
[0044] In order to compensate for misalignment of a data bit and its corresponding data strobe, as noted above, various techniques are provided for in the art to introduce phase lag into data bits within a subgroup, or to accelerate assertion of data strobe signals, so that the signals (in the presence of radial strobe distribution) are optimally aligned. Yet, all of these mechanisms require experimentation, testing, circuitry external to a device, and/or programming of devices comprising a system on a motherboard. And the present inventors have noted that such experimentation, testing, circuitry, and/or programming is limiting in that each design must be uniquely configured to compensate for differences in the phase of a data strobe signal and its associated data bits, when the phase difference is chiefly due to radial distribution of the data strobe signal within a given receiving device.
[0045] In addition, the present inventors note that although the length of any particular propagation path for a strobe signal may be known, even in the presence of a radial distribution scheme, the timing of this path (and the resultant phase lag) will dynamically change as a result of voltage, temperature, and fabrication process variations. Consequently, to introduce a specified amount of phase delay into data bits within a subgroup, as is presently provided for by the prior art, is a suboptimal compensation technique at best.
[0046] The present invention overcomes the above noted limitations and disadvantages, and others, by providing a mechanism that automatically and dynamically aligns the phase of a data strobe and its associated data bit signals within a receiving device. The present invention dynamically adjusts the alignment of these signals as environmental factors (e.g., voltage, temperature, and process) change within a host device. The present invention will now be discussed with reference to FIGS. 3-9 .
[0047] Referring now to FIG. 3 , a block diagram is presented featuring an apparatus 300 for automated local synchronous signals alignment according to the present invention. The apparatus 300 is preferably disposed within a receiving device (e.g., “bus agent”) that is coupled to a source synchronous bus, such as has been discussed above. In one embodiment, the receiving device comprises an x86-compatible microprocessor disposed as a die within an integrated circuit package that is physically coupled to a motherboard or system board. In another embodiment, the receiving device comprises an x86-compatible microprocessor configured as one or a plurality of x86-compatible microprocessors disposed on a single die within an integrated circuit package. One or more of the apparatuses 300 may be included within the receiving device to synchronize one or more data groups and their corresponding strobe signals, regardless of the type of data involved (e.g., data, address, or control). The apparatus 300 includes a radial distribution element 303 for a synchronous data strobe DSTROBE, as will be described below in further detail. The radial distribution element 303 equalizes all of the propagation paths (including loads and buffering) for DSTROBE as it is distributed. DSTROBE is received from a transmitting device (e.g., “bus agent”) (not shown) as is described above.
[0048] The apparatus 300 may have a plurality of synchronous lag receivers 304 configured to receive one or more data bit signals DATA 1 -DATAN along with phase-aligned and load-matched strobe signals DSTROBE 1 -DSTROBN, which are derived from DSTROBE. A first one of the plurality of data signals DATA 1 enters the receiving device at a first point 311 and a first signal 312 is routed to a first synchronous receiver 304 . A last one of the plurality of data signals DATAN enters the device at a last point 3 N 1 and a last signal 3 N 2 is routed to its associated synchronous receiver 304 . The receivers 304 output respective received data signals OUT 1 -OUTN.
[0049] The data strobe DSTROBE enters the device at point 301 where an internal strobe signal 302 is routed to a strobe receiver 313 , which receives the strobe signal 302 . The output of the strobe receiver 313 is coupled the radial distribution element 303 . The radial distribution element 303 includes a plurality of delay elements 303 . 1 - 303 .N, each associated with a corresponding one of the plurality of synchronous receivers 304 . Each of the plurality of delay elements 303 . 1 - 303 .N is configured to introduce a portion of a radial propagation path into the propagation path of DSTROBE as it is routed from the radial distribution element 303 to a corresponding receiver 304 . In one embodiment, the radial propagation path may comprise a worst-case path in terms of load, trace length, and buffering that is associated with one of a plurality of distributed strobe signals DSTROBE 1 -DSTROBEN. The portion of the radial propagation path corresponding to a particular receiver 304 introduces additional propagation length, load, and buffering beyond the length, load, and buffering associated with the corresponding strobe signal DSTROBE 1 -DSTROBEN such that the cumulative length, load, and buffering for that corresponding strobe signal DSTROBE 1 -DSTROBEN is equal to the radial propagation path described above. Thus, from the perspective of a particular receiver 304 , its corresponding data strobe signal DSTROBE 1 -DSTROBEN lags its corresponding data signal 321 - 3 N 2 in phase by the same amount as is seen by all other receivers 304 within a given data subgroup.
[0050] The apparatus 300 also includes bit lag control 305 that receives the data strobe signal 302 , an update signal UPDATE, and one of the plurality of distributed data strobe signals DSTROBEN. In one embodiment, the bit lag control generates a 4-bit lag bus LAG[3:0] that indicates an amount of phase that the distributed strobe signals DSTROBE 1 -DSTROBEN lag behind the received data strobe signal DSTROBE. The lag bus LAG[3:0] is routed to each of the lag receivers 304 in the data subgroup.
[0051] Operationally, when UPDATE is asserted, the bit lag control 305 measures the lag between assertion of DSTROBE and assertion of DSTROBEN when DSTROBE is received by the receiving device, and the lag is indicated by the value of LAG[3:0]. The receivers 304 may register the value of LAG[3:0] and introduce an equal amount of lag into their corresponding data signals 312 - 3 N 2 during a following data cycle when DSTROBE is asserted. Thus, the amount of phase lag in the distributed data strobe signals DSTROBE 1 -DSTROBEN is updated at each data cycle and this lag is employed for a following data cycle, where each of the receivers 304 will introduce this same amount of delay into reception of their corresponding data signal 312 - 3 N 2 , consequently centering assertion of the distributed data strobe signals DSTROBE 1 -DSTROBEN in a period when the data signals 312 - 3 N 2 are valid. Accordingly, the present invention delays each of the data signals 312 - 3 N 2 by an amount indicated by LAG[3:0] to provide for equal setup and hold times for each of the receivers 304 , thus allowing higher frequency bus transactions than have heretofore been provided for.
[0052] A 4-bit lag bus LAG[3:0] is employed to provide an acceptable amount of resolution in the amount of lag delay, however higher or lower resolution may be achieved by increasing or decreasing the complexity of the bit lag control 305 , the number of bits on the lag bus LAG[3:0], and the complexity of the receivers 304 to introduce lag.
[0053] Signal UPDATE may be deasserted for any number of well known reasons to include reset states, sleep states, power control, and the like. In one embodiment, when UPDATE is not asserted, the bit lag control 305 may not update the value of the lag bus LAG[3:0], and the former value is employed by the receivers 304 during all subsequent data cycles until UPDATE is again asserted.
[0054] As one skilled in the art will appreciate, the worst-case propagation path (and the resulting lag) dynamically changes as a function of temperature, voltage, operating frequency, and fabrication process variation (die-to-die variation and also point-to-point location variation on a die). Advantageously, since the amount of lag measured by the bit lag control 305 is replicated by each of the receivers 304 , the value indicated by LAG[3:0] also dynamically adjusts as a function of the above noted attribute variations.
[0055] The apparatus 300 according to the present invention is configured to perform the functions and operations as discussed above. The apparatus 300 comprises logic, circuits, devices, or microcode, or a combination of logic, circuits, devices, or microcode, or equivalent elements that are employed to execute the functions and operations according to the present invention as noted. The elements employed to accomplish these operations and functions within the apparatus 300 may be shared with other circuits, microcode, etc., that are employed to perform other functions and/or operations within the receiving device.
[0056] The apparatus 300 provides a mechanism that directly measures the lag between a received strobe DSTROBE and its distributed strobe signals DSTROBE 1 -DSTROBEN, and thus provides a simple technique for compensating for radial strobe lag within a particular data subgroup. However, the present inventors have noted that alternative embodiments of the present invention may provide for a more timely dynamic adjustment of the lag by employing a replica radial distribution mechanism where the lag is measured offline. That is, according to the alternative embodiments, the lag may be measured and distributed to lag receivers asynchronous to when the synchronous bus is active. Accordingly, attention is now directed to FIG. 4 , where a block diagram is presented showing an apparatus 400 for automated dynamic synchronous signals alignment according to the present invention.
[0057] The apparatus 400 is preferably disposed within a receiving device that is coupled to a source synchronous bus, such as has been discussed above. In one embodiment, the receiving device comprises an x86-compatible microprocessor disposed as a die within an integrated circuit package that is physically coupled to a motherboard or system board. In another embodiment, the receiving device comprises an x86-compatible microprocessor configured as one or a plurality of x86-compatible microprocessors disposed on a single die within an integrated circuit package. One or more of the apparatuses 400 may be included within the receiving device to synchronize one or more data groups and their corresponding strobe signals, regardless of the type of data involved (e.g., data, address, or control). Like the apparatus 300 discussed with reference to FIG. 3 , the apparatus 400 of FIG. 4 includes a radial distribution element 403 for a synchronous data strobe DSTROBE, as will be described below in further detail. The radial distribution element 403 equalizes all of the propagation paths (including loads and buffering) for DSTROBE. DSTROBE is received from a transmitting bus agent (not shown) as described above.
[0058] The apparatus 400 has a plurality of synchronous lag receivers 404 configured to receive one or more data bit signals DATA 1 -DATAN along with phase-aligned and load-matched strobe signals DSTROBE 1 -DSTROBN, which are derived from DSTROBE. A first one of the plurality of data signals DATA 1 enters the receiving device at a first point 411 and a first signal 412 is routed to a first synchronous receiver 404 . A last one of the plurality of data signals DATAN enters the device at a last point 4 N 1 and a last signal 4 N 2 is routed to its associated synchronous receiver 404 . The receivers 404 output respective received data signals OUT 1 -OUTN.
[0059] The data strobe DSTROBE enters the device at point 401 where an internal strobe signal 402 is routed to a strobe receiver 413 , which receives the strobe signal 402 . The output of the strobe receiver 413 is coupled the radial distribution element 403 . The radial distribution element 403 includes a plurality of delay elements 403 . 1 - 403 .N, each associated with a corresponding one of the plurality of synchronous receivers 404 . Each of the plurality of delay elements 403 . 1 - 403 .N is configured to introduce a portion of a radial propagation path into the propagation path of DSTROBE as it is routed from the radial distribution element 403 to a corresponding receiver 404 . In one embodiment, the radial propagation path comprises a worst-case path in terms of load, trace length, and buffering that is associated with one of a plurality of distributed strobe signals DSTROBE 1 -DSTROBEN. The portion of the radial propagation path corresponding to a particular receiver 404 introduces additional propagation length, load, and buffering beyond the length, load, and buffering associated with the corresponding strobe signal DSTROBE 1 -DSTROBEN such that the cumulative length, load, and buffering for that corresponding strobe signal DSTROBE 1 -DSTROBEN is equal to the radial propagation path described above. Thus, from the perspective of a particular receiver 404 , its corresponding data strobe signal DSTROBE 1 -DSTROBEN lags its corresponding data signal 412 - 4 N 2 in phase by the same amount as all other is seen by all other receivers 404 within a given data subgroup.
[0060] The apparatus 400 also includes a replica strobe receiver element (REPRCVR) 415 , that receives a lag pulse signal LAGPLS. In one embodiment, LAGPLS may be an internal clock signal. The replica strobe receiver element 415 is a matched replica of the strobe receiver 413 . The output of the replica receiver 415 is coupled to a replica radial distribution element 406 that is a replica of the radial distribution element 403 , including a matched circuit configuration, propagation path lengths, loads, and buffering. The replica radial distribution element 406 includes a plurality of delay elements 406 . 1 - 406 .N, each associated with a corresponding one of the plurality of synchronous receivers 404 . Each of the plurality of delay elements 406 . 1 - 406 .N is configured to introduce a portion of a radial propagation path into the propagation path of DSTROBE as it is routed from the radial distribution element 403 to a corresponding receiver 404 . In one embodiment, the radial propagation path comprises a worst-case path in terms of load, trace length, and buffering that is associated with one of a plurality of distributed strobe signals DSTROBE 1 -DSTROBEN. In another embodiment, the replica radial distribution element 406 may comprise only one delay element 406 .X, which replicates the worst-case path. One of the outputs REPS 1 of the replica radial distribution element 406 is coupled to a bit lag control element 405 , which generates an output lag bus LAG[3:0], and which is coupled to each of the receivers 404 . An update signal UPDATE and LAGPLS are coupled as well to the bit lag control 405 . In one embodiment, the bit lag control 405 generates a 4-bit lag bus LAG[3:0] that indicates an amount of phase that the output REPS 1 lags behind LAGPLS. Since the combination of elements 415 and 406 completely replicates the propagation path exhibited by the strobe receiver 413 and radial distribution element 403 , it is noted that the amount of phase lag indicated by LAG[3:0] represents the same phase lag that is exhibited by the strobe receiver 413 and the radial distribution element 403 , and thus is substantially equivalent to the amount of phase that the distributed strobes DSTROBE 1 -DSTROBEN lag behind DSTROBE.
[0061] Operationally, when UPDATE is asserted, the bit lag control 405 measures the lag between assertion of LAGPLS and assertion of RESP 1 , and the lag is indicated by the value of LAG[3:0]. In one embodiment, LAGPLS is a continuous signal derived from a core processor clock signal (not shown). In one embodiment, UPDATE is asserted every 64 cycles of the core processor clock signal. Other embodiments are contemplated as well, with the express purpose of ensuring a timely update of LAG[3:0] without exhibiting a processing or power burden on remaining elements of a bus agent. The receivers 404 register the value of LAG[3:0] and introduce an equal amount of lag into their corresponding data signals 412 - 4 N 2 during a next data cycle when DSTROBE is asserted. Thus, the amount of phase lag in the distributed data strobe signals DSTROBE 1 -DSTROBEN is updated at each data cycle, as replicated by pulsing LAGPLS through the replica receiver 415 and distribution element 406 , and this lag is employed for a next data cycle and all data cycles occurring until the next periodic update of LAG[3:0], where each of the receivers 404 will introduce this same amount of delay into reception of their corresponding data signal 412 - 4 N 2 , consequently centering assertion of the distributed data strobe signals DSTROBE 1 -DSTROBEN in a period when the data signals 412 - 4 N 2 are valid. Accordingly, the present invention delays each of the data signals 412 - 4 N 2 by an amount indicated by LAG[3:0] to provide for equal setup and hold times for each of the receivers 404 , thus allowing higher frequency bus transactions than have heretofore been provided for.
[0062] In contrast to the local alignment apparatus 300 of FIG. 3 , the dynamic alignment apparatus 400 of FIG. 4 does not depend upon assertion of DSTROBE in order to measure and indicate how much a distributed strobe DSTROBE 1 -DSTROBEN will lag behind the data strobe DSTROBE.
[0063] The 4-bit lag bus LAG[3:0] is employed to provide an acceptable amount of resolution in the amount of lag delay, however higher or lower resolution may be achieved by increasing or decreasing the complexity of the bit lag control 405 , the number of bits on the lag bus LAG[3:0], and the complexity of the receivers 404 .
[0064] Signal UPDATE may be deasserted for any number of well known reasons to include reset states, sleep states, power control, and the like. When UPDATE is not asserted, the bit lag control 405 does not update the value of the lag bus LAG[3:0], and the former value is employed by the receivers 404 during subsequent data cycles.
[0065] The apparatus 400 according to the present invention is configured to perform the functions and operations as discussed above. The apparatus 400 comprises logic, circuits, devices, or microcode, or a combination of logic, circuits, devices, or microcode, or equivalent elements that are employed to execute the functions and operations according to the present invention as noted. The elements employed to accomplish these operations and functions within the apparatus 400 may be shared with other circuits, microcode, etc., that are employed to perform other functions and/or operations within the receiving device.
[0066] Turning to FIG. 5 , a block diagram is presented detailing one embodiment of a bit lag control element 500 according to the present invention. The bit lag control 500 may be employed in the embodiments of FIGS. 3 and 4 . The bit lag control 500 includes a delay element 501 that is coupled to a mux 502 . The mux 502 is coupled to delay lock control 503 via signal SLAG. The delay lock control 503 generates a 4-bit lag select signal LAGSELECT[3:0] that is coupled to the mux 502 and to a gray encoder 504 . An update signal UPDATE is coupled to the gray encoder 504 , which generates a gray-encoded 4-bit lag signal LAG[3:0] indicating the number of matched inverter pairs U 1 A/B-U 15 A/B that a radially distributed pulse RESP 1 lags behind a lag clock pulse LAGCLK.
[0067] The delay element 501 and the delay lock control 503 receive the lag clock LAGCLK. The delay lock control 503 also receives the distributed lag clock REPS 1 . In the embodiment of FIG. 3 , LAGCLK is represented by signal DSTROBE and REPS 1 is represented by DSTROBEN. In the apparatus 400 of FIG. 4 , LAGCLK is represented by LAGPLS and REPS 1 is represented by the like-named signal. The delay element 501 includes a plurality of inverter pairs U 1 A/B-U 15 A/B. A tap LC 0 -LC 15 is coupled to each of the pairs U 1 A/B-U 15 A/B, and the taps LC 0 -LC 15 are coupled to the register mux 502 . In the embodiment of FIG. 5 , 15 inverter pairs U 1 A/B-U 15 A/B are depicted having matched inverters U 1 A/B-U 15 A/B each exhibiting a delay of 20 picoseconds per inverter U 1 A/B-U 15 A/B (40 picoseconds per inverter pair U 1 A/B-U 15 A/B, which is acceptable resolution for measuring phase lag in a receiving device operating at but speeds from approximately 500 Megahertz to 1.5 Gigahertz. Other embodiments are contemplated comprising different numbers of inverter pairs U 1 A/B-U 15 A/B as is appropriate with the application. An inverter pair U 1 A/B-U 15 A/B exhibiting a 40 picosecond delay is commensurate with receiving devices fabricated according to a 28-nanometer CMOS fabrication process and operating within the aforementioned frequency range. It is noted that the configuration shown in FIG. 5 is presented to teach the present invention and that modifications can be made to provide accuracy and resolution under different fabrication processes and different operating frequencies.
[0068] As noted above, the gray encoder 504 generates a gray-encoded bus LAG[3:0] that indicates the amount of time that RESP 1 lags in phase behind LAGCLK, which is the amount of time that it takes for a data strobe to propagate through a radial distribution network up to a data bit receiver according to the present invention.
[0069] In operation, UPDATE enables or disables operation of the bit lag control 500 , as has been described above. When UPDATE is asserted, upon assertion of LAGCLK, successively delayed versions of LAGCLK are generated by the delay element 501 and are provided on taps LC 0 -LC 15 to the mux 502 . The delay lock control increments or decrements the value of LAGSELECT[3:0] in order to select one of the taps LC 0 -LC 15 on signal SLAG such that the value of SLAG is equal to RESP 1 subsequent to assertion of LAGCLK. Thus, the delay lock control 503 operates substantially similar to a delay lock loop in order to converge on a phase delay that is one inverter pair U 1 A/B-U 15 A/B less than the delay corresponding to one of the inverter pairs U 1 A/B-U 15 A/B. In one embodiment, to provide for stability of the bit lag control 500 , once a phase lag is locked in place, the delay lock control increments/decrements LAGSELECT[3:0] about the selected value such that changes of measured delay vary only by one bit.
[0070] In one embodiment, measurement of the phase lag operates independently and asynchronously from assertion of the update signal UPDATE. When UPDATE is asserted, the gray-encoded value of LAGSELECT[3:0] is placed on bus LAG[3:0]. Accordingly, a 4-bit value of 0011 on LAGSELECT[3:0] may indicate that RESP 1 lags behind LAGCLK by 120 picoseconds under certain temperature, voltage, and frequency conditions. But since the present invention is configured to provide for automatic and dynamic measurement of phase lag and adjustment of the same timing in a data bit receiver, it is more precise to state that the above noted value of LAGSELECT[3:0] indicates that RESP 1 lags behind LAGCLK by three inverter pairs U 1 A/B-U 15 A/B. Since matched replicas of these inverter pairs U 1 A/B-U 15 A/B are present in every data bit receiver according to the present invention, this phase “delay” can be replicated at each of the data bit receivers to provide for optimum reception of data.
[0071] The gray-encoded 4-bit lag bus LAG[3:0] is distributed to each of the data bit receivers that are associated with the radial distribution network being measured. Typically, these will comprise all of the data bit receivers in a particular data subgroup that each are activated by the same synchronous data strobe signal. In one embodiment, a different bit lag control 500 is employed for each different radial distribution network. In alternative embodiments, the gray encoder 504 may be deleted and the lag select bus LAGSELECT[3:0] is sent directly to the receivers. In such alternative embodiments, provisions must be made to accommodate glitches in LAGSELECT[3:0].
[0072] The apparatus 500 according to the present invention is configured to perform the functions and operations as discussed above. The apparatus 500 comprises logic, circuits, devices, or microcode, or a combination of logic, circuits, devices, or microcode, or equivalent elements that are employed to execute the functions and operations according to the present invention as noted. The elements employed to accomplish these operations and functions within the apparatus 500 may be shared with other circuits, microcode, etc., that are employed to perform other functions and/or operations within the receiving device.
[0073] Now turning to FIG. 6 , a block diagram is presented showing a fuse-adjustable bit lag control element 600 according to the present invention. The bit lag control element 600 is provided to enable the amount of delay indicated by a delay lock control element 603 via LAGSELECT[3:0] in such a manner as to provide compensation for lot variations, process variations, and other factors that may come to light during or following manufacture of a host device. The bit lag control 600 may be employed in the embodiments of FIGS. 3 and 4 . The bit lag control 600 includes a delay element 601 that is coupled to a mux 602 . The mux 602 is coupled to delay lock control 603 via signal SLAG. The delay lock control 603 generates a 4-bit lag select signal LAGSELECT[3:0] that is coupled to the mux 602 and to adjust logic 606 . The adjust logic 606 is coupled to a gray encoder 604 . The adjust logic 606 is also coupled to an adjust value ADJVAL 605 via bus SUB[1:0]. An update signal UPDATE is coupled to the gray encoder 604 , which generates a gray-encoded 4-bit lag signal LAG[3:0] indicating the number of matched inverter pairs U 1 A/B-U 15 A/B that a radially distributed pulse RESP 1 lags behind a lag clock pulse LAGCLK, as adjusted by the value indicated on SUB[1:0].
[0074] The delay element 601 and the delay lock control 603 receive the lag clock LAGCLK. The delay lock control 603 also receives the distributed lag clock REPS 1 . In the embodiment of FIG. 3 , LAGCLK is represented by signal DSTROBE and REPS 1 is represented by DSTROBEN. In the apparatus 400 of FIG. 4 , LAGCLK is represented by LAGPLS and REPS 1 is represented by the like-named signal. The delay element 601 includes a plurality of inverter pairs U 1 A/B-U 15 A/B. A tap LC 0 -LC 15 is coupled to each of the pairs U 1 A/B-U 15 A/B, and the taps LC 0 -LC 15 are coupled to the register mux 602 . In the embodiment of FIG. 6 , 15 inverter pairs U 1 A/B-U 15 A/B are depicted having matched inverters U 1 A/B-U 15 A/B each exhibiting a delay of 20 picoseconds per inverter U 1 A/B-U 15 A/B (40 picoseconds per inverter pair U 1 A/B-U 15 A/B, which is acceptable resolution for measuring phase lag in a receiving device operating at but speeds from approximately 500 Megahertz to 1.5 Gigahertz. Other embodiments are contemplated comprising different numbers of inverter pairs U 1 A/B-U 15 A/B as is appropriate with the application.
[0075] The gray encoder 604 generates a gray-encoded bus LAG[3:0] that indicates the amount of time that RESP 1 lags in phase behind LAGCLK, as adjusted by the value of bus ALAG[3:0], which is an adjusted amount of time that it takes for a data strobe to propagate through a radial distribution network up to a data bit receiver according to the present invention.
[0076] In operation, UPDATE enables or disables operation of the bit lag control 600 , as has been described above. When UPDATE is asserted, upon assertion of LAGCLK, successively delayed versions of LAGCLK are generated by the delay element 601 and are provided on taps LC 0 -LC 15 to the mux 602 . The delay lock control increments or decrements the value of LAGSELECT[3:0] in order to select one of the taps LC 0 -LC 15 on signal SLAG such that the value of SLAG is equal to RESP 1 subsequent to assertion of LAGCLK. Thus, the delay lock control 603 operates substantially similar to a delay lock loop in order to converge on a phase delay that is one inverter pair U 1 A/B-U 15 A/B less than the delay corresponding to one of the inverter pairs U 1 A/B-U 15 A/B. In one embodiment, to provide for stability of the bit lag control 600 , once a phase lag is locked in place, the delay lock control increments/decrements LAGSELECT[3:0] about the selected value such that changes of measured delay vary only by one bit.
[0077] In operation, the adjust logic 606 that receives a compensation value over bus SUB[1:0] and performs a subtraction function, in one embodiment, from LAGSELECT[3:0]. The amount to be subtracted from LAGSELECT[3:0] is indicated by the value of signal SUB[1:0], which is received from the ADJVAL logic 605 . In one embodiment, SUB[1:0] indicates a number of bits to right shift the valued of LAGSELECT[3:0]. Then the right-shifted version of LAGSELECT[3:0] is subtracted from LAGSELECT[3:0] by the adjust logic 606 to produce an adjusted 4-bit vector ALAG[3:0]. In one embodiment, the number of bits to right shift LAGSELECT[3:0] is as shown below in Table 1.
[0000]
TABLE 1
Adjustment Values for 4-Bit Select Vector
NUMBER OF BITS
SUB[1:0] VALUE
TO RIGHT SHIFT
00
0 BITS
01
1 BIT
10
2 BITS
11
3 BITS
[0078] In one embodiment, the ADJVAL logic 605 comprises one or more metal or poly fuses which are blown during fabrication of the device or IC. An alternative embodiment contemplates the ADJVAL logic circuit 606 as programmable, read-only memory located on the device or IC. A further alternative embodiment comprehends ADJVAL logic 605 that is located off the device or IC and that provides SUB[1:0] as signals to I/O pins (not shown) on the device or IC. Other embodiments of the ADJVAL logic 605 are contemplated as well, to include, but not limited to, a number of signals of bus SUB which are more or less than two signals. By providing the ADJVAL logic circuit 605 and the adjust logic circuit 606 , a designer is allowed to tweak the amount of delay indicated by the delay lock control 603 via LAGSELECT[3:0] in such a manner as to provide compensation for lot variations, process variations, and other factors that may come to light during or following manufacture of the IC. The adjust logic 606 thus generates an adjusted 4-bit select vector ALAG[3:0] by subtracting a right-shifted value of LAGSELECT[3:0] from LAGSELECT[3:0] as indicated by SUB[1:0].
[0079] In one embodiment, measurement of the phase lag operates independently and asynchronously from assertion of the update signal UPDATE. When UPDATE is asserted, the gray-encoded value of ALAG[3:0] is placed on bus LAG[3:0]. Accordingly, a 4-bit value of 0011 on LAGSELECT[3:0] may indicate that RESP 1 lags behind LAGCLK by 120 picoseconds under certain temperature, voltage, and frequency conditions. But since the present invention is configured to provide for automatic and dynamic measurement of phase lag and adjustment of the same timing in a data bit receiver, it is more precise to state that the above noted value of LAGSELECT[3:0] indicates that RESP 1 lags behind LAGCLK by three inverter pairs U 1 A/B-U 15 A/B. Since matched replicas of these inverter pairs U 1 A/B-U 15 A/B are present in every data bit receiver according to the present invention, this phase “delay” can be replicated at each of the data bit receivers to provide for optimum reception of data. A value of 01 on SUB[1:0] indicates to the adjust logic 606 to right shift the value of LAGSELECT[3:0] by one bit and subtract this right shifted value (i.e., 0001) from the true value of LAGSELECT[3:0] (i.e., 0011), yielding a value of LAG[3:0] of 0010, which indicates that RESP 1 lags behind LAGCLK by only 80 picoseconds, as opposed to the 120-picosecond lag indicated by LAGSELECT[3:0].
[0080] The gray-encoded 4-bit lag bus LAG[3:0] is distributed to each of the data bit receivers that are associated with the radial distribution network being measured. Typically, these will comprise all of the data bit receivers in a particular data subgroup that each are activated by the same synchronous data strobe signal. In one embodiment, a different bit lag control 600 is employed for each different radial distribution network. In alternative embodiments, the gray encoder 604 may be deleted and the adjusted lag select bus ALAG[3:0] is sent directly to the receivers. In such alternative embodiments, provisions must be made to accommodate glitches in LAGSELECT[3:0].
[0081] The apparatus 600 according to the present invention is configured to perform the functions and operations as discussed above. The apparatus 600 comprises logic, circuits, devices, or microcode, or a combination of logic, circuits, devices, or microcode, or equivalent elements that are employed to execute the functions and operations according to the present invention as noted. The elements employed to accomplish these operations and functions within the apparatus 600 may be shared with other circuits, microcode, etc., that are employed to perform other functions and/or operations within the receiving device.
[0082] Now turning to FIG. 7 , a block diagram is presented showing a JTAG-adjustable bit lag control element 700 according to the present invention. The bit lag control element 700 is provided to enable the amount of delay indicated by a delay lock control element 703 via LAGSELECT[3:0] in such a manner as to provide compensation for lot variations, process variations, and other factors that may come to light during or following manufacture of a host device. The bit lag control 700 may be employed in the embodiments of FIGS. 3 and 4 . The bit lag control 700 includes a delay element 701 that is coupled to a mux 702 . The mux 702 is coupled to delay lock control 703 via signal SLAG. The delay lock control 703 generates a 4-bit lag select signal LAGSELECT[3:0] that is coupled to the mux 702 and to adjust logic 706 . The adjust logic 706 is coupled to a gray encoder 704 . The adjust logic 706 is also coupled to a Joint Test Action Group (JTAG) interface 705 via bus SUB[1:0]. The JTAG interface 705 receives control information over a standard JTAG bus JTAG[N:0] that provides information applicable for the adjustment of the delay determined by the delay lock control 703 . An update signal UPDATE is coupled to the gray encoder 704 , which generates a gray-encoded 4-bit lag signal LAG[3:0] indicating the number of matched inverter pairs U 1 A/B-U 15 A/B that a radially distributed pulse RESP 1 lags behind a lag clock pulse LAGCLK, as adjusted by the value indicated on SUB[1:0].
[0083] The delay element 701 and the delay lock control 703 receive the lag clock LAGCLK. The delay lock control 703 also receives the distributed lag clock REPS 1 . In the embodiment of FIG. 3 , LAGCLK is represented by signal DSTROBE and REPS 1 is represented by DSTROBEN. In the apparatus 400 of FIG. 4 , LAGCLK is represented by LAGPLS and REPS 1 is represented by the like-named signal. The delay element 701 includes a plurality of inverter pairs U 1 A/B-U 15 A/B. A tap LC 0 -LC 15 is coupled to each of the pairs U 1 A/B-U 15 A/B, and the taps LC 0 -LC 15 are coupled to the register mux 702 . In the embodiment of FIG. 7 , 15 inverter pairs U 1 A/B-U 15 A/B are depicted having matched inverters U 1 A/B-U 15 A/B each exhibiting a delay of 20 picoseconds per inverter U 1 A/B-U 15 A/B (40 picoseconds per inverter pair U 1 A/B-U 15 A/B, which is acceptable resolution for measuring phase lag in a receiving device operating at but speeds from approximately 500 Megahertz to 1.5 Gigahertz. Other embodiments are contemplated comprising different numbers of inverter pairs U 1 A/B-U 15 A/B as is appropriate with the application.
[0084] The gray encoder 704 generates a gray-encoded bus LAG[3:0] that indicates the amount of time that RESP 1 lags in phase behind LAGCLK, as adjusted by the value of bus ALAG[3:0], which is an adjusted amount of time that it takes for a data strobe to propagate through a radial distribution network up to a data bit receiver according to the present invention.
[0085] In operation, UPDATE enables or disables operation of the bit lag control 700 , as has been described above. When UPDATE is asserted, upon assertion of LAGCLK, successively delayed versions of LAGCLK are generated by the delay element 701 and are provided on taps LC 0 -LC 15 to the mux 702 . The delay lock control increments or decrements the value of LAGSELECT[3:0] in order to select one of the taps LC 0 -LC 15 on signal SLAG such that the value of SLAG is equal to RESP 1 subsequent to assertion of LAGCLK. Thus, the delay lock control 703 operates substantially similar to a delay lock loop in order to converge on a phase delay that is one inverter pair U 1 A/B-U 15 A/B less than the delay corresponding to one of the inverter pairs U 1 A/B-U 15 A/B. In one embodiment, to provide for stability of the bit lag control 700 , once a phase lag is locked in place, the delay lock control increments/decrements LAGSELECT[3:0] about the selected value such that changes of measured delay vary only by one bit.
[0086] In operation, well-known JTAG programming techniques are employed to program the precise amount of compensation that is indicated over SUB[1:0]. Such programming is performed when a host device is in a state where JTAG programming is allowed, such as a RESET state. Upon exit from the state, bus SUB[1:0] indicates a compensation value. As with the embodiment 700 of FIG. 7 , the adjust logic 706 that receives the compensation value over bus SUB[1:0] and performs a subtraction function, in one embodiment, from LAGSELECT[3:0]. The amount to be subtracted from LAGSELECT[3:0] is indicated by the value of signal SUB[1:0]. In one embodiment, SUB[1:0] indicates a number of bits to right shift the valued of LAGSELECT[3:0]. Then the right-shifted version of LAGSELECT[3:0] is subtracted from LAGSELECT[3:0] by the adjust logic 706 to produce an adjusted 4-bit vector ALAG[3:0]. In one embodiment, the number of bits to right shift LAGSELECT[3:0] is as shown below in Table 2.
[0000]
TABLE 2
Adjustment Values for 4-Bit Select Vector
SUB[1:0] VALUE
NUMBER OF BITS TO RIGHT SHIFT
00
0 BITS
01
1 BIT
10
2 BITS
11
3 BITS
[0087] Other embodiments of the JTAG interface 705 are contemplated, including, but not limited to, a number of signals of bus SUB which are more or less than two signals. By providing the JTAG interface 707 and the adjust logic circuit 706 , a designer is allowed to tweak the amount of delay indicated by the delay lock control 703 via LAGSELECT[3:0] in such a manner as to provide compensation for lot variations, process variations, and other factors that may come to light during or following manufacture of the IC. The adjust logic 706 thus generates an adjusted 4-bit select vector ALAG[3:0] by subtracting a right-shifted value of LAGSELECT[3:0] from LAGSELECT[3:0] as indicated by SUB[1:0].
[0088] In one embodiment, measurement of the phase lag operates independently and asynchronously from assertion of the update signal UPDATE. When UPDATE is asserted, the gray-encoded value of ALAG[3:0] is placed on bus LAG[3:0]. Accordingly, a 4-bit value of 0011 on LAGSELECT[3:0] may indicate that RESP 1 lags behind LAGCLK by 120 picoseconds under certain temperature, voltage, and frequency conditions. But since the present invention is configured to provide for automatic and dynamic measurement of phase lag and adjustment of the same timing in a data bit receiver, it is more precise to state that the above noted value of LAGSELECT[3:0] indicates that RESP 1 lags behind LAGCLK by three inverter pairs U 1 A/B-U 15 A/B. Since matched replicas of these inverter pairs U 1 A/B-U 15 A/B are present in every data bit receiver according to the present invention, this phase “delay” can be replicated at each of the data bit receivers to provide for optimum reception of data. A value of 01 on SUB[1:0] indicates to the adjust logic 706 to right shift the value of LAGSELECT[3:0] by one bit and subtract this right shifted value (i.e., 0001) from the true value of LAGSELECT[3:0] (i.e., 0011), yielding a value of LAG[3:0] of 0010, which indicates that RESP 1 lags behind LAGCLK by only 80 picoseconds, as opposed to the 120-picosecond lag indicated by LAGSELECT[3:0].
[0089] The gray-encoded 4-bit lag bus LAG[3:0] is distributed to each of the data bit receivers that are associated with the radial distribution network being measured. Typically, these will comprise all of the data bit receivers in a particular data subgroup that each are activated by the same synchronous data strobe signal. In one embodiment, a different bit lag control 700 is employed for each different radial distribution network. In alternative embodiments, the gray encoder 704 may be deleted and the adjusted lag select bus ALAG[3:0] is sent directly to the receivers.
[0090] The apparatus 700 according to the present invention is configured to perform the functions and operations as discussed above. The apparatus 700 comprises logic, circuits, devices, or microcode, or a combination of logic, circuits, devices, or microcode, or equivalent elements that are employed to execute the functions and operations according to the present invention as noted. The elements employed to accomplish these operations and functions within the apparatus 700 may be shared with other circuits, microcode, etc., that are employed to perform other functions and/or operations within the receiving device.
[0091] Referring now to FIG. 8 , a block diagram is presented depicting a synchronous lag receiver 800 according to the present invention. The receiver 800 may be employed in the embodiments of FIGS. 3-4 and functions to introduce a delay into the propagation path of a data bit DATAX that is received from a transmitting device, where the delay is indicated by the value of a lag bus LAG[3:0] that is updated by a bit lag control element according to the present invention, such as is described above with reference to FIGS. 3-8 .
[0092] The receiver 800 includes a delay element 801 that receives the data bit DATAX. The delay element 801 is coupled to a mux 802 via a delayed data bit bus DDATAX[15:0]. The lag bus LAG[3:0] is coupled to the mux 802 . The mux 802 is coupled to a synchronous bit receiver 804 via a selected delayed data signal SDATAX. The bit receiver 804 receives SDATAX and a data strobe DSTROBEX. DSTROBEX is distributed from a radial distribution element 303 , 403 , such as is discussed above with reference to FIGS. 3-4 . The bit receiver 804 generates a received data bit signal RDATAX.
[0093] Operationally, a bit lag controller according to the present invention updates the value of LAG[3:0] to position reception of DATAX optimally in relation to the phase of DSTROBEX. In one embodiment, this positioning is such that DSTROBEX switches approximately halfway during assertion of DATAX. Other embodiments are contemplated that enable positioning of DATAX to favor increased setup time or increased hold time for DATAX. The delay element 801 is a replica of the delay elements 501 , 601 , 701 , 801 described with reference to FIGS. 1-8 , and comprises 15 matched inverter pairs (not shown). Thus, in one embodiment, DDATAX[15:0] comprises 16 successively delayed versions of DATAX, ranging from no delay to delay through all 15 inverter pairs.
[0094] The value of LAG[3:0] is employed by the mux 802 to select one of the signals on DDATAX[15:0]. The selected signal is routed to the bit receiver 804 on SDATAX. When DSTROBEX switches, the bit receiver 804 registers the value of SDATAX and outputs this value on RDATAX. RDATAX represents the received state of DATAX.
[0095] Turning now to FIG. 9 , a block diagram is presented detailing a precision delay element 900 according to the present invention. The precision delay element 900 may be substituted for any of the delay elements 501 , 601 , 701 , 801 discussed above with reference to FIGS. 5-8 , and is employed to provide both finer resolution of lag measurement and lag introduction in embodiments of the present invention. The delay element 900 includes a first mux 901 having a first input tied to a logic low level (i.e., “0”) and a second input tied to a logic high level (i.e., “1”). In one embodiment, the high level comprises a core voltage (i.e., VDD) and the low level comprises a reference voltage (i.e., ground). Other embodiments are contemplated. The first mux 901 employs a lag clock LAGCLK as a select input to select either the signal on the first input or the second input. The element 900 also includes a second mux 902 having a first input tied to a 1 and a second input tied to a 0, which is the opposite configuration from that of the first mux 901 . LAGCLK is also coupled to the select input of the second mux 902 . In the embodiments of FIGS. 5-7 , LAGCLK represents a signal for measurement of propagation delay as the like-named signals. In the embodiment of FIG. 8 , LAGCLK represents the data bit DATAX to be delayed.
[0096] The delay element 900 includes a first group of 15 delay inverters, U 0 A-U 14 A, coupled in series cascade configuration, where the output of the first mux 901 is coupled to the input of U 0 A and the output of U 14 A is coupled to a most delayed signal LC 31 . The delay element 900 also includes a second group of 15 delay inverters, U 0 B-U 14 B, coupled in series cascade configuration, where the output of the second mux 902 is coupled to the input of U 0 B and the input of U 14 B is coupled to a next most delayed signal LC 30 .
[0097] The outputs of all like numbered delay inverters (e.g., U 0 A and U 0 B, U 5 A and U 5 B) are coupled together via full keeper inverter pairs K 1 -K 15 . The outputs of even numbered inverters from the first group of 15 delay inverters (i.e., U 0 A, U 2 A, etc.) are coupled to odd numbered successively delayed signals (i.e., LC 1 , LC 3 , . . . , LC 31 ) and the inputs of even numbered inverters from the second group of 15 delay inverters (i.e., U 0 B, U 2 B, etc.) are coupled to even numbered successively delayed signals (i.e., LC 0 , LC 2 , . . . , LC 30 ). Each of the delay inverters U 0 A-U 14 A, U 0 B-U 14 B are matched. In one embodiment, the delay through each inverter is substantially 20 picoseconds and thus the most delayed signal LC 31 represents a delay in LAGCLK of approximately 300 picoseconds.
[0098] In operation, either state of LAGCLK may be employed to generate the successively delayed versions that are output on LC 0 -LC 31 , although a high level will be used in this operational discussion. Accordingly, in one embodiment, when LAGCLK is 1, then the input to U 0 A is 0 and the input to U 0 B is 1. Thus, LC 0 is a 1, the output of U 0 A is 1, the output of U 0 B is a 0, and the value of LC 1 is a 1 after a delay of one inverter. And so on until the most delayed version of LAGCLK is presented on LC 31 . Keepers K 1 -K 15 function to ensure that state changes on LC 1 -LC 31 are synchronized with regard to state changes of their corresponding like numbered inverter pair U 0 [A:B]-U 14 [A:B].
[0099] The precision delay element 900 according to the present invention may be employed by any of the muxes 502 , 602 , 702 , 802 , 902 described above. However, the width of corresponding lag busses must be increased by one bit to accommodate the increased resolution provided.
[0100] Portions of the present invention and corresponding detailed description are presented in terms of software, or algorithms and symbolic representations of operations on data bits within a computer memory. These descriptions and representations are the ones by which those of ordinary skill in the art effectively convey the substance of their work to others of ordinary skill in the art. An algorithm, as the term is used here, and as it is used generally, is conceived to be a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of optical, electrical, or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0101] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, or as is apparent from the discussion, terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, a microprocessor, a central processing unit, or similar electronic computing device, that manipulates and transforms data represented as physical, electronic quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
[0102] Note also that the software implemented aspects of the invention are typically encoded on some form of program storage medium or implemented over some type of transmission medium. The program storage medium may be electronic (e.g., read only memory, flash read only memory, electrically programmable read only memory), random access memory magnetic (e.g., a floppy disk or a hard drive) or optical (e.g., a compact disk read only memory, or “CD ROM”), and may be read only or random access. Similarly, the transmission medium may be metal traces, twisted wire pairs, coaxial cable, optical fiber, or some other suitable transmission medium known to the art. The invention is not limited by these aspects of any given implementation.
[0103] The particular embodiments disclosed above are illustrative only, and those skilled in the art will appreciate that they can readily use the disclosed conception and specific embodiments as a basis for designing or modifying other structures for carrying out the same purposes of the present invention, and that various changes, substitutions and alterations can be made herein without departing from the scope of the invention as set forth by the appended claims.
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A method is provided that compensates for misalignment on a synchronous data bus. The method includes: replicating propagation path lengths, loads, and buffering of a radial distribution network for a strobe; receiving a first signal, and generating a second signal by employing the replicated propagation path lengths, loads, and buffering; when an update signal is asserted, when an update signal is asserted, measuring a propagation time beginning with assertion of the first signal and ending with assertion of the second signal by selecting one of a plurality of successively delayed versions of the first signal that coincides with the assertion of the second signal, wherein said selecting comprises incrementing and decrementing bus states of select inputs on a mux, wherein the plurality of successively delayed versions of the first signal comprises inputs to the mux; gray encoding a value on a lag bus that indicates the propagation time; and receiving one of a plurality of radially distributed strobes and a data bit, and delaying registering of the data bit by the propagation time. The receiving includes generating successively delayed versions of the data bit; receiving the value on the lag bus, and selecting one of the successively delayed versions of the data bit that corresponds to the value; and registering the state of the one of the successively delayed versions of the data bit upon assertion of one of a plurality of radially distributed strobe signals.
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FIELD OF THE INVENTION
This invention relates to optical scanning of imaged film. More particularly, it relates to a means for optimizing the scanning process for digitization of images film for signal processing and/or transmission, thereby providing continual, error-free scanning of the film images.
BACKGROUND OF THE INVENTION
To digitize a film for signal processing, transmission, or storage, the film is advanced frame by frame past an optical scanner. The thin film material must be kept flat within the depth of focus of the optical system in order to assure accurate pickup of the image on the film. The required flatness may be a few micrometers, which is particularly difficult when dealing with the thin, flexible films typically used for photographic imaging. For example, when mounted between two sprockets, 35 mm movie film tends to stretch into a cylindrical shape in the unsupported region between the holding sprockets. Therefore, it has become necessary to utilize additional means for flattening the film while it passes by the optical scanner.
One method for maintaining the planarity of film during scanning is to place the film material under a flat plate of transparent material, such as glass. A disadvantage to this method is that the transparent plate adds another optical element between the film and the scanning system, which can introduce errors in addition to interfering with the illumination during scanning.
An alternative film flattening technique has been to pass the film material through a frame which contacts the periphery of the film image area and has an open window through which the film image can be scanned. While the open window area avoids the problems of lighting alteration and of introducing artifacts to the scanned film image, optimal film flatness cannot be realized with only peripheral film contact. Both of the foregoing solutions require that additional time be spent in advancing the film and aligning the film image to the plate or window between scans. In addition, the prior art solutions both introduce new sources of error since physical elements of the system are contacting the film as it advances, which could lead to scratching or tearing of the film material.
It is therefore an objective of the present invention to provide a method and system for optimizing film flatness during scanning.
It is another objective of the invention to provide a system and method for achieving optimal film flatness without introducing additional optical elements as possible sources of error to the scanning system.
Yet another objective of the invention is to provide a system which allows scanning of film to be conducted continually, without the need to regularly stop the scanning process in order to advance and align the film.
Still another objective of the invention is to provide a system and method for film scanning which does not damage the film during the scanning process.
SUMMARY OF THE INVENTION
These and other objectives are realized by the present inventive system and method for continually advancing film through an air-bearing film flattening system having at least one scanning area through which the air-flattened film may be scanned. The film is provided to an air-bearing mechanism comprising at least two opposing air-bearing plates which create opposing air cushions for maintaining the planarity of the film. The scanning area may include at least one optical aperture, in at least one of the air-bearing plates, through which the scanner views the film, or a "viewing" area occupied by bundled coherent optical fibers which sequentially pick up image information from aligned regions of the image. The system provides for time efficient, clean, and error-free reading of the scanned image.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with specific reference to the drawings wherein:
FIG. 1 illustrates an embodiment of the present air-bearing film conveyer system incorporated into a scanner which uses light transmitted through the air-flattened film, via three color filtered apertures to three linear scanning arrays, thereby allowing three color scanning of the imaged film.
FIG. 2 provides a more detailed view of the air-bearing film conveyer of the present invention.
FIG. 3 schematically illustrates the internal view of one of the air-bearing surfaces of an embodiment of the present invention.
FIG. 4 depicts a single aperture embodiment of the air-flattening scanner system wherein the single scanning line is separated into three colors.
FIG. 5 illustrates another embodiment of the invention wherein reflected light is provided to the air-flattened film.
FIG. 6 shows an embodiment of the present invention wherein bundled optical fibers pick up the image via light transmitted through the air-flattened film.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is implemented within an optical scanning system, such as had been found in the prior art, including a light source for providing transmitted or reflected light onto a section of film, and from the film to an array of optical sensors. The ensuing description should be read to include other non-contact scanning systems, such as inspection equipment, hash mark locating and/or marking systems, etc., which would also require scanning of perfectly planar flexible film materials. In the prior optical scanning art, area arrays were generally required to receive the image from a stationary window of the film, which window was either viewed through a transparent flattening plate or through a peripherally-framed flattening and viewing area, as discussed above. After the area array had collected the image information from a stationary section of the film, the film was advanced and re-aligned to the flattening mechanism prior to activating the array for scanning of the next image. Use of the present invention will allow the film to be advanced continually, thereby allowing a single or multiple linear array to scan continually as the film advances.
FIG. 1 provides an illustration of one embodiment of the present invention wherein film 10 mounted on sprockets 12 advances through air-bearing mechanism 11. A light source 13 is directed to apertures (not shown) on the lower plate of the air-bearing mechanism, through film 10, out the apertures 15 of the upper plate, and onto linear array 17, via imaging lens 16. The film 10, which is physically being advanced by the movement of sprockets 12, is continually being provided to the air-bearing mechanism 11. The film advancement mechanism is shown as a tensioning system having sprocketed wheels on either side of the scanning area. While it may be possible to exert the requisite tension on the film by a single-stage film advancement system, or via a non-sprocketed tensioning system, the two-stage system is illustratively used.
In the air-bearing mechanism, the film is effectively flattened by exposure to opposing air currents issuing forth from the top and bottom plates of the air-bearing mechanism. There may be a plurality of plates located above and below the film; however, for generation of uniform opposing air cushions, single coextensive plates above and below the film are preferable. Apertures 15 are slits provided to allow light to pass through the film and onto the linear array of the optical scanner, as further discussed below.
The illustrated embodiment of FIG. 1 may be used to conduct a three-color (RGB) scan of the film image, whereby three apertures are provided at both the top and the bottom of the air-bearing mechanism. The apertures at the bottom of the film advancement mechanism are covered with color filters, 14, one each for red, green and blue light, so that the linear array is receiving specialized color information of the image through each aperture. Alternatively, a set of complementary filters, such as yellow, cyan and magenta, can be used.
The film advances at what is ideally a fixed rate past the apertures in the air-bearing mechanism, thereby allowing continuous scanning at the apertures by the linear array of the optical system. Due to the fact that the overall scanning speed is dependent upon the amount of light needed for a particular scanning application, film tracking electronics 19 communicates with the linear array electronics 18 to synchronize the rate of advancement of the film with the scanning speed. In general, use of a more intense light source will facilitate faster scanning speed; however, a light source may be too intense for scanning film with images having high brightness levels. Therefore, for optical scanning for film image transfer, the light source and the scanning speed must be chosen to maximize both efficiency and accurate image transfer.
FIG. 2 provides a more detailed illustration of the air-bearing mechanism 11. The air-bearing mechanism is comprised of air-bearing plates, lower air-bearing plate 20 and upper air-bearing plate 22. As discussed briefly above, elements 20 and 22 may each be comprised of more than one plate, if desired. For the embodiment illustrated in FIG. 1, each air-bearing plate has at least one viewing aperture, 15, although viewing apertures per se may not be required for some scanning systems. For the FIG. 1 embodiment, the apertures on the bottom air-bearing plate are additionally fitted with optical filters, a feature which will be included for use with only some optical scanning systems.
The lower air-bearing plate apertures are provided for allowing light to pass through the apertures, through the film, and through the apertures in the upper air-bearing plate, which apertures are preferably aligned to the lower air-bearing plate apertures. The apertures in the upper air-bearing plate provide viewing or scanning access to the film by the optical array. Since linear arrays can be utilized, and their pixels are generally on the order of 10-15 micrometers, the aperture width may be made relatively small so that their presence in the plates will not compromise the air cushion to any appreciable extent. Assuming usage of 1:1 magnification, aperture width of slightly larger than the 10-15 micrometer pixel size is workable. In practice, the apertures may be tapered, so that the opening is larger on the outside of the plate where a larger area may be required to accommodate the angle of the incident light, and the opening at the inner, air-bearing surface narrower to minimize the amount of air escaping through the aperture.
Both the upper and the lower air-bearing plates of the air-bearing mechanism have a port 24 for connection to an air supply. It is not necessary to use purified air or any specific "ambient," unless such could affect either the film material or the scanning equipment. Filtering of the air supply is preferable in order to avoid clogging the small orifices found on most air-bearing surfaces and to reduce the possibility of air-borne particulates damaging the film or being mistakenly detected as part of the scanned image. The pressure of the air supply is not critical to the present invention, assuming that uniform, balanced upper and lower cushions are provided to hold the film planar. Commercially available air-bearing systems, of the sort used to transport solid items (e.g., semiconductor wafers) on a single air cushion, generally provide pressure in the 50-100 psi range, which range would be more than adequate for the present invention.
Within each of the upper and lower plates, as further illustrated in FIG. 3, are located air passages for creating the upper and lower cushions of air to which the advancing film is exposed and by which it is held flat during scanning. The air passages can comprise grooves formed in the inner surfaces of the plates, as shown in FIG. 3, or air channels having porous walls along the inner surfaces of the plates. The air passages, 27, are provided on the plates in all areas except for the areas at which the film sprocket holes are located. While uniform distribution of the air passages will facilitate predictability and control of the air flow and of the resulting air pressure for flattening the film material, it is not necessary that the air passages be uniformly positioned; nor is it necessary that the upper and lower plates have mirror image air passages.
What is necessary is that each plate include means for regulating the air flow, such as the orifices associated with the air grooves at 28 of FIG. 3, the details of which are well known in commercially available air-bearing systems. For the inventive air-bearing system, where the load on the air cushion is small and does not undergo appreciable change during usage, small orifices (on the order of 15-20 micrometers in diameter) are optimal. The use of smaller orifices will result in a stiffer bearing (i.e., one having small changes in the air gap based upon variations in the vertical load), a smaller nominal air gap thickness (e.g., less than 10 micrometers), and minimal air consumption.
Film flatness will be realized by establishment of a uniform cushion of air at each surface of the film. One of the upper and the lower air-bearing plates should be movably mounted to allow for movement in the Z-direction, perpendicular to the film plane, and thereby provide the flexible air gap necessary to "float" the film along the mechanism. Preferably, for ease of design, the upper plate is the one which is movably mounted. Flexure 26, as the illustrated moveable mounting for the upper plate of the air-bearing mechanism in FIG. 2, allows Z-direction movement of the upper plate, but is immovable in the X and Y directions. A uniform downward force is required to maintain pressure of the film and hence maintain film flatness. A number of means can be used to provide the constant downward pressure. FIG. 2 shows the force being provided by a preload on the flexure spring. Other ways in which the force can be exerted include gravity, whereby a weight is added to the air-bearing plate, or a compression spring acting on the upper air-bearing plate.
Those having skill in the art will recognize that the air film gap is controlled by the magnitude of the downward force and the size of the orifices that control the air flow. Since the invention uses air bearing in an unconventional way, i.e., to flatten a film between two air cushions rather than to move a heavy object along a single air cushion, the load on the air bearings is considerably smaller than in typical air-bearing applications. As a practical matter, one should use the smallest orifices possible and then add the minimum vertical force sufficient to stabilize the air-bearing plates. It is contemplated that the use of air channels having porous surfaces will optimize air flow regulation with the minimum need for a compensating load.
The position being scanned on the film is sensed by an encoder or like device incorporated into the drive motor. Since a direct measurement at the point of scan cannot be made, any unknown length variations between the point of scan and the encoder will cause errors in the sensed position of the scan line of the film. One such source of error lies with the sprocket holes on the film. If the sprocket holes are not perfectly uniformly spaced, a position error will occur, and propagate. To minimize the effects of such an error source, a large sprocket wheel having many sprocket teeth is utilized so that hole-to-hole variation is effectively averaged over many holes to minimize position errors.
It is to be noted that the inventive air-bearing flattening system provides a virtually frictionless film advancement system (apart from the sprocket-to-perforation contact which is carried on outside of the air-bearing mechanism). This low friction environment will minimize any contact with the film image surface, thereby preventing film damage during scanning. In addition, the air-bearing mechanism may actually improve image transfer during optical scanning because the flowing air can actually remove any accumulated debris from the film image surfaces.
FIGS. 4 through 6 provide alternative optical scanning systems which incorporate the inventive air-bearing mechanism. The system shown in FIG. 4 provides an alternative way of obtaining a three color scan of the film images which also does not require repeated scanning of the film. Light source 43 is provided to one aperture (not shown) at the outer surface of the lower plate of air-bearing mechanism 41. As film is advanced by the sprocketing system 42 and through the air-bearing mechanism 41, it passes by aperture 45 in the upper plate of the air-bearing mechanism, which is aligned to the lower plate aperture. White light passing through the lower aperture, film, and upper aperture is directed by beam splitters or mirrors 44 via imaging lenses 46 to each of three different linear arrays, 47, one each for a red, a blue and a green sensor. As an alternative, a single lens may be employed between the light-splitting elements and the film, as is common in three color cameras utilizing charge coupled devices or CCDs. The electronics, 48, for providing input to and receiving input from the linear arrays will additionally be in communication with the film advancement electronics 49, as noted above with reference to the corresponding components in FIG. 1.
FIG. 5 illustrates an optical film scanning system which utilizes reflected rather than transmitted light for illumination of the film. Light from source 53 is provided at an angle of incidence through upper plate aperture 55 to film 10 in the air-bearing mechanism, 51. The lower plate of the air-bearing mechanism will not be outfitted with an aperture for the FIG. 5 embodiment. Light reflected off of the film 10 will be provided via lens system 56 to linear array 57. As above, electronics 58 and 59 will coordinate the linear array scanning rate with the film advancement rate to assure continual accurate scanning of the images. The above-mentioned three color scanning schemes, utilizing beam splitters and multiple CCDs is also applicable here.
Finally, FIG. 6 illustrates an optical scanning system which incorporates bundled coherent optical fibers, 65, for providing light to the linear array, 67. Light from source 63, provided to the film 10 in the air-bearing mechanism 61 by an aperture (not shown) in the lower plate, is received by one or more of the optical fibers in bundle 65 and is transmitted to the linear array or arrays by the fibers. Optical array control electronics 68 coordinates the film advancement with electronics 69, as above.
The invention has been described with reference to several specific embodiments. One having skill in the relevant art will recognize that modifications may be made without departing from the spirit and scope of the invention as set forth in the appended claims.
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An inventive system and method for continually advancing film through an air-bearing film flattening system having at least one scanning area through which the air-flattened film may be scanned. The film is provided to an air-bearing mechanism comprising two opposing air-bearing plates which create opposing air cushions for maintaining the planarity of the film. The scanning area may comprise at least one optical aperture in the air-bearing plate or plates through which the scanner views the film, or a "viewing" area occupied by bundled coherent optical fibers which sequentially pick up image information from aligned regions of the image. The system provides for time efficient, clean, and error-free reading of the scanned image.
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BACKGROUND
[0001] Synchronization mechanisms such as critical sections are used by software developers to coordinate the usage of resources by different threads of execution. For example, a software developer may use a synchronization mechanism to ensure that only one thread at a time manipulates the contents of a data structure, or that only one thread at a time executes a sensitive section of code.
[0002] It is typical for a synchronization mechanism to provide 4 functions:
Initialize: create the synchronization mechanism and prepare it for use Acquire: seek to own the synchronization mechanism in order to be able to interact with the associated resource; thread is blocked until Acquire succeeds Release: relinquish ownership of the synchronization mechanism Delete: delete the synchronization mechanism
[0003] These functions often have different names in various operating systems. Function names can also vary between different types of synchronization mechanisms provided by the same operating system. Parameters of these functions can similarly vary.
[0004] In some cases, synchronization mechanisms are implemented in a way that creates unpredictable and/or undesirable results when these functions are called in certain orders. For example, in some versions of Microsoft Windows, one or more of the following combinations of function calls for a critical section synchronization mechanism can produce unpredictable and/or undesirable results: (1) calling the Acquire or Release function before the Initialize function is called; (2) calling the Acquire or Release function after the Delete function is called; and (3) calling the Delete function while one or more threads is blocked on the synchronization mechanism.
[0005] Because the simultaneous execution of multiple threads can create unexpected execution scenarios, it is sometimes difficult for software developers to generate code that uniformly avoids these combinations of function calls under all conditions.
BACKGROUND
[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0007] A software facility that establishes a wrapper around a native synchronization mechanism provided by an operating system and native functions called to interact with the native synchronization mechanism in order to preclude undesirable behavior of the native synchronization mechanism (“the facility”) is described. As part of the wrapper, the facility provides an analog for each of the native synchronization object functions as follows:
safeInitialize: analog of Initialize safeAcquire: analog of Acquire safeRelease: analog of Release safeDelete: analog of Delete
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates an example of a suitable computing system environment or operating environment in which the techniques or facility may be implemented.
[0013] FIG. 2 is an object diagram showing the implementation of the wrapper as a SafeSynchronizationMechanism object in some embodiments.
[0014] FIG. 3 is a flow diagram showing steps typically performed by the facility when the safeInitialize( ) function is called.
[0015] FIG. 4 is a flow diagram showing steps typically performed by the facility when the safeAcquire( ) function is called.
[0016] FIG. 5 is flow diagram showing steps typically performed by the facility when the safeRelease( ) function is called.
[0017] FIG. 6 is a flow diagram showing steps typically performed by the facility when the safeDelete( ) function is called.
DETAILED DESCRIPTION
[0018] A software facility that establishes a wrapper around a native synchronization mechanism provided by an operating system and native functions called to interact with the native synchronization mechanism in order to preclude undesirable behavior of the native synchronization mechanism (“the facility”) is described. In some embodiments, the facility implements these analog functions as methods on a wrapper synchronization object. In some embodiments, in order to maintain the integrity of the wrapper functions when the analog functions are called in various combinations by different threads, the facility implements the analog functions using atomic variable access operations—such as InterlockedXXX operations provided by Microsoft Windows—that, once begun, are uninterruptible.
[0019] As part of the wrapper, the facility provides an analog for each of the native synchronization object functions as follows:
safeInitialize: analog of Initialize safeAcquire: analog of Acquire safeRelease: analog of Release safeDelete: analog of Delete
[0024] In some embodiments, the facility implements safeInitialize and safeAcquire in such a manner that they fail if called before safeInitialize is called or after Delete is called.
[0025] In some embodiments, the facility implements safeDelete so that, rather calling Delete, it marks the synchronization mechanism for later deletion by safeRelease. SafeRelease deletes a synchronization mechanism marked for deletion only after a reference count maintained on the synchronization mechanism by the facility indicates that no threads currently own or are waiting to acquire the synchronization mechanism. In some embodiments, safeAcquire requires any threads that acquire the synchronization mechanism after it has been marked for deletion to immediately release the synchronization mechanism. In some embodiments, safeAcquire prevents threads from attempting to acquire the synchronization mechanism after it has been marked for deletion.
[0026] By providing a synchronization mechanism wrapper in some or all of the ways described above, the facility precludes potential undesirable behavior of the native synchronization object, making it easier to develop reliable software using the native synchronization mechanism through the wrapper than using the native synchronization mechanism directly.
[0027] FIG. 1 illustrates an example of a suitable computing system environment 110 or operating environment in which the techniques or facility may be implemented. The computing system environment 110 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the facility. Neither should the computing system environment 110 be interpreted as having any dependency or requirement relating to any one or a combination of components illustrated in the exemplary operating environment 110 .
[0028] The facility is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the facility include, but are not limited to, personal computers, server computers, hand-held or laptop devices, tablet devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0029] The facility may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, and so forth that perform particular tasks or implement particular abstract data types. The facility may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in local and/or remote computer storage media including memory storage devices.
[0030] With reference to FIG. 1 , an exemplary system for implementing the facility includes a general purpose computing device in the form of a computer 111 . Components of the computer 111 may include, but are not limited to, a processing unit 120 , a system memory 130 , and a system bus 121 that couples various system components including the system memory 130 to the processing unit 120 . The system bus 121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus.
[0031] The computer 111 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer 111 and includes both volatile and nonvolatile media and removable and nonremovable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media include volatile and nonvolatile, removable and nonremovable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the computer 111 . Communication media typically embody computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and include any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared, and other wireless media. Combinations of any of the above should also be included within the scope of computer-readable media.
[0032] The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . A basic input/output system (BIOS) 133 , containing the basic routines that help to transfer information between elements within the computer 111 , such as during start-up, is typically stored in ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by the processing unit 120 . By way of example, and not limitation, FIG. 1 illustrates operating system 134 , application programs 135 , other program modules 136 and program data 137 .
[0033] The computer 111 may also include other removable/nonremovable, volatile/nonvolatile computer storage media. By way of example only, FIG. 1 illustrates a hard disk drive 141 that reads from or writes to nonremovable, nonvolatile magnetic media, a magnetic disk drive 151 that reads from or writes to a removable, nonvolatile magnetic disk 152 , and an optical disk drive 155 that reads from or writes to a removable, nonvolatile optical disk 156 such as a CD-ROM or other optical media. Other removable/nonremovable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 141 is typically connected to the system bus 121 through a nonremovable memory interface such as interface 140 , and magnetic disk drive 151 and optical disk drive 155 are typically connected to the system bus 121 by a removable memory interface, such as interface 150 .
[0034] The drives and their associated computer storage media, discussed above and illustrated in FIG. 1 , provide storage of computer-readable instructions, data structures, program modules, and other data for the computer 111 . In FIG. 1 , for example, hard disk drive 141 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers herein to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 111 through input devices such as a tablet or electronic digitizer 164 , a microphone 163 , a keyboard 162 and pointing device 161 , commonly referred to as a mouse, trackball or touch pad. Other input devices not shown in FIG. 1 may include a joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 120 through a user input interface 160 that is coupled to the system bus 121 , but may be connected by other interface and bus structures, such as a parallel port, game port, or a universal serial bus (USB). A monitor 191 or other type of display device is also connected to the system bus 121 via an interface, such as a video interface 190 . The monitor 191 may also be integrated with a touch-screen panel or the like. Note that the monitor 191 and/or touch screen panel can be physically coupled to a housing in which the computer 111 is incorporated, such as in a tablet-type personal computer. In addition, computing devices such as the computer 111 may also include other peripheral output devices such as speakers 195 and printer 196 , which may be connected through an output peripheral interface 194 or the like.
[0035] The computer 111 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 . The remote computer 180 may be a personal computer, a server, a router, a network PC, a peer device, or other common network node, and typically includes many or all of the elements described above relative to the computer 111 , although only a memory storage device 181 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 171 and a wide area network (WAN) 173 , but may also include other networks. Such networking environments are commonplace in offices, enterprisewide computer networks, intranets and the Internet. For example, in the present facility, the computer 111 may comprise the source machine from which data is being migrated, and the remote computer 180 may comprise the destination machine. Note, however, that source and destination machines need not be connected by a network or any other means, but instead, data may be migrated via any media capable of being written by the source platform and read by the destination platform or platforms.
[0036] When used in a LAN networking environment, the computer 111 is connected to the LAN 171 through a network interface or adapter 170 . When used in a WAN networking environment, the computer 111 typically includes a modem 172 or other means for establishing communications over the WAN 173 , such as the Internet. The modem 172 , which may be internal or external, may be connected to the system bus 121 via the user input interface 160 or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 111 , or portions thereof, may be stored in the remote memory storage device 181 . By way of example, and not limitation, FIG. 1 illustrates remote application programs 185 as residing on memory storage device 181 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
[0037] While various functionalities and data are shown in FIG. 1 as residing on particular computer systems that are arranged in a particular way, those skilled in the art will appreciate that such functionalities and data may be distributed in various other ways across computer systems in different arrangements. While computer systems configured as described above are typically used to support the operation of the facility, one of ordinary skill in the art will appreciate that the facility may be implemented using devices of various types and configurations, and having various components.
[0038] FIG. 2 is an object diagram showing the implementation of the wrapper as a SafeSynchronizationMechanism object in some embodiments. A SynchronizationMechanism object 250 representing the native synchronization mechanism has data members 260 containing the native synchronization mechanism's state, as well as function members 270 . The function members of the SynchronizationMechanism object include Initialize( ), Acquire( ), Release( ), and Delete( ).
[0039] An instance 211 of the SynchronizationMechanism object is among the data members of a SafeSynchronizationMechanism object 200 . The data members 210 of the SafeSynchronizationMechanism object further include a reference count variable 212 and initialization state flag 213 . The function members 220 of the SafeSynchronizationMechanism object include safeInitialize( ), safeAcquire( ), safeRelease( ), and safeDelete( ), which ultimately call the function members of the SynchronizationMechanism object.
[0040] Those skilled in the art will appreciate that, while the wrapper is shown here is being implemented as an object containing a native synchronization mechanism object, in various embodiments, the native synchronization mechanism, the wrapper, or both may be implemented using procedural programming or another programming scheme. Where the native synchronization mechanism or the wrapper is an object, those skilled and there will appreciate that it may be implemented having different contents and/or organization than shown.
[0041] FIGS. 3-6 illustrate the four wrapper functions. FIG. 3 is a flow diagram showing steps typically performed by the facility when the safeInitialize( ) function is called. In step 301 , if the initialization flag m_flnit is true, indicating that the synchronization mechanism is already initialized, then the facility continues in step 302 to return failure, else the facility continues in step 303 . In step 303 , the facility calls the Initialize( ) function to initialize the native synchronization mechanism, passing it the address of the native synchronization mechanism. In step 304 , the facility sets reference count m_IRefCount equal to zero, indicating that no threads own or are waiting for the synchronization mechanism. In step 305 , the facility sets initialization flag m_flnit to true, indicating that the synchronization mechanism has been initialized. In step 306 , the facility returns success.
[0042] FIG. 4 is a flow diagram showing steps typically performed by the facility when the safeAcquire( ) function is called. In step 401 , if the initialization flag is false, indicating that the synchronization mechanism isn't initialized, then the facility continues in step 402 to return failure, else the facility continues in step 403 . In step 403 , the facility calls an atomic increment function—such as the InterlockedIncrement( ) function provided by Microsoft Windows—to atomically increment the reference count to reflect the acquisition of the synchronization mechanism. If the result is greater than or equal to the DELETION_DONE constant, indicating that the synchronization mechanism has been marked by the safeRelease( ) function as deleted, then the facility continues in step 404 to return failure, else the facility continues in step 405 . In step 405 , the facility calls the Acquire( ) function to acquire the native synchronization mechanism, passing it the address of the native synchronization mechanism. In step 406 , if the reference count is greater than or equal to the TO_BE_DELETED constant, indicating that the synchronization mechanism has been marked for deletion by the safeDelete( ) function, then the facility continues in step 408 , else the facility continues in step 407 to return success. If the 408 , the facility calls the Release( ) function to release the native transition mechanism, passing it the address of the native synchronization mechanism. In step 409 , the facility returns failure.
[0043] FIG. 5 is flow diagram showing steps typically performed by the facility when the safeRelease( ) function is called. In step 501 , if the initialization flag is false, indicating that the synchronization mechanism isn't initialized, then the facility continues in step 502 to return failure, else the facility continues in step 503 . In step 503 , the facility calls the Release( ) function to release the native synchronization mechanism, passing it the address of the native synchronization mechanism. In step 504 , the facility calls an atomic compare exchange function—such as the InterlockedCompareExchange( ) function provided by Microsoft Windows—to atomically store the value of the DELETE_DONE constant in the reference count if the reference count is equal to one more than the value of the TO_BE_DELETED constant—that is, if the synchronization mechanism has been marked for deletion by the safeDelete( ) function and the thread executing the safeRelease( ) function is the last thread owning or waiting for the synchronization mechanism. If this condition is satisfied, then the facility continues in step 505 , else the facility continues in step 507 . In step 505 , the facility sets initialization flag to false, indicating that the synchronization mechanism is no longer initialized. In step 506 , the facility calls the Delete( ) function to delete the native synchronization mechanism, passing it the address of the native synchronization mechanism. After step 506 , the facility continues in step 508 to return success. In step 507 , the facility calls an atomic decrement function—such as the InterlockedDecrement( ) function provided by Microsoft Windows—to atomically decrement the reference count to reflect the release of the synchronization mechanism. After step 507 , the facility continues in step 508 to return success.
[0044] FIG. 6 is a flow diagram showing steps typically performed by the facility when the safeDelete( ) function is called. In step 601 , if the initialization flag is false, indicating that the synchronization mechanism isn't initialized, then the facility continues in step 602 to return failure, else the facility continues in step 603 . In step six a 3 - 605 , the facility acquires the synchronization mechanism to be sure that owns the synchronization mechanism when it marks the synchronization mechanism for deletion, then releases the synchronization mechanism to undo its acquisition. In step 603 , the facility calls the Acquire( ) function to acquire the native synchronization mechanism, passing it the address of the native synchronization mechanism. If this function call returns success, then the facility continues in step 604 , else the facility continues in step 606 . In step 604 , the facility calls an atomic exchange add function—such as the InterlockedExchangeAdd( ) function provided by Microsoft Windows—to atomically add the value of the TO_BE_DELETED constant to the reference count, indicating that the synchronization mechanism is to be deleted. In step 605 , the facility calls the Release( ) function to release the native synchronization mechanism, passing at the address of the native synchronization mechanism. In step 606 , the facility returns success.
[0045] Tables 1 and 2 below contain pseudocode that can be used to implement some embodiments of the facility, such as embodiments directed to wrapping a critical section object provided by the Microsoft Windows operating system. Table 1 is a structure declaration for a SafeCS wrapper object.
TABLE 1 1 // provides enhanced functionality to the normal CRITICAL_SECTION object 2 struct SafeCS 3 { 4 CRITICAL_SECTION m_cs; //the actual critical section object 5 LONG m_IRefCount; //to keep track of the number of threads waiting for/already holding the CS object 6 BOOL m_fInit; //to check for initialization consistency 7 // This function is used to safely initialize the critical section object. 8 // Ensure that the SafeCS object is zero filled before calling initialize (to ensure that m_fInit is FALSE) 9 BOOL Initialize( ); 10 // to enter the critical section, returns TRUE is successful, FALSE is failed 11 // this function will fail, if... 12 // 1. if we try to enter un-initialized object 13 // 2. if we try to enter an object that has been deleted (un-initialized) 14 // 3. if we are waiting for entering this object while someone else has deleted the object 15 BOOL Enter( ); 16 // to leave the acquired critical section 17 // caller has to ensure that he calls this fn. only if he had successfully acquired the critical section using Enter( ) 18 BOOL Leave( ); 19 // used to safely delete the critical section object 20 // after this object has been deleted everyone waiting for this object will return with a failure 21 // this function internally enters the critical section object, callers have to ensure that this behavior doesn't cause deadlock 22 BOOL Delete( ); 23 };
[0046] The SafeCS wrapper object contains the following data members: m_CS, a native critical section object; m_IRefCount, a counter of the number of threads that are waiting for or already holding the native critical section object, with adjustments to reflect to-be-deleted and deletion-done status; and m_flnit, to indicate whether the safe critical section object has been initialized more recently than it has been deleted. The SafeCS object has the following function members: Initialize, Enter, Leave, and Delete.
[0047] Table 2 below shows pseudocode containing implementations for the Initialize, Enter, Leave, and Delete methods of the SafeCS object.
[0048] m_IRefCount is used throughout the SafeCS object's function members. This variable is used to keep track of the total number of threads which are either waiting to enter the critical section or has entered the critical section.
[0049] This reference count is a counter in the normal sense when the object is initialized and being used.
[0050] When the object is marked for deletion, this reference count will be greater than or equal to the value of TO_BE_DELETED. The reference count minus TO_BE_DELETED will give the number of threads which are either waiting to enter the critical section object or has entered the critical section object.
[0051] When the critical section object is actually deleted, the reference count will be made equal to DELETION_DONE, and any other thread which tries to enter the object after this will find the reference count value to be greater than this and will return failing the call.
TABLE 2 1 #include “pch.h” 2 #include “SafeCS.h” 3 #define TO_BE_DELETED (0x20000000) 4 //added to the reference count variable to indicate the object is to be deleted 5 #define DELETION_DONE (0x40000000) 6 //added to reference count var. to indicate that the object has been deleted and can't be used further 7 /********************************************************************************* 8 ** Function Name: SafeCS.Initialize( ) 9 ** Comments: simple fn. to initialize the object, ensure that the object is zero filled before calling this fn. 10 *********************************************************************************/ 11 BOOL SafeCS::Initialize( ) 12 { 13 //Step #1: ensure that this is not already initialized 14 if ( TRUE == m_fInit ) 15 return FALSE; 16 17 //Step #2: do the required setting up 18 InitializeCriticalSection ( &m_cs ); 19 m_lRefCount = 0; 20 m_fInit = TRUE; 21 //Step #3: things were successful 22 return TRUE; 23 } 24 /********************************************************************************* 25 ** Function Name: SafeCS.Enter( ) 26 ** Comments: to enter the critical section, will fail if the object is deleted (or marked for deletion) 27 *********************************************************************************/ 28 BOOL SafeCS::Enter( ) 29 { 30 //Step #1: valid only if this object has been initialized already (and not yet deleted) 31 if ( FALSE == m_fInit ) 32 return FALSE; 33 //Step #2: to ensure that the object is not yet deleted 34 // deleted objects will have this flag set on the reference count variable 35 // we do the increment simultaneously to have the operation as atomic 36 if ( DELETION_DONE <= InterlockedIncrement ( &m_lRefCount ) ) 37 return FALSE; 38 //Step #3: now we can safely enter the critical section as it is not yet deleted 39 // even if some other thread marks the object for deletion we don't mind 40 // as we have incremented the reference count, we can safely wait to enter 41 EnterCriticalSection ( &m_cs ); 42 //Step #4: but if it is marked for deletion, we have to leave and return failure 43 // while waiting, if some other guy has marked this object for deletion 44 // we must leave this object asap and return a failure 45 if ( TO_BE_DELETED <= m_lRefCount ) 46 { 47 Leave( ); 48 return FALSE; 49 } 50 //Step #5: return success, as we've successfully acquired the critical section object 51 return TRUE; 52 } 53 /********************************************************************************* 54 ** Function Name: SafeCS.Leave( ) 55 ** Comments: to leave an acquired critical section, assumes that the call will be legitimate (i.e., leave only if successfully entered) 56 *********************************************************************************/ 57 BOOL SafeCS::Leave( ) 58 { 59 //Step #1: valid only if this object has been initialized already 60 if ( FALSE == m_fInit ) 61 return FALSE; 62 //Step #2: leave the critical section first 63 LeaveCriticalSection ( &m_cs ); 64 //Step #3: check if we are the last person holding this critical section and delete if needed 65 // refer to MSDN to see how ‘InterlockedCompareExchange’ works 66 // we are the last person if reference count equals 1 or (TO_BE_DELETED+1) 67 // if the reference count is (TO_BE_DELETED+1), it means that we need to delete the object after this 68 // else if the reference count is ‘x’ or (TO_BE_DELETED+‘x’) where ‘x’>1, a simple decrement is enough 69 // if the critical section is deleted, we also update the reference count to indicate DELETION_DONE 70 if ( TO_BE_DELETED+1 == InterlockedCompareExchange ( &m_lRefCount, DELETION_DONE, TO_BE_DELETED+1 ) ) 71 { 72 m_fInit = FALSE; 73 DeleteCriticalSection ( &m_cs ); 74 } 75 else 76 InterlockedDecrement ( &m_lRefCount ); 77 //the object is not yet deleted, a simple reference count decrement is enough 78 //Step #4: we simply return a success 79 return TRUE; 80 } 81 /********************************************************************************* 82 ** Function Name: SafeCS.Delete( ) 83 ** Comments: used to mark that a critical section object is to be deleted and no one should be given access to it 84 *********************************************************************************/ 85 BOOL SafeCS::Delete( ) 86 { 87 //Step #1: valid only if this object has been initialized already 88 if ( FALSE == m_fInit ) 89 return FALSE; 90 //Step #2: enter the critical section, this is to ensure that a CS is not marked for deletion when someone else is holding it 91 // however, if the same thread is holding this critical section, it is not a problem 92 if ( TRUE == Enter( ) ) 93 { 94 //Step #3: add TO_BE_DELETED to the reference count to indicate that it is to be deleted 95 InterlockedExchangeAdd ( &m_lRefCount, TO_BE_DELETED ); 96 //Step #4: done the job, hereafter, anyone waiting to enter on the critical section will return with FALSE 97 // leave the critical section now 98 Leave( ); 99 } 100 //Step #5: we simply return a success 101 return TRUE; 102 }
[0052] The facility addresses the problem of calling safeAcquire or safeRelease before safeInitialize by maintaining and testing the m_flnit variable, which indicates whether the SafeSynchronization mechanism is currently initialized or uninitialized. safeAcquire and safeRelease both test this variable, and return failure if it is false.
[0053] The facility addresses the problem of a thread calling the safeAcquire or safeRelease function after the synchronization mechanism object has been deleted by calling safeDelete in the same manner as described immediately above.
[0054] The facility addresses the problem of a thread calling safeDelete while the synchronization mechanism is owned or being waited on by one or more other threads by ensuring that a thread which tries to delete the SafeSynchronizationMechanism object has to first acquire the synchronization mechanism (after ensuring that it is initialized first of all using safeInitialize( )). Once the synchronization mechanism is acquired in safeDelete( ), it is marked as unusable by other threads which might be waiting for it. (The TO_BE_DELETED flag is used for this.)
[0055] By acquiring the synchronization mechanism in safeDelete( ), the facility ensures that no other thread is holding onto it. Further, since the synchronization mechanism is not immediately deleted, but rather marked as unusable, other threads that are waiting for it still have the proper synchronization mechanism object to work upon.
[0056] If any thread waiting in safeAcquire( ) acquires the synchronization mechanism after it has been marked as unusable, it will release it immediately and the safeAcquire( ) call would fail (returning FALSE).
[0057] When the last thread waiting in Acquire( ) to acquire the synchronization mechanism while the synchronization mechanism is marked as unusable returns from Acquire( ), safeAcquire( ) marks the object as deleted, delete the synchronization mechanism, and fails the call (returning FALSE).
[0058] The techniques may be described in the general context of computer-executable instructions, such as program modules, executed by one or more computers or other devices. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various embodiments.
[0059] It will be appreciated by those skilled in the art that the above-described facility may be straightforwardly adapted or extended in various ways. For example, the facility may be used to interact with various types of synchronization mechanisms, implemented by various operating systems or other software systems. The facility may be implemented using various programming schemes, including but not limited to object-oriented programming and procedural programming. While the foregoing description makes reference to particular embodiments, the scope of the invention is defined solely by the claims that follow and the elements recited therein.
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A facility for managing a synchronization mechanism that supports initialization, acquisition, release, and deletion operations is described. When a thread seeks to perform the acquisition operation, the facility permits performance of the acquisition operation only if the initialization operation has been performed more recently than the deletion operation. When a thread seeks to perform the deletion operation, the facility waits until any threads that are seeking to perform the acquisition operation or have performed the acquisition operation more recently than the release operation have performed the release operation before deleting the synchronization mechanism.
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FIELD OF THE INVENTION
[0001] The invention relates to memory circuits. In particular, the invention relates to improving power consumption and memory access speed in a dynamic random access memory (DRAM) circuit.
BACKGROUND OF THE INVENTION
[0002] An essential semiconductor device is semiconductor memory, such as a random access memory (RAM) device. A RAM device allows the user to execute both read and write operations on its memory cells. Typical examples of RAM devices include dynamic random access memory (DRAM) and static random access memory (SRAM).
[0003] DRAM is a specific category of RAM containing an array of individual memory cells, where each cell includes a capacitor for holding a charge and a transistor for accessing the charge held in the capacitor. The transistor is often referred to as the access transistor or the transfer device of the DRAM cell.
[0004] FIG. 1 illustrates a portion of a DRAM memory circuit containing two neighboring DRAM cells 10 . Each cell 10 contains a storage capacitor 14 and an access field effect transistor or transfer device 12 . For each cell, one side of the storage capacitor 14 is connected to a reference voltage (illustrated as a ground potential for convenience purposes). The other side of the storage capacitor 14 is connected to the drain of the transfer device 12 . The gate of the transfer device 12 is connected to a signal line known in the art as a word line 18 . The source of the transfer device 12 is connected to a signal line known in the art as a bit line 16 (also known in the art as a digit line). With the memory cell 10 components connected in this manner, it is apparent that the word line 18 controls access to the storage capacitor 14 by allowing or preventing the signal (representing a logic “0” or a logic “1”) carried on the bit line 16 to be written to or read from the storage capacitor 14 . Thus, each cell 10 contains one bit of data (i.e., a logic “0” or logic “1”).
[0005] A typical DRAM circuit has input/output (I/O) transistors that allow data to be read from and written to a memory array using specific I/O data lines. Due to the DRAM memory array structure, I/O data line lengths will vary. This occurs because a particular I/O data line is coupled to an individual memory module that can be located in one of various locations within the memory array. The capacitance on an individual I/O line varies with the length of the data line. The longer the I/O data line, the greater the capacitance of the I/O data line and the greater amount of time required before data transmitted on the I/O can be sensed.
[0006] FIG. 2 illustrates a conventional DRAM circuit 100 . DRAM circuit 100 includes DRAM memory array 110 , datapath 120 , delay circuit 130 , combinatorial logic circuit 140 and output pads 150 . Memory array 110 includes individual DRAM memory modules 112 , 114 , 116 and 118 that possess a certain amount of memory, for example 512 Kb. The memory array 110 may contain more or less memory modules. Moreover, the size of each module may contain more or less memory than illustrated. Each memory module 112 , 114 , 116 , 118 is connected to a data sense amplifier (DSA), such as for example, DSAs 122 and 124 , in datapath 120 by I/O data lines.
[0007] As illustrated, due to an alignment of memory modules, the I/O data lines 113 for memory module 112 are longer than the I/O data lines 119 for memory module 118 . The difference in length is due to the fact that memory module 112 is farther away from the data sense amplifiers than memory module 118 . Consequently, the capacitance of the I/O data lines 113 (e.g., 0.8-1.2 pf, typically around 1 pf) connected to memory module 112 is greater than the capacitance of the I/O pair tine 119 (e.g., 0.4-0.8 pf, typically around 0.6 pf) connected to memory module 118 . A threshold distance between I/O data lines which is considered-short or long is dependent upon various factors that include e.g., speed, current, layout, process and voltage.
[0008] Delay circuit 130 , which includes delay device 132 , is coupled to an enable line of each data sense amplifier and controls the timing of when data is received by the data sense amplifiers from an I/O data line. The length of delay produced by delay circuit 130 before enabling all data sense amplifiers is associated with the memory module with the longest I/O data lines, in this case memory module 112 . Thus, each I/O data line, regardless of its length, has the same delay (i.e., the delay associated with memory module 112 and I/O data lines 113 ).
[0009] Because transmissions on all the I/O data lines are given the same amount of delay, longer I/O data lines, i.e., 113 , experience an acceptable change in voltage (delta V) of approximately 300 mV as illustrated in FIG. 5 . Shorter I/O data lines; however, experience a delta V equal to a full rail voltage, which results in unnecessary power consumption.
[0010] Once data is sensed by the sense amplifiers, i.e., DSAs 122 and 124 , the sensed data is transmitted to combinatorial logic circuit 140 via data lines. The data is subsequently sent to output pads 150 for use by a requesting device.
[0011] FIG. 5 illustrates the signal timing for DRAM circuit 100 . At time t 1 , a chip select signal CS for all data sense amplifiers transitions from low to high. At time t 2 , the delay signal Hfflat produced by delay circuit 130 transitions from low to high, enabling all data sense amplifiers in datapath 120 . Delay signal Hfflat is associated with and generated in accordance with the time required for the most capacitive I/O data lines, in this case the I/O data line 113 . Delay signal Hfflat is used to transfer data from memory module 112 to DSA 124 within a given time period, for example 2 ns. At time t 3 , the delay signal Hfflat transitions from high to low. While the delay signal Hfflat is high, the delta V for the more capacitive I/O data lines is approximately 300 mv. However, the delta V for the less capacitive I/O data lines is a full rail voltage, which produces an unnecessary current draw for the less capacitive I/O data lines. At time t 4 , I/O pull up signal IOPU transitions from low to high in order to pull the I/O lines high.
[0012] As discussed above, in current designs all I/O data lines coming from a memory array are given equal separation time before being sensed by a datapath sense amplifier. The delay for transmission on the I/O lines affects the memory access time for the memory array. In addition, I/Os with a lower capacitance must remain on longer to accommodate the timing of more capacitive I/Os, resulting in excessive power consumption.
[0013] Thus, it is desirable to produce a memory device with reduced power consumption.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention provides a DRAM circuit that consumes less power during memory array access. The sense timing for an individual I/O data line connected to a memory array is dependent upon its length/capacitance. I/O data lines that are smaller in comparison to a predetermined length/capacitance are sensed before I/O data lines that are larger than the predetermined length/capacitance. This allows faster access from parts of the memory array connected with a smaller I/O data line.
[0015] By sensing an I/O data line based on its length/capacitance only the minimum required separation time for the I/O data line is utilized, current during array access and overall power consumption are both reduced. This sensing technique also permits faster back-to-back array accesses on less capacitive I/O data lines because the sensing of the I/O data lines are controlled independently of the sensing of the other I/O data lines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing and other advantages and features of the invention will become more apparent from the detailed description of exemplary embodiments provided below with reference to the accompanying drawings in which:
[0017] FIG. 1 is a circuit diagram illustrating conventional dynamic random access memory (DRAM) cells;
[0018] FIG. 2 is a conventional DRAM circuit showing input/output lines;
[0019] FIG. 3 is an exemplary DRAM circuit according to an embodiment of the present invention;
[0020] FIG. 4 is a timing diagram for sensing I/O lines in the FIG. 3 circuit according to the present invention;
[0021] FIG. 5 is a timing diagram for sensing I/O lines according for a conventional DRAM circuit; and
[0022] FIG. 6 is a processor system using a FIG. 3 DRAM circuit.
DETAILED DESCRIPTION OF THE INVENTION
[0023] In the following detailed description, reference is made to the accompanying drawings, which are a part of the specification, and in which is shown by way of illustration various embodiments whereby the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to make and use of the invention. It is to be understood that other embodiments may be utilized, and that structural, logical, and electrical changes, as well as changes in the materials used, may be made without departing from the spirit and scope of the present invention.
[0024] FIG. 3 illustrates an exemplary DRAM circuit 200 according to an embodiment of the present invention. DRAM circuit 200 is similar to DRAM circuit 100 and includes memory array 110 , datapath 120 , combinatorial logic circuit 140 and output pads 150 . However delay circuit 130 ( FIG. 1 ) is replaced with delay circuit 210 constructed in accordance with the invention.
[0025] Delay circuit 210 has multiple delay devices, i.e., delay devices 212 and 214 , which are used to control the timing of when data is received and sensed by the data sense amplifiers from respective I/O data lines. Instead of delaying all data sense amplifiers based on the longest I/O data lines, the delay timing for the sense amplifiers are divided into stages that allow shorter I/O data lines to be sensed sooner than longer I/O data lines.
[0026] With staged delays, delay circuit 210 produces multiple delay times. For example, because memory module 112 has long I/O data lines (in comparison to the other I/O data lines), a longer delay is required before its associated data sense amplifier 124 should be enabled. Accordingly, the enable line for data sense amplifier 124 receives a delay signal HffLong that enables data sense amplifier 124 according to a timing delay necessary for longer, more capacitive I/O data lines. The delay signal HffLong is created by combining the timing delay produced by both delay devices 212 and 214 . The determination of which data line receives which delay signal (HffLong or HffShort) can be determined at various stages in design, for example fabrication, testing, etc.
[0027] Because memory module 118 has short I/O data lines, a shorter delay (in comparison to the other I/O data lines), is required before the data sense amplifier 122 is enabled. Accordingly, the enable line for data sense amplifier 122 receives a delay signal HffShort, which enables data sense amplifier 122 according to a timing delay necessary for shorter, less capacitive I/O lines. The delay signal HffShort is created by delay device 212 only. Data is output from the data sense amplifiers 122 and 124 to output pads 150 as previously discussed.
[0028] FIG. 4 illustrates exemplary signal timing for DRAM circuit 200 . At time t 1 , chip select signals CS Short and CS Long transition from low to high. At time t 2 , the delay signal HffShort produced by delay device 212 of delay circuit 210 transitions from low to high, enabling the sense amplifiers in datapath 120 connected to the shorter, less capacitive I/O lines pairs. At time t 3 , the delay signal HffLong produced by delay devices 212 and 214 of delay circuit 210 transitions from low to high, enabling the sense amplifiers in datapath 120 connected to the longer, more capacitive I/O lines pairs. At time t 4 , the delay signal HffShort transitions from high to low since data transfer to data sense amplifier 122 has completed. Also at time t 4 , the chip select signal CS Short for the data sense amplifiers coupled to delay circuit 210 by delay signal HffShort, i.e., data sense amplifier 122 , transitions from high to low, and I/O pull up signal IOPU Short transitions from low to high in order to pull the shorter, less capacitive I/O lines high. At time t 5 , the delay signal HffLong transitions from high to low once data transfer to data sense amplifier 124 is complete. Also at time t 5 , the chip select signal CS Long for the data sense amplifiers coupled to delay circuit 210 by delay signal HffLong, i.e., data sense amplifier 124 , transitions from high to low. At time t 6 , I/O pull up signal IOPU Long transitions from low to high in order to pull the longer, more capacitive I/O data lines high.
[0029] In utilizing multiple delay signals, HffShort and HffLong, sensing of those I/O data lines that are shorter is not delayed for an unnecessary amount of time (which as discussed above with regard to FIG. 5 leads to an increased current draw during memory access and increased power consumption). By sensing shorter, less capacitive I/O data lines independently of the longer, more capacitive I/O data lines, the delta V for the more capacitive I/O data lines and less capacitive I/O data lines are both approximately 300 mv, which is desirable (in comparison to the prior art). Consequently, the current draw for the less capacitive I/O data lines is thereby reduced.
[0030] FIG. 6 illustrates an exemplary processing system 500 that utilizes a DRAM memory device 200 in accordance with the embodiments of the present invention disclosed above in FIGS. 1-3 . FIG. 4 depicts an exemplary personal computer or work station architecture. The processing system 500 includes one or more processors 501 coupled to a local bus 504 . A memory controller 502 and a primary bus bridge 503 are also coupled to the local bus 504 . The processing system 500 may include multiple memory controllers 502 and/or multiple primary bus bridges 503 . The memory controller 502 and the primary bus bridge 503 may be integrated as a single device 506 .
[0031] The memory controller 502 is also coupled to one or more memory buses 507 . Each memory bus accepts memory components 508 that include at least one memory device 200 . The memory components 508 may be a memory card or a memory module. Examples of memory modules include single inline memory modules SIMMs and dual inline memory modules DIMMs. The memory components 508 may include one or more additional devices 509 . For example, in a SIMM or DIMM, the additional device 509 might be a configuration memory, such as serial presences detect SPD memory. The memory controller 502 may also be coupled to a cache memory 505 . The cache memory 505 may be the only cache memory in the processing system. Alternatively, other devices, for example, processors 501 may also include cache memories, which may form a cache hierarchy with cache memory 505 . If the processing system 500 includes peripherals or controllers, which are bus masters or which support direct memory access DMA, the memory controller 502 may implement a cache coherency protocol. If the memory controller 502 is coupled to a plurality of memory buses 516 , each memory bus 516 may be operated in parallel, or different address ranges may be mapped to different memory buses 507 .
[0032] The primary bus bridge 503 is coupled to at least one peripheral bus 510 . Various devices, such as peripherals or additional bus bridges may be coupled to the peripheral bus 510 . These devices may include a storage controller 511 , a miscellaneous I/O device 514 , a secondary bus bridge 515 , a multimedia processor 518 , and a legacy device interface 520 . The primary bus bridge 503 may also be coupled to one or more special purpose high speed ports 522 . In a personal computer, for example, the special purpose port might be the Accelerated Graphics Port AGP, used to couple a high performance video card to the processing system 500 .
[0033] The storage controller 511 couples one or more storage devices 513 , via a storage bus 512 , to the peripheral bus 510 . For example, the storage controller 511 may be a SCSI controller and storage devices 513 may be SCSI discs. The I/O device 514 may be any type of peripheral. For example, the I/O device 514 may be a local area network interface, such as an Ethernet card. The secondary bus bridge may be used to interface additional devices via another bus to the processing system. For example, the secondary bus bridge may be a universal serial port USB controller used to couple USB devices 517 via to the processing system 500 . The multimedia processor 518 may be a sound card, a video capture card, or any other type of media interface, which may also be coupled to one additional device such as speakers 519 . The legacy device interface 520 is used to couple legacy devices, for example, older style keyboards and mice, to the processing system 500 .
[0034] The processing system 500 illustrated in FIG. 6 is only an exemplary processing system with which the invention may be used. While FIG. 3 illustrates a processing architecture especially suitable for a general purpose computer, such as a personal computer or a workstation, it should be recognized that well known modifications could be made to configure the processing system 500 to become more suitable for use in a variety of applications. For example, many electronic devices that require processing may be implemented using a simpler architecture that relies on a CPU 501 coupled to memory components 508 and/or memory buffer devices 504 . These electronic devices may include, but are not limited to audio/video processors and recorders, gaming consoles, digital television sets, wired or wireless telephones, navigation devices (including system based on the global positioning system GPS and/or inertial navigation), and digital cameras and/or recorders. The modifications may include, for example, elimination of unnecessary components, addition of specialized devices or circuits, and/or integration of a plurality of devices.
[0035] While the invention has been described and illustrated with reference to specific exemplary embodiments, it should be understood that many modifications and substitutions could be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.
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A DRAM circuit with reduced power consumption and in some circumstances faster memory array access speed. Input/output lines connected to a memory array are sensed according to their capacitance/length in comparison to a threshold capacitance/length. The out/output lines that are shorter, or less capacitive, than the threshold are sensed sooner than those input/output lines that are longer, more capacitive, than the threshold. Since shorter input/output lines are sensed sooner, they require less power and may be accessed faster.
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BACKGROUND
With the ever-increasing popularity of personal mobile devices, e.g., cell phones, smartphones, personal digital assistants (PDAs), personal music players, laptops, etc., ‘mobility’ has been the focus of many consumer products as well as services of wireless providers. For example, in the telecommunications industry, ‘mobility’ is at the forefront as consumers are no longer restricted by location with regard to communications and computing needs. Rather, today, as technology advances, more and more consumers use portable devices in day-to-day activities, planning and entertainment.
As mobile device popularity increases, the ability to make telephone calls, access electronic mail, communicate via instant message (IM) and access online services from any location has also continued to evolve. Although wireless technology for data transmission has been available for quite some time, limitations such as bandwidth and area coverage plague service providers. More particularly, these types of limitations have prevented providers from seamlessly establishing mass deployments of wireless networks.
More recent innovations such as the WiFi standards and other expanded wireless technologies have made it possible to deploy location-based (e.g., city-wide) wireless access networks and thereafter, to offer revenue-generating mobile wireless access services. However, most often, these wireless access networks do not extend to less populated areas due to driving economic concerns. Rather, these conventional networks target areas with a high population density and do not address those potential consumers in less populated areas. This lack of expansion is most often due to the wired characteristics of the wireless repeater nodes, as well as costs associated therewith. For example, most often, rural areas are not covered by the service area of a conventional cell tower or mesh network thereby leaving a gap in the coverage area.
An ‘opportunistic’ network can refer to the use of a co-operating set of mobile or stationary devices to transfer data whenever connection opportunities arrive. These opportunities may be limited by the effects of mobility, bandwidth limitations, and other factors. Both wired and wireless links can be used as connection opportunities. Opportunistic networks have the advantage of being able to employ “store and forward” data transfer where data is not sent from one end of the network to the other immediately, but is instead passed hop-by-hop and stored on intermediate nodes until that node has a suitable connection opportunity to pass it on in turn. This allows opportunistic networks to cope with large variations in network topology and with poor link qualities, in addition to traditional networking situations (e.g. where Internet access is available).
SUMMARY
The following presents a simplified summary of the innovation in order to provide a basic understanding of some aspects of the innovation. This summary is not an extensive overview of the innovation. It is not intended to identify key/critical elements of the innovation or to delineate the scope of the innovation. Its sole purpose is to present some concepts of the innovation in a simplified form as a prelude to the more detailed description that is presented later.
The innovation disclosed and claimed herein, in one aspect thereof, comprises an opportunistic network that can facilitate data transfer through a group of network connected devices where each device effectively contributes to the transfer of the information. In other words, the innovation describes an opportunistic network of devices where an external carrier need not be used in order to transfer data. Rather, the carrier infrastructure is embodied and distributed throughout the individual devices comprising the network.
In one aspect, the innovation describes a store/forward model by way of the opportunistic network whereby health-related data can be communicated to and shared between devices. This sophisticated communication framework can be based upon a peer-to-peer (P2P) framework, or combination of P2P together with an external (e.g., cell tower) infrastructure. For example, the infrastructure can be a completely ad hoc P2P or combination of ad hoc together with a traditional hub-and-spoke framework.
In various health-related aspects, the innovation can be applied to situations ranging from monitoring basic health-related patient criteria to proactively identifying and alerting of natural disasters and/or bioterrorism. In other words, if an effect is observed, it can be reported, captured and subsequently transferred across the opportunistic network to ensure prompt attention to the matter.
In yet another aspect thereof, a machine learning and reasoning (MLR) component is provided that employs a probabilistic and/or statistical-based analysis to prognose or infer an action that a user desires to be automatically performed. By way of example, MLR mechanisms can be employed to make inferences that facilitate timely and accurate transmission of data across the network, and to infer the correct recipient depending on properties of the data itself. In a specific example, an MLR component, based upon type of data, time of day and other contextual factors, can determine which devices to select as the destination for the data, and also as carriers across the opportunistic network in order to ensure timely and safe delivery of the data.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles of the innovation can be employed and the subject innovation is intended to include all such aspects and their equivalents. Other advantages and novel features of the innovation will become apparent from the following detailed description of the innovation when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a mobile device that facilitates transmission of data across an opportunistic network in accordance with an aspect of the innovation.
FIG. 2 illustrates an example wireless opportunistic network in accordance with an aspect of the innovation.
FIG. 3 illustrates an example data handoff by way of nodes of an opportunistic network in accordance with an aspect of the innovation.
FIG. 4 illustrates an example flow chart of procedures that facilitate transfer of data across a network in accordance with an aspect of the innovation.
FIG. 5 illustrates an example flow chart of procedures that facilitate establishment of a hop or carrier path through an opportunistic network in accordance with an aspect of the innovation.
FIG. 6 illustrates an example opportunistic connection component that enables a device to communication with another device in accordance with an aspect of the innovation.
FIG. 7 illustrates an example data communication component that facilitates receipt and transfer of data in accordance with an aspect of the innovation.
FIG. 8 illustrates an example receiving component that facilitates data analysis, verification and aggregation in accordance with an aspect of the innovation.
FIG. 9 illustrates an example analysis component that facilitates evaluation of data content in accordance with an aspect of the innovation.
FIG. 10 illustrates an example data transfer component that facilitates routing and transferring of data within an opportunistic network in accordance with an aspect of the innovation.
FIG. 11 illustrates an example data routing component that determines available and efficient routes throughout an opportunistic network in accordance with an aspect of the innovation.
FIG. 12 is a schematic block diagram of a portable device that facilitates analysis and transfer of data (e.g., health-related data) across an opportunistic network according to one aspect of the subject invention.
FIG. 13 illustrates an architecture of a portable device that includes a machine learning and reasoning component that can automate functionality in accordance with an aspect of the invention.
FIG. 14 illustrates a block diagram of a computer operable to execute the disclosed architecture.
FIG. 15 illustrates a schematic block diagram of an exemplary computing environment in accordance with the subject innovation.
DETAILED DESCRIPTION
The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the subject innovation. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the innovation.
As used in this application, the terms “component” and “system” are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component can be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components can reside within a process and/or thread of execution, and a component can be localized on one computer and/or distributed between two or more computers.
As used herein, the term to “infer” or “inference” refer generally to the process of reasoning about or inferring states of the system, environment, and/or user from a set of observations as captured via events and/or data. Inference can be employed to identify a specific context or action, or can generate a probability distribution over states, for example. The inference can be probabilistic—that is, the computation of a probability distribution over states of interest based on a consideration of data and events. Inference can also refer to techniques employed for composing higher-level events from a set of events and/or data. Such inference results in the construction of new events or actions from a set of observed events and/or stored event data, whether or not the events are correlated in close temporal proximity, and whether the events and data come from one or several event and data sources.
Referring initially to the drawings, FIG. 1 illustrates a system 100 that facilitates transmission of data across an opportunistic network in accordance with an aspect of the innovation. Generally, system 100 illustrates a mobile device 102 having an opportunistic connection component 104 and a data communication component 106 therein. These components ( 104 , 106 ) enable the transfer of an input (e.g., 108 ) to a target device (not shown). In other words, output (e.g., 110 ) can be delivered to a target device from mobile device 102 without any external infrastructure.
As will be understood upon a review of the figures that follow, the communication infrastructure can be totally encapsulated within network-connected mobile devices (e.g., 102 ) in the form of an opportunistic connection component 104 and a data communication component 106 . In other words, in one example, a peer-to-peer (P2P) type infrastructure can be established such that the external communication infrastructures are not necessary to enable communication. However, it is to be understood that some of the features, functions and benefits described herein can be employed in other, more conventional, infrastructures such as hub and spoke (e.g., cell tower-based) infrastructures as well as combinations with P2P infrastructures.
Referring now to FIG. 2 , there is illustrated a system 200 that facilitates the transmission of health-related data by way of an opportunistic network. As shown, a health-related opportunistic network 202 can be employed to transfer data between an origin device 204 to a target device 206 . Because mobile devices (e.g., cell phones) are ubiquitous in many markets today, it can be possible to establish a peering network or opportunistic network 202 such that each device can participate in information transfer throughout the network. As depicted by dashed lines throughout the network 202 , information can have multiple paths by which it can travel from an origin device 204 to a target device 206 . These multiple paths illustrate sophisticated collaboration between the devices with respect to bandwidth, available processing capacity, signal strength, cost, security, etc. Effectively, logic within each device can establish redundancies associated with the type of data which can ensure timely and accurate delivery.
In summary, the subject innovation relates to an opportunistic network 202 that can be established between network-connected mobile devices (e.g., 204 , 206 ), for example, cellular telephones, personal digital assistants (PDAs), smartphones or the like. Rather than employing conventional cell towers that provide a centralized topology, the innovation shifts to an ‘erratic’ or dynamic topology 202 where each mobile device can carry a piece of traffic such that the infrastructure is integral to the mobile device itself (or group of devices themselves). In one example, it is possible to use the opportunistic network 202 as an intranet where data packets can be aggregated and passed to devices within the network.
It will be appreciated that one feature/benefit of the opportunistic network 202 is that low communication signals can be mitigated and possibly eliminated. Reduction and/or elimination of low signal problems is essentially possible because the vast number of mobile (e.g., cellular) devices employed will effectively create a service grid 202 where each device is a node of the grid 202 . As an inherent feature of the grid 202 , each device can obtain service through a number of proximate devices. Thus, redundancy can be accomplished thereby enhancing performance of the system 200 .
Overall, this opportunistic network 202 can provide ubiquitous connectivity and/or computing between network-connected devices. In other words, the more connected devices available, the better they can participate in the health-related eco-system of the subject innovation. As described supra, it is also to be understood that this ‘opportunistic’ 202 technique can be applied to most any type of portable and/or mobile computing device such as cellular telephones, smartphones, PDAs, laptops or the like.
In one particular aspect, the opportunistic network 202 can execute applications with particular networking needs in a health-care context. For example, a first device 204 such as an event recorder component can be used to capture images of events associated with a monitored entity (e.g., patient, elderly person). The images can be initially stored on the first device and transferred to a subsequent device when an opportunistic connection is able to be established. In other words, when the location of the origin device in relation to the opportunistic network 202 , or in relation to at least one device of the opportunistic network, permits connectivity, the images can be automatically transferred in a P2P manner. As will be understood, this transfer can occur instantaneously (e.g., real-time), or stored/forwarded in accordance with forward criteria. For instance, images can be batch downloaded based upon a user-defined or location-based trigger.
FIG. 3 is provided to add perspective to an aspect of the innovation. Effectively, FIG. 3 illustrates an example data handoff 300 between devices of an opportunistic network. As shown, health data 302 can be transmitted from a monitored entity to a first device. This handoff of data is illustrated as a first transmission path 304 . Subsequently, the data can be passed or forwarded to other devices within the opportunistic network as indicated by transmission paths 306 - 310 . Although only four passes are illustrated in FIG. 3 , it is to be appreciated that the opportunistic network can include N devices, where N is an integer.
Accordingly, the data can be passed throughout the opportunistic network until ultimately reaching the end device 312 . It is to be understood and appreciated that this example illustrated in FIG. 3 is somewhat simplistic in nature and is provided to illustrate core concepts of store/forward of the innovation. In other aspects, multiple paths can be established between devices in order to effectively and/or efficiently transfer data within the opportunistic network. These alternative aspects are to be included within the scope of the innovation and claims appended hereto.
FIG. 4 illustrates a methodology of transmitting data within an opportunistic networking accordance with an aspect of the innovation. While, for purposes of simplicity of explanation, the one or more methodologies shown herein, e.g., in the form of a flow chart, are shown and described as a series of acts, it is to be understood and appreciated that the subject innovation is not limited by the order of acts, as some acts may, in accordance with the innovation, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the innovation.
At 402 , an opportunistic connection can be established, for example, a P2P connection can be established directly between mobile devices (e.g., cell phones). In other aspects, ‘hybrid’ connections can be established, for example, a connection to a opportunistic network can be established that employs both P2P as well as conventional hub-and-spoke (e.g., cell tower) technologies. It is to be understood that the innovation described herein includes most any connection framework or infrastructure completely or partially embodied within a distributed mobile device network. As such, although many examples described herein are directed to a P2P protocol, other examples exist and are to be included within the scope of this disclosure and claims appended hereto.
A path from an origin device (or group of devices) to a target device (or group of devices) can be determined at 404 . In other words, whether, one-to-many, many-to-many, many-to-one, or one-to-one, a path (or appropriate paths) throughout the network can be determined at 404 . This path(s) can identify hops necessary to reach a desired target location as a function of most any criteria, including but not limited to, location, time of day, context, traffic content, sender identity, receiver identity, etc. As will be understood upon a review of the figures that follow, a policy and/or inference can be used to determine the path throughout the network.
Once a path is determined, the data can be transmitted at 406 . However, it is to be understood that, in aspects, the complete path need not be determined before the data is transferred. Rather, only the next hop toward a target location needs to be established. For example, because the network can be dynamically changing (e.g., as mobile devices travel in/out of range), each hop within the journey to the target can be independently determined. This is indicated by the dashed line between 406 and 404 , which effectively denotes the possible recursive nature of these acts within the methodology.
Referring now to FIG. 5 , there is illustrated a methodology of establishing and selecting a connection in accordance with an aspect of the innovation. Essentially, this methodology illustrates the ability to employ sophisticated intelligence or logic as well as inference mechanisms to establish a connection within the opportunistic network by which data can be transmitted. Accordingly, a different connection can be selected for a routine voice call as would be for a priority health-related data transfer (e.g., life threatening heart rate).
Similarly, a different connection can be selected for unprivileged versus confidential or classified information. This connection can be a function of the number of hops necessary to reach a target, integrity of the carrier unit, etc. By way of further example, an analysis can be determined with regard fluidity of the opportunistic network thereby locating a potential carrier unit that is traveling closer to a potential target. As such, this carrier unit could be deemed desirable as a lesser number of hops could potentially be necessary to reach the target, thereby protecting the data from unintentional disclosure, loss or corruption.
At 502 , an opportunistic connection can be established. Here, the location and/or motion of a subject device can be considered in determining availability of a transmission opportunistic network. At 504 , a determination can be made if a connection is available. If not, establishment of an opportunistic connection continues until the subject unit is within range of an available next-hop device. In an example, data can be stored upon a mobile device that is ‘out of range’ of any suitable transmission path. As such, data, for example health-related statistics, can continue to be aggregated until the mobile device becomes connected to an appropriate target device. In this example, it can be possible for the mobile device to continually monitor and store physiological statistics of a patient over a period of time. Subsequently, the unit can be automatically configured to forward or dump the data when the device becomes connected to a health care office. These concepts are better illustrated by acts 506 and 508 that follow.
Once an initial connection is made, hop options can be identified as a function of the connected network. For example, as described above, criteria such as relative location and/or motion based upon the origin and target can be factored to determine available hop options. Still further, context such as current activity of a particular unit can be factored into hop option availability.
At 508 , a next hop unit can be selected as a function of the dynamic network as well as a function of criteria of each unit within the network. As described above, the next hop can be a function of data type (e.g., voice, health, urgent, confidential, non-urgent) as well as a function of criteria of devices within the network, for example, location, motion, availability, device type, owner, classification, inferred destination, etc. It is to be understood that the examples are too numerous to list thus, alternative aspects that employ features, functions and benefits contemplated herein as well as by those in the art are to be included within the scope of this disclosure and claims appended hereto.
Referring now to FIG. 6 , an example block diagram of an opportunistic connection component 102 (as described with reference to FIG. 1 ) is shown. Generally, an opportunistic connection component 102 can include a network analysis component 602 and a connection selection component 604 , each of which will be described in greater detail infra. Together, these components ( 602 , 604 ) enable a device to intelligently analyze an available network and to thereafter select and appropriate connection in view of those connections available.
The network analysis component 602 can search for an available network or device available for connection. As well, the network analysis component 602 can analyze and/or evaluate the details of available devices within a network. For example, as mentioned above, the network analysis component 602 can search for an available network and subsequently evaluate availability and criteria of devices within the identified network.
The connection selection component 604 can be employed to intelligently decide an appropriate device for which to connect. It is to be understood that the store/forward concepts described herein enable unique opportunities for service providers. For instance, a service provider can offer different rate packages in accordance with reserving a portion of a device's processing capability. In other words, if a user is willing to allow a device to be used as a hop or carrier device for other's traffic, a service provider can incorporate this into the user's service plan, for example, by offering a lower rate if there is an agreement to share resources (e.g., processor, storage). It will be appreciated that these monetization schemes can be based upon most any criteria, for example, permit transfer at a particular time of day, day of week, for a particular type of traffic, from particular origins, etc.
FIG. 7 illustrates an example block diagram of a data communication component 104 which generally includes a receiving component 702 and a data transfer component 704 . Essentially, the receiving component 702 can receive data from a source (e.g., physiological sensor, environmental sensor, user, application) or group of sources, analyze the data, verify the data and aggregate data (if desired). The data transfer component 704 can effectively forward the data to an appropriate target or group of targets. Each of these components ( 702 , 704 ) will be described in more detail with reference to the figures that follow.
FIG. 8 illustrates a block diagram of an example receiving component 702 in accordance with an aspect of the innovation. As shown, generally, the receiving component 702 can include an analysis component 802 , a verification component 804 and an aggregation component 806 each of which enable a device to capture information in the ‘store’ phase of a ‘store/forward’ process. More particularly, these components ( 802 , 804 , 806 ) enable sophisticated logic with regard to a data input 808 , such as health-related data. As will be understood, the input 808 can be of most any data format, including but not limited to, alphanumeric text, audio, video, image, etc.
In operation, the analysis component 802 can evaluate the data to determine criteria of the data, for example, type, size, origin, etc. It is to be appreciated that data can be push to or pulled by way of the receiving component 702 . Once analyzed, the receiving component 702 can determine if the data is to be immediately forwarded, aggregated, etc. or if the data should be stored (e.g., cached, buffered) for later action. For example, the receiving component 702 , based upon the type of data, can determine if more data is to be received, urgency of delivery (e.g., priority), target location, etc. In addition to core content analysis techniques, the analysis component 802 can also employ techniques such as pattern recognition, speech recognition, or the like to analyze content of the received data.
The verification component 804 can be employed to confirm accurate delivery of the data. Here, accuracy relates both to the lack of corruption as well as completeness of the data. In other words, the verification component 804 can establish if more information is necessary to complete the data transmission before a ‘forward’ action or transfer of the data is instantiated.
The aggregation component 806 can facilitate collection of additional information if deemed necessary. For example, if the verification component 804 deems a transmission incomplete, the aggregation component 806 can be employed to collect additional information thus, completing the transmission. In addition to completeness, the logic of the verification component 806 can be employed to otherwise determine if more information can be gathered. For example, if it is deemed that current information is to be delivered to a particular target within the network and capacity is still available to capture additional information bound for the same target, in the interest of efficiency, the aggregation component 806 can gather additional information prior to forwarding. For instance, information about a health-related issue can be gathered from other proximate devices in the event that capacity is available. Here, this additional information can give a different perspective of an event such as images of a patient just prior to a heart attack, epileptic seizure, outburst, collapse, etc.
Referring now to FIG. 9 , an example block diagram of an analysis component 802 is shown as having a content analysis component 902 , a target determination component 904 , and a policy component 906 . As described above, each of these components contribute to intelligent process of data. Continuing with the health-related example from above, data can be analyzed to determine type and relevance of the data, where the data is to be sent and, based upon determined criteria, how best and most efficiently to transfer the data. This functionality can be accomplished by the analysis component 902 , the target determination component 904 and the policy component 906 respectively.
More specifically, the content analysis component 902 can evaluate received data to determine characteristics that can be used in processing and handling the data. For example, suppose the data is received from a physiological sensor mechanism—in this example, the content analysis can determine what the information represents (e.g., blood pressure measurement from a particular patient) and, based upon the determined content, it can further be determined if the information is urgent, confidential, etc. This determination can be made as a function of policy component 906 . Here, the policy component 906 can include rules for quality of service, priority delivery, etc. all of which can be factored to determine delivery.
The target determination component 904 can further employ the policy 906 in determining where to deliver the information. For example, suppose A is a patient of doctor B—here, if it is determined that the information is not urgent, it can routinely be delivered to doctor B no matter how long the delivery may take. However, if it is determined that urgent or priority delivery is desired, the target determination component 904 can identify another suitable target such that action can be promptly taken based upon the type of information. It is also to be understood that, the target determination component can identify multiple targets to which to deliver the information. Continuing with the above example, here, the data can be sent to the alternative location (e.g., emergency medical facility) so as to prompt immediate action while still delivering a copy of the information to doctor B.
FIG. 10 illustrates an example block diagram of a data transfer component 704 in accordance with an aspect of the innovation. Generally the data transfer component 704 includes a data routing component 1002 and a transmission system component 1004 . As the target destinations are determined by the content analysis component 902 , the data routing component 1002 can be employed to determine specifics with regard to transferring the data throughout the network. The data routing component 1002 employs specifics about the data in determining how best to route the data throughout the network.
The transmission system component 1004 enables transfer of the data within the network. For example, the transmission system component 1004 can be based upon a P2P communications network that allows all devices in the network to act as servers and share their files with all other users and devices on the network. In accordance with the opportunistic network described herein, in aspects, most any wireless protocol can be used for example, most any cellular technology, 802.11, infrared, Bluetooth, or the like.
FIG. 11 illustrates an example block diagram of a data routing component 904 . In determining a route (or group of routes) throughout the opportunistic network, a proximate device locator component 1102 can be used to identify optional ‘in-range’ devices by which data can be transferred. Further, the proximate device locator component 1102 can include logic capable of inferring locations of devices based upon historical and/or statistical data. In other words, machine learning and reasoning (MLR) mechanisms can be employed to infer if a device will be in range when data is ready or should/could be transferred.
A transmit path determination component 1104 can employ the proximate device information to specify a route (or group of routes) throughout the opportunistic network. This component can also employ MLR mechanisms when determining hops or carrier devices in view of the dynamic network as a function of the data. Both the proximate device locator component 1102 as well as the transit path determination component 1104 can optionally factor device load into decisions. For instance, an optional load analysis component 1106 can be employed to assist in device identification and path determination as a function of current and/or inferred future load of a device.
Referring now to FIG. 12 , there is illustrated a schematic block diagram of a portable device 1200 according to one aspect of the subject innovation, in which a processor 1202 is responsible for controlling the general operation of the device 1200 . It is to be understood that the portable device 1200 can be representative of most any portable device including, but not limited to, a cell phone, smartphone, PDA, a personal music player, image capture device (e.g., camera), personal game station, health monitoring device, event recorder component, etc.
The processor 1202 can be programmed to control and operate the various components within the device 1200 in order to carry out the various functions described herein. The processor 1202 can be any of a plurality of suitable processors. The manner in which the processor 1202 can be programmed to carry out the functions relating to the subject innovation will be readily apparent to those having ordinary skill in the art based on the description provided herein. As will be described in greater detail infra, an MLR component and/or a rules-based logic component can be used to effect an automatic action of processor 1202 .
A memory and storage component 1204 connected to the processor 1202 serves to store program code executed by the processor 1202 , and also serves as a storage means for storing information such as data, services, metadata, device states or the like. In aspects, this memory and storage component 1204 can be employed in conjunction with other memory mechanisms that house health-related data. As well, in other aspects, the memory and storage component 1204 can be a stand-alone storage device or otherwise synchronized with a cloud or disparate network based storage means, thereby established a local on-board storage of health-related data.
The memory 1204 can be a non-volatile memory suitably adapted to store at least a complete set of the information that is acquired. Thus, the memory 1204 can include a RAM or flash memory for high-speed access by the processor 1202 and/or a mass storage memory, e.g., a micro drive capable of storing gigabytes of data that comprises text, images, audio, and video content. To this end, it is to be appreciated that the health-related data described herein can be of most any form including text (e.g., sensor readings), images (e.g., captured image sequences) as well as audio or video content. According to one aspect, the memory 1204 has sufficient storage capacity to store multiple sets of information relating to disparate services, and the processor 1202 could include a program for alternating or cycling between various sets of information corresponding to disparate services.
A display 1206 can be coupled to the processor 1202 via a display driver system 1208 . The display 1206 can be a color liquid crystal display (LCD), plasma display, touch screen display or the like. In one example, the display 1206 is a touch screen display. The display 1206 functions to present data, graphics, or other information content. Additionally, the display 1206 can display a variety of functions that control the execution of the device 1200 . For example, in a touch screen example, the display 1206 can display touch selection buttons which can facilitate a user to interface more easily with the functionalities of the device 1200 .
Power can be provided to the processor 1202 and other components forming the device 1200 by an onboard power system 1210 (e.g., a battery pack). In the event that the power system 1210 fails or becomes disconnected from the device 1200 , a supplemental power source 1212 can be employed to provide power to the processor 1202 (and other components (e.g., sensors, image capture device)) and to charge the onboard power system 1210 . The processor 1202 of the device 1200 can induce a sleep mode to reduce the current draw upon detection of an anticipated power failure.
The device 1200 includes a communication subsystem 1214 having a data communication port 1216 , which is employed to interface the processor 1202 with a remote computer, server, service, or the like. The port 1216 can include at least one of Universal Serial Bus (USB) and IEEE 1394 serial communications capabilities. Other technologies can also be included, but are not limited to, for example, infrared communication utilizing an infrared data port, Bluetooth™, etc.
The device 1200 can also include a radio frequency (RF) transceiver section 1218 in operative communication with the processor 1202 . The RF section 1218 includes an RF receiver 1220 , which receives RF signals from a remote device via an antenna 1222 and can demodulate the signal to obtain digital information modulated therein. The RF section 1218 also includes an RF transmitter 1224 for transmitting information (e.g., data, service) to a remote device, for example, in response to manual user input via a user input 1226 (e.g., a keypad) or automatically in response to a detection of entering and/or anticipation of leaving a communication range or other predetermined and programmed criteria.
An opportunistic connection component 1228 is provided which, as described supra, can facilitate connection of the device 1200 with an opportunistic network which can be used to transmit data in a device-to-device manner (e.g., P2P). Additionally, a data communication component 1230 can be employed to further facilitate delivery of data to a target device via the opportunistic network. It is to be appreciated that these components can enable functionality of like components (and sub-components) described supra.
FIG. 13 illustrates an example device 1300 that employs MLR component 1302 which facilitates automating one or more features in accordance with the subject innovation. The subject innovation (e.g., in connection with determining carrier devices, delivery priority, data characteristics/completeness) can employ various MLR-based schemes for carrying out various aspects thereof. For example, a process for determining which carrier devices to employ as a function of data type can be facilitated via an automatic classifier system and process. Moreover, where multiple paths to a target are available, the classifier can be employed to determine which carrier devices to select in view of context and other situational factors.
A classifier is a function that maps an input attribute vector, x=(x1, x2, x3, x4, xn), to a confidence that the input belongs to a class, that is, f(x)=confidence(class). Such classification can employ a probabilistic and/or statistical-based analysis (e.g., factoring into the analysis utilities and costs) to prognose or infer an action that a user desires to be automatically performed.
A support vector machine (SVM) is an example of a classifier that can be employed. The SVM operates by finding a hypersurface in the space of possible inputs, which the hypersurface attempts to split the triggering criteria from the non-triggering events. Intuitively, this makes the classification correct for testing data that is near, but not identical to training data. Other directed and undirected model classification approaches include, e.g., naïve Bayes, Bayesian networks, decision trees, neural networks, fuzzy logic models, and probabilistic classification models providing different patterns of independence can be employed. Classification as used herein also is inclusive of statistical regression that is utilized to develop models of priority.
As will be readily appreciated from the subject specification, the subject innovation can employ classifiers that are explicitly trained (e.g., via a generic training data) as well as implicitly trained (e.g., via observing user behavior, receiving extrinsic information). For example, SVM's are configured via a learning or training phase within a classifier constructor and feature selection module. Thus, the classifier(s) can be used to automatically learn and perform a number of functions, including but not limited to determining according to a predetermined criteria how to classify data, where to send data, what priority should be employed, which carrier device(s) to employ, when to store and for how long, when to transmit data, etc. It is further to be appreciated that device 1300 can be equipped with an optional rules-based component (not shown) that facilitates policies and/or threshold based logic to be employed in making determinations associated with the functionality described herein.
In other aspects, the example device 1300 can trade off cost and privacy versus emergency needs. For example, if a user is having a heart attack, it may be a logical tradeoff to reveal confidential information and medical data (e.g., ECG) or how much it costs to send in exchange for reaching help in sufficient time to address the urgency. However, as described supra, in a ‘normal’ scenario, it can be possible to reduce or limit costs, for example, by storing data until a free network or P2P transfer agent is available rather than use expensive cell-based networks while maintaining data security/privacy.
In another example, the device 1300 can automatically decide (by inference) to send data to a service rather than sending to a node-name. By way of example, an ECG can be sent to a nearby paramedic or doctor, regardless of which one, or sent to whichever device is being carried by the on-call medical resident for Ward B, as opposed to a particular named doctor or named device. As described above, these decisions can be based upon user preference, inference or rule as a function of data content or context.
Still further, implicit trust relationships can be established based upon context. For example, with regard to the privacy and security context, when a device is in a hospital environment, a trust relationship can automatically be established with other devices in near proximity. This automatic trust establishment can facilitate interoperation without restrictive continual authentication demands.
Referring now to FIG. 14 , there is illustrated a block diagram of a computer operable to execute the disclosed architecture of an opportunistic network-based mobile device and network. In order to provide additional context for various aspects of the subject innovation, FIG. 14 and the following discussion are intended to provide a brief, general description of a suitable computing environment 1400 in which the various aspects of the innovation can be implemented. While the innovation has been described above in the general context of computer-executable instructions that may run on one or more computers, those skilled in the art will recognize that the innovation also can be implemented in combination with other program modules and/or as a combination of hardware and software.
Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods can be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.
The illustrated aspects of the innovation may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.
A computer typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media can comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the computer.
Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism, and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer-readable media.
With reference again to FIG. 14 , the exemplary environment 1400 for implementing various aspects of the innovation includes a computer 1402 , the computer 1402 including a processing unit 1404 , a system memory 1406 and a system bus 1408 . The system bus 1408 couples system components including, but not limited to, the system memory 1406 to the processing unit 1404 . The processing unit 1404 can be any of various commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit 1404 .
The system bus 1408 can be any of several types of bus structure that may further interconnect to a memory bus (with or without a memory controller), a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory 1406 includes read-only memory (ROM) 1410 and random access memory (RAM) 1412 . A basic input/output system (BIOS) is stored in a non-volatile memory 1410 such as ROM, EPROM, EEPROM, which BIOS contains the basic routines that help to transfer information between elements within the computer 1402 , such as during start-up. The RAM 1412 can also include a high-speed RAM such as static RAM for caching data.
The computer 1402 further includes an internal hard disk drive (HDD) 1414 (e.g., EIDE, SATA), which internal hard disk drive 1414 may also be configured for external use in a suitable chassis (not shown), a magnetic floppy disk drive (FDD) 1416 , (e.g., to read from or write to a removable diskette 1418 ) and an optical disk drive 1420 , (e.g., reading a CD-ROM disk 1422 or, to read from or write to other high capacity optical media such as the DVD). The hard disk drive 1414 , magnetic disk drive 1416 and optical disk drive 1420 can be connected to the system bus 1408 by a hard disk drive interface 1424 , a magnetic disk drive interface 1426 and an optical drive interface 1428 , respectively. The interface 1424 for external drive implementations includes at least one or both of Universal Serial Bus (USB) and IEEE 1394 interface technologies. Other external drive connection technologies are within contemplation of the subject innovation.
The drives and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, and so forth. For the computer 1402 , the drives and media accommodate the storage of any data in a suitable digital format. Although the description of computer-readable media above refers to a HDD, a removable magnetic diskette, and a removable optical media such as a CD or DVD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as zip drives, magnetic cassettes, flash memory cards, cartridges, and the like, may also be used in the exemplary operating environment, and further, that any such media may contain computer-executable instructions for performing the methods of the innovation.
A number of program modules can be stored in the drives and RAM 1412 , including an operating system 1430 , one or more application programs 1432 , other program modules 1434 and program data 1436 . All or portions of the operating system, applications, modules, and/or data can also be cached in the RAM 1412 . It is appreciated that the innovation can be implemented with various commercially available operating systems or combinations of operating systems.
A user can enter commands and information into the computer 1402 through one or more wired/wireless input devices, e.g., a keyboard 1438 and a pointing device, such as a mouse 1440 . Other input devices (not shown) may include a microphone, an IR remote control, a joystick, a game pad, a stylus pen, touch screen, or the like. These and other input devices are often connected to the processing unit 1404 through an input device interface 1442 that is coupled to the system bus 1408 , but can be connected by other interfaces, such as a parallel port, an IEEE 1394 serial port, a game port, a USB port, an IR interface, etc.
A monitor 1444 or other type of display device is also connected to the system bus 1408 via an interface, such as a video adapter 1446 . In addition to the monitor 1444 , a computer typically includes other peripheral output devices (not shown), such as speakers, printers, etc.
The computer 1402 may operate in a networked environment using logical connections via wired and/or wireless communications to one or more remote computers, such as a remote computer(s) 1448 . The remote computer(s) 1448 can be a workstation, a server computer, a router, a personal computer, portable computer, microprocessor-based entertainment appliance, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 1402 , although, for purposes of brevity, only a memory/storage device 1450 is illustrated. The logical connections depicted include wired/wireless connectivity to a local area network (LAN) 1452 and/or larger networks, e.g., a wide area network (WAN) 1454 . Such LAN and WAN networking environments are commonplace in offices and companies, and facilitate enterprise-wide computer networks, such as intranets, all of which may connect to a global communications network, e.g., the Internet.
When used in a LAN networking environment, the computer 1402 is connected to the local network 1452 through a wired and/or wireless communication network interface or adapter 1456 . The adapter 1456 may facilitate wired or wireless communication to the LAN 1452 , which may also include a wireless access point disposed thereon for communicating with the wireless adapter 1456 .
When used in a WAN networking environment, the computer 1402 can include a modem 1458 , or is connected to a communications server on the WAN 1454 , or has other means for establishing communications over the WAN 1454 , such as by way of the Internet. The modem 1458 , which can be internal or external and a wired or wireless device, is connected to the system bus 1408 via the serial port interface 1442 . In a networked environment, program modules depicted relative to the computer 1402 , or portions thereof, can be stored in the remote memory/storage device 1450 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers can be used.
The computer 1402 is operable to communicate with any wireless devices or entities operatively disposed in wireless communication, e.g., a printer, scanner, desktop and/or portable computer, portable data assistant, communications satellite, any piece of equipment or location associated with a wirelessly detectable tag (e.g., a kiosk, news stand, restroom), and telephone. This includes at least Wi-Fi and Bluetooth™ wireless technologies. Thus, the communication can be a predefined structure as with a conventional network or simply an ad hoc communication between at least two devices.
Wi-Fi, or Wireless Fidelity, allows connection to the Internet from a couch at home, a bed in a hotel room, or a conference room at work, without wires. Wi-Fi is a wireless technology similar to that used in a cell phone that enables such devices, e.g., computers, to send and receive data indoors and out; anywhere within the range of a base station. Wi-Fi networks use radio technologies called IEEE 802.11 (a, b, g, etc.) to provide secure, reliable, fast wireless connectivity. A Wi-Fi network can be used to connect computers to each other, to the Internet, and to wired networks (which use IEEE 802.3 or Ethernet). Wi-Fi networks operate in the unlicensed 2.4 and 5 GHz radio bands, at an 11 Mbps (802.11a) or 54 Mbps (802.11b) data rate, for example, or with products that contain both bands (dual band), so the networks can provide real-world performance similar to the basic 10BaseT wired Ethernet networks used in many offices.
Referring now to FIG. 15 , there is illustrated a schematic block diagram of an exemplary computing environment 1500 in accordance with the subject wireless opportunistic network and/or device innovation. The system 1500 includes one or more client(s) 1502 . The client(s) 1502 can be hardware and/or software (e.g., threads, processes, computing devices). The client(s) 1502 can house cookie(s) and/or associated contextual information by employing the innovation, for example.
The system 1500 also includes one or more server(s) 1504 . The server(s) 1504 can also be hardware and/or software (e.g., threads, processes, computing devices). The servers 1504 can house threads to perform transformations by employing the innovation, for example. One possible communication between a client 1502 and a server 1504 can be in the form of a data packet adapted to be transmitted between two or more computer processes. The data packet may include a cookie and/or associated contextual information, for example. The system 1500 includes a communication framework 1506 (e.g., a global communication network such as the Internet) that can be employed to facilitate communications between the client(s) 1502 and the server(s) 1504 .
Communications can be facilitated via a wired (including optical fiber) and/or wireless technology. The client(s) 1502 are operatively connected to one or more client data store(s) 1508 that can be employed to store information local to the client(s) 1502 (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) 1504 are operatively connected to one or more server data store(s) 1510 that can be employed to store information local to the servers 1504 .
What has been described above includes examples of the innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject innovation, but one of ordinary skill in the art may recognize that many further combinations and permutations of the innovation are possible. Accordingly, the innovation is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
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A wireless opportunistic network that can facilitate data transfer by way of interconnected devices is disclosed. In accordance with this opportunistic network, each of the devices effectively contributes to the transfer of the information thereby obviating the need for an external carrier. In this manner, the carrier infrastructure is embodied and distributed throughout the individual devices of the network. In a particular aspect, the opportunistic network is employed to transfer and make available health-related data. This functionality can be used in many scenarios related to heath from, monitoring patients and conveying basic diagnostic data to identifying bioterrorism by way of collaborating data between a number of devices within the network. Essentially, the innovation provides for at least two core functional ideas, the opportunistic network infrastructure and the use of the network in health related scenarios.
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This patent application is a continuation application of patent application Ser. No. 11/178,949, filed on Jul. 12, 2005, which in turn claims the benefit of the Korean Patent Application No. 10-2004-0061804, filed on Aug. 5, 2004, both of which are hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cable broadcast program receiver and transmitter, and more particularly, to a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report, wherein the program receiver provides status information of a plurality of peripheral devices connected to the cable broadcast program receiver (or digital cable TV receiver) through a DVI link or a HDMI link.
2. Discussion of the Related Art
Generally, a Digital Visual Interface (DVI) is a transmission standard established by a consortium called the Digital Display Working Group (DDWG), which has been created by a group of leaders in the computer industry. The DVI is used to digitally connect a personal computer (PC) to a flat monitor. More specifically, the DVI is a standard for digitally connecting signals exchanged between the PC and the monitor. The DVI has mainly been adopted to peripheral devices that are used by being connected to a PC, such as personal computers, office projectors, general plasma displays, electric boards. And, recently, the DVI has also been adopted in digital television (TV) receivers and cable digital television (TV) receivers. Before the DVI standard was developed, digital signals were exchanged by a complicated process. First, the PC creates digital data. Then, even though the digital display device is capable of receiving digital data, the digital data transmitted from the PC is converted to analog data, which is converted back to digital data and then transmitted to the digital display device. Therefore, in order to avoid such a complicated process, the DVI standard has been developed to allow the digital data created from the PC to be digitally transmitted directly to the display device through a cable. In the DVI standard, digital broadcast signals that are not compressed are transmitted in a single direction.
A High-Definition Multimedia Interface (HDMI) is a transmission standard enabling digital audio and video signals to be connected by a single cable without compression. More specifically, since a multiple channel transmission (5.1 channel) can be performed in case of the audio signal, it will be more accurate to refer to the interface as a multimedia interface, rather than a video interface. In other words, the difference between the HDMI and the DVI is that the HDMI is smaller than the DVI, has a High-bandwidth Digital Content Protection (HDCP) coding functions provided therein, and supports multiple channel audio. Therefore, the HDMI standard enables the DVI to be adopted in both audio and video electronic appliances, whereas the DVI standard can adopt the DVI interface only in video electronic appliances. And so, since the HDMI is considered to be an updated version of the DVI, the related industry is beginning to renew the Input/Output interfaces applied to digital televisions (TVs) and Set-Top boxes from the DVI standard to the HDMI standard. Since the HDMI standard is an integration of the DVI-based HDCP and audio signals (EIA/CEA-861), the HDMI standard may also be referred to as DVI-HDMI. However, in order to make a clear distinction between the HDMI and the DVI in the present invention, the HDMI standard will simply be referred to as “HDMI”. Furthermore, the DVI/HDMI described in the present invention refers to “DVI and/or HDMI” and is distinguished from the term “DVI-HDMI”.
Meanwhile, a cable broadcast system broadly includes a cable broadcast station (or cable TV station) and a cable broadcast program receiver (or digital cable TV receiver). Herein, the cable broadcast station is a transmitting and receiving end transmitting cable broadcast programs, and the cable broadcast program receiver receives the transmitted cable broadcast program. The cable broadcast station may be referred to a SO head-end or a MSO head-end. The SO refers to a System Operator (SO), which is a Korean Cable System Operator (i.e., the Local Cable TV System Operator), and the MSO refers to a Multiple System Operator (MSP), which is a group of system operators.
Moreover, the cable broadcast program receiver adopts an open cable, wherein a Point of Deployment (POD) module including a Conditional Access (CA) system is separated (or detached) from the main body. For example, the POD module uses a Personal Computer Memory Card International Association (PCMCIA) card which can be mounted onto and separated from a main body slot of the cable broadcast program receiver. Therefore, the POD module may also be referred to as a cable card, and the main body, wherein the POD module is inserted, may also be referred to as a host. For example, a Digital Built-in TV or a Digital Ready TV corresponds to the host, and a combination of the host and the POD module is referred to as the cable broadcast program receiver. At this point, the host may be connected to other peripheral devices (e.g., a Digital TV, a DVD player, a digital camera/camcorder, a Set-Top box, etc.) through one of a DVI link and a HDMI link. More specifically, one or more DVI ports or HDMI ports may exist within the host. Accordingly, a plurality of peripheral devices may be connected to the host through a DVI link or a HDMI link.
Meanwhile, in the open cable standard, wherein the POD module is separated from the main body, a diagnostic function is provided to allow each status of the host to be monitored. The diagnostic function checks various statuses, such as operation status of the host and connection status of the peripheral devices. For example, in the STCE 28 2004 standard, the Generic Diagnostic Protocol is defined in a host-POD interface resource layer. The Generic Diagnostic Protocol has been defined to enable each status information of the host to be monitored in real-time through local broadcast stations (local, user) or cable broadcast stations (remote, MSO head-end). Herein, the Generic Diagnostic Protocol defines the following diagnostics shown in Table 1 below:
TABLE 1
Diagnostic ID
Diagnostic
00
Set-Top memory allocation
01
Software version
02
Firmware version
03
MAC status
04
FAT status
05
FDC status
06
Current Channel Report
07
1394 Port
08
DVI status
09~FF
Reserved for future use
More specifically, when a request for diagnostic is transmitted to the host from the POD module, and when the Diagnostic ID is ‘08’, the details of the request consist of verifying the DVI status of the host and reporting the verified DVI status to the POD module.
FIG. 1 illustrates an example of a Diagnostic Confirm Object Syntax through which the host verifies a DVI status and transmits a report to the POD module. More specifically, the POD module parses a Diagnostic_cnf APDU (i.e., a Diagnostic Confirm Object Syntax) transmitted from the host and parses a report syntax corresponding to each Diagnostic ID, thereby extracting the status information for each diagnostic item. For example, in the Diagnostic Confirm Object Syntax of FIG. 1 , when the parsed Diagnostic ID is ‘0x08’, then a DVI Status Report Syntax is parsed, thereby extracting the DVI status information. In other words, when the POD module transmits a diagnostic request (Diagnostic_reg APDU) to the host requesting the host to verify the DVI status and to report the verified results back to the POD module, the host checks the DVI status and transmits the result back to the POD module in the form of a DVI Status Report Syntax (Diagnostic_cnf APDU). Therefore, according to the Generic Diagnostic Protocol shown in FIG. 1 , the POD module cannot request a HDMI status information from the host, and the host cannot provide any HDMI status information to the POD module.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report that substantially obviate one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report that can transmit a request a HDMI status information from a POD module and that can verify the HDMI status and transmit the verified result to the POD module from a host.
Another object of the present invention is to provide a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report that can expand a Generic Diagnostic Protocol defined in a SCTE 28 standard (wherein, “SCTE” stands for the Society of Cable Telecommunications Engineers), so that a POD module can transmit a request for a HDMI status information.
Another object of the present invention is to provide a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report that can expand a Generic Diagnostic Protocol defined in a SCTE 28 standard, so that a host can verify the HDMI status and transmit the verified result to the POD module.
A further object of the present invention is to provide a digital cable TV receiver, a diagnosis method for the same, and a data structure of a HDMI status report that can expand a Generic Diagnostic Protocol defined in a SCTE 28 standard, so that all status information can be transmitted to the POD module, when a plurality of peripheral devices is simultaneously connected to a host through DVI/HDMI ports.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a digital cable TV receiver includes a POD module, and a host device comprising a controller and a HDMI port linked to a peripheral device, wherein the controller generates a HDMI status report and transmits the HDMI status report to the POD module when a diagnostic request for HDMI status is received from the POD module, the HDMI status report comprising HDMI status information associated with the peripheral device.
In another aspect of the present invention, a diagnostic method for a digital cable TV receiver includes receiving a diagnostic request for HDMI status from a POD module, and performing a diagnostic function in response to the diagnostic request by generating a HDMI status report and transmitting the HDMI status report to the POD module, the HDMI status report comprising HDMI status information associated with a peripheral device which is linked to a HDMI port.
In another aspect of the present invention, a data structure of a HDMI status report for use in a digital cable TV receiver includes a connection status field indicating whether a connection exists on a HDMI port, and HDMI status information associated with a peripheral device linked to the HDMI port.
In another aspect of the present invention, a digital cable TV receiver includes a POD module, and a host device comprising a controller, a HDMI port linked to a first peripheral device, and a DVI port linked to a second peripheral device, the controller generating a HDMI/DVI status report and transmits the HDMI/DVI status report to the POD module when a diagnostic request for HDMI/DVI status is received from the POD module, the HDMI/DVI status report comprising HDMI status information associated with the first peripheral device and DVI status information associated with the second peripheral device.
In another aspect of the present invention, a diagnostic method for a digital cable TV receiver includes receiving a diagnostic request for HDMI/DVI status from a POD module, and performing a diagnostic function in response to the diagnostic request by generating a HDMI/DVI status report and transmitting the HDMI/DVI status report to the POD module, the HDMI/DVI status report comprising HDMI status information associated with a first peripheral device which is linked to a HDMI port and DVI status information associated with a second peripheral device which is linked to a DVI port.
In a further aspect of the present invention, a data structure of a HDMI/DVI status report for use in a digital cable TV receiver includes a connection status field indicating whether a connection exists on any one of a HDMI port and a DVI port, HDMI status information associated with a first peripheral device linked to the HDMI port, and DVI status information associated with a second peripheral device linked to the DVI port.
In another aspect of the present invention, a host includes a plurality of HDMI ports, and a controller is configured to receive a request from a source external to the host, wherein the controller is further configured to collect HDMI status information associated with more than one HDMI port in response to the request.
In yet another aspect of the present invention, a method includes the steps of receiving a request from a source external to the host, and collecting HDMI status information associated with more than one HDMI port in response to the request.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 illustrates an example of a Diagnostic_cnf syntax of a general STCE standard;
FIG. 2 illustrates an example of a message exchange protocol in a Generic Diagnostic according to the present invention;
FIG. 3 illustrates an example of an expanded Diagnostic_cnf syntax of the STCE standard according to the present invention;
FIGS. 4A to 4C illustrate a HDMI_DVI_status_report( ) syntax according to an embodiment of the present invention;
FIG. 5 illustrates an example of a digital cable TV receiver according to the present invention;
FIG. 6 illustrates a flow chart of process steps for creating and transmitting DVI/HDMI status information according to an embodiment of the present invention;
FIGS. 7A to 7C illustrate a HDMI_status_report( ) syntax according to another embodiment of the present invention; and
FIG. 8 illustrates a flow chart of process steps for creating and transmitting information according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. In addition, although the terms used in the present invention are selected from generally known and used terms, some of the terms mentioned in the description of the present invention have been selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein, Furthermore, it is required that the present invention is understood, not simply by the actual terms used but by the meaning of each term lying within.
The present invention relates to requesting a host from a POD module to verify a HDMI status and to report the result to the POD module, and also relates verifying the HDMI status information from the host and transmitting the result back to the POD module. As an example, in order to carry out such process, the above-described related art Generic Diagnostic Protocol is expanded. Herein, the expansion of the Generic Diagnostic Protocol is for maintaining compatibility with all cable broadcast program receivers (or digital cable TV receivers) adopting the SCTE 28 standard. As described above, the Generic Diagnostic Protocol has been defined to enable each status information of the host to be monitored in real-time through local broadcast stations (local, user) or cable broadcast stations (remote, MSO head-end).
FIG. 2 illustrates an example of a message exchange protocol in a Generic Diagnostic according to the present invention. In this example, the POD module transmits a diagnostic request (Diagnostic_req APDU) to the host, and the host transmits the diagnostic result (Diagnostic_cnf APDU) to the POD module. More specifically, when the POD module receives a diagnostic command, the POD module transmits a diagnostic request (Diagnostic_req APDU) to the host. Herein, the diagnostic request may be transmitted to the POD module from the cable broadcast station, or may be inputted directly to the POD module by a user using a remote controller. Alternatively, even when a diagnostic request is not transmitted from the POD module, the system status may be regularly (or periodically) verified from the host, and the corresponding results may be transmitted to the POD module.
For example, under the assumption that a cable broadcast program is not displayed normally, and if a diagnostic command option is provided, which can be selected by a user through a remote controller or a menu screen, the user may be able to select the diagnostic command option by using the remote controller or the menu screen. If the user is in an environment in which he/she is unable to select the diagnostic command directly, the user would contact the cable broadcast station by phone or the Internet. Thereafter, the cable broadcast station will transmit a diagnostic command to the POD module of the corresponding digital cable TV receiver.
Meanwhile, the host receiving the diagnostic request (Diagnostic_req APDU) from the POD module verifies the status of each diagnostic item corresponding to the Diagnostic ID. Then, the host reports the verified results (Diagnostic_cnf APDU) to the POD module. The POD module may either transmit the verified results (Diagnostic_cnf APDU) received from the host to the cable broadcast station or may display the verified results (Diagnostic_cnf APDU) to the user through an OSD Diagnostic application of the host. For example, if a bi-directional transmission can be performed between the cable broadcast station (or cable TV station) and the cable broadcast program receiver (or digital cable TV receiver), the diagnostic results are transmitted to the cable broadcast station through 00B. At this point, the diagnostic result may be simultaneously transmitted to the cable broadcast station and displayed on the TV screen through the OSD Diagnostic application. In case the digital cable TV receiver is mono-directional, the diagnostic result is displayed onto the TV screen through the OSD Diagnostic application. And, when the user notifies the cable broadcast station of the displayed contents, the cable broadcast station performs operations in accordance with the diagnostic results (e.g., door-to-door or wireless/wired after-services).
In the present invention, the Generic Diagnostic Protocol is expanded so that the POD module can request the host to perform a diagnostic of the DVI/HDMI status, and also that the host can verify the DVI/HDMI status and transmit the corresponding status information back to the POD module. More specifically, the definition of the diagnostic items for the Diagnostic ID being assigned as 0x08 within the Generic Diagnostic Protocol is expanded as shown in Table 2 below. And, the DVI Status Report Syntax is expanded as a DVI/HDMI Status Report Syntax shown in FIGS. 4A to 4C . In other words, the POD module includes a Diagnostic ID (i.e., 0x8) requesting a DVI/HDMI status to be diagnosed within the Diagnostic_req APDU and transmits the Diagnostic_req APDU to the host. Subsequently, the host includes all status information of all peripheral devices connected to the host by either one of the DVI link and the HDMI link within the Diagnostic_cnf APDU and transmits the Diagnostic_cnf APDU back to the POD module. Table 2 shows the Diagnostic items defined in the expanded Generic Diagnostic Protocol according to the present invention and the IDs assigned for each Diagnostic item.
TABLE 2
Diagnostic ID
Diagnostic
00
Set-Top memory allocation
01
Software version
02
Firmware version
03
MAC status
04
FAT status
05
FDC status
06
Current Channel Report
07
1394 Port
09~FF
Reserved for future use
Herein, the Diagnostic ID and item marked in bold italic characters are newly defined within the Generic Diagnostic Protocol according to the present invention. More specifically, in the new definition, when the Diagnostic ID is 0x08, all of the DVI statuses and HDMI statuses are requested to be verified and reported. The above-described Table 2 shows an embodiment having a request for diagnosing HDMI status added to the Diagnostic ID requesting the DVI status to be diagnosed.
FIG. 3 illustrates an example of a Diagnostic Confirm Object Syntax according to the present invention, which verifies the DVI or HDMI link from the host and reports the result to the POD module. More specifically, when the Diagnostic ID is 0x08, the HMDI_DVI_status_report( ) of FIGS. 4A and 4C is parsed, and the status information of the DVI links and the HMDI links are extracted.
FIGS. 4A to 4C illustrate an example of a DVI/HDMI Status Report Syntax of the General Diagnostic Protocol according to the present invention. More specifically, with the exception of a connection_status field, a host_HDCP_status field, a Device_HDCP_status field, a video_format field, a horizontal_lines field, a vertical_lines field, a scan_rate field, an aspect_ratio field, and a prog_inter_type field, the remaining fields are status information that are newly defined in the present invention. Nevertheless, the definition for each of the above-mentioned fields is also expanded to the HDMI link. Hereinafter, the DVI/HDMI Status Report Syntax of FIGS. 4A to 4C will now be described in detail.
First of all, the connection_status field indicates whether a connection exists on a DVI port or a HDMI port of the host. And, when the connection_status field value is ‘00 2 ’, then no DVI or HDMI link (or connection) exists. Therefore, the DVI/HDMI status information can only be created when the connection_status field value is not equal to ‘00 2 ’. More specifically, an IF conditional statement ‘if(connection_status !=0x00) { }’ can be performed only when the connection_status field value is not equal to ‘00 2 ’. Additionally, a connection_count field is allocated with 8 bits and indicates the number of DVI/HDMI links, when peripheral devices are connected to the host by DVI link or HDMI link. For example, when a DVD Player is connected to the host by a DVI link and a Set-Top box is connected to the host by a HDMI link, the connection_status field value is equal to ‘2’.
Moreover, a FOR loop statement ‘for(i=0; i<connection_count; i++) { }’, which is repeatedly performed as much as the connection_status field value, is used for transmitting all status information to the POD module, when at least one or, most particularly, a plurality of peripheral devices are connected to the host by DVI/HDMI link. The number of repetition of the FOR loop is identical to the connection_count field value, which indicates the number of peripheral devices connection to the host by DVI/HDMI link. For example, when the connection_count field value is equal to ‘2’, the FOR loop is repeated twice. In other words, each time the FOR loop is performed, a status information for the HDMI link is created and transmitted to the POD module. Therefore, when the FOR loop is repeated twice, the status information for a plurality of DVI/HDMI links is created and transmitted to the POD module.
Hereinafter, the fields that will now be described are all located within the repetition statement configured with the FOR loop. The connection_no field is allocated with 8 bits and is defined to indicate the order of the DVI/HDMI link. More specifically, the order consists of the order of the DVI/HDMI links having their current status information created and transmitted, when a plurality of peripheral devices is connected to the host by DVI link or HDMI link. In addition, a connection_mode field is allocated with one (1) bit and indicates whether the status information that is currently being created in the FOR loop corresponds to a DVI link or a HDMI link. For example, when a peripheral device is currently connected to the host by HDMI link, the connection_mode field value within the FOR loop is set to ‘1’. Conversely, when the connection_mode field value is ‘0’, this indicates that the peripheral device is currently connected to the host by DVI link. The connection_type field is allocated with 2 bits. Herein, the connection_type field indicates the connection type between the corresponding peripheral device and the host for each DVI/HDMI link. In other words, the connection_type field indicates whether the DVI/HDMI port of the host connected to the corresponding peripheral device is a DVI/HDMI Input port, a DVI/HDMI Output port or a DVI/HDMI Input/Output port. For example, ‘00 2 ’ indicates the DVI/HDMI Input port (i.e., an input connection only), ‘01 2 ’ represents the DVI/HDMI Output port (i.e., an output connection only), and ‘10 2 ’ indicates the DVI/HDMI Input/Output port (i.e., an input/output connection). Furthermore, ‘11 2 ’ represents an unused (or reserved) status.
The host_HDCP_status field indicates whether a HDCP is enabled within the DVI/HDMI link. (Herein, ‘HDCP’ stands for a High-bandwidth Digital Content Protection standard.) For example, when the host_HDCP_status field value is ‘00 2 ’, the HDCP is not enabled. The Device_HDCP_status field indicates the HDCP status of the peripheral device connected to the host through the DVI/HDMI port. The video_format field indicates the current video format used on the DVI/HDMI port. The horizontal_lines field, the vertical_lines field, the scan_rate field, the aspect_ratio field, and the prog_inter_type field create information corresponding to the video format within the DVI/HDMI link.
The fields that will now be defined correspond to HDMI status information that are created when the peripheral device is connected to the host by HDMI link, i.e., when the current connection_mode field value within the FOR loop is equal to ‘1’. An auxiliary_information_status field is allocated with 5 bits and is defined to indicate the status information of the peripheral device connected to the host by HDMI link. Hereinafter, a detailed description of the definition for each auxiliary_status_field value will now follow.
For example, when the value is 00000 2 , Auxiliary information (auxiliary information, only video format) does not exist. When the value is 00001 2 , an Auxiliary Video Information (AVI) InfoFrame information exists, and when the value is 00010 2 , an AUDIO InfoFrame information exists. Additionally, when the value is 00100 2 , a Source Product Description (SPD) InfoFrame information exists, and when the value is 01000 2 , an MPEG source InfoFrame information exists. Furthermore, when the value is 10000 2 , a General Control (GC) InfoFrame information exists. Therefore, when the value is 00011 2 , both the AVI InfoFrame information and the AUDIO InfoFrame information exist. And, similarly, when the value is 11111 2 , all of the AVI InfoFrame information, the AUDIO InfoFrame information, the SPD InfoFrame information, the MPEG source InfoFrame information, and the GC InfoFrame information exist. For example, when a DVD Player is currently connected to the host by HDMI link, and when the AVI information, the AUDIO information, and the MPEG information are transmitted, the auxiliary_information_status field value is equal to ‘01011 2 ’. Moreover, the AVI information, the AUDIO information, and the MPEG information are created by an AVI_info{ } syntax, an AUDIO_info{ } syntax, and an MPEG_info{ } syntax. Therefore, when the auxiliary_information_status field value is parsed, and when the corresponding value is equal to ‘01011 2 ’, the AVI_info{ } syntax, the AUDIO_info{ } syntax, and the MPEG_info{ } syntax are parsed, so as to extract the AVI information, the AUDIO information, and the MPEG information.
Hereinafter, a detailed description of the process of creating the AVI information, the AUDIO information, the SPD information, the MPEG information, and the GC information will now follow. More specifically, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x01 is equal to ‘1’, the current AVI information used within the HDMI port is created by using the next newly defined AVI information fields within the AVI_info{ } syntax. The newly defined AVI information fields include a version field, a color_space field, an active_format field, a bar_info field, a scan_info field, an aspect_ratio field, an active_format_aspect_ratio field, a picture_scaling field, a video_id_code field, and a pixel_repetition field.
The version field indicates the AVI InfoFrame version. The color_space field indicates the color space information associated with the video on the current HDMI link. For example, each value indicates the following:
00 2 =RGB; 01 2 =YCbCr 4:2:2; 10 2 =YCbCr 4:4:4; and 11 2 =reserved.
The active_format field indicates the present active format associated with the video on the HDMI link. For example, each value indicates the following:
0 2 =No data; and 1 2 =Active format information valid.
The bar_info field indicates the bar information associated with the video on the HDMI link. For example, each value indicates the following:
00 2 =Bar data not valid; 01 2 =Vertical Bar information valid; 10 2 =Horizontal Bar information valid; and 11 2 =Vertical and Horizontal Bar information valid.
The scan_info field indicates the scan information associated with the video on the HDMI link. For example, each value indicates the following:
00 2 =No data; 01 2 =Overscanned (television); 10 2 =Underscanned (computer); and 11 2 =reserved.
The colorimetry field indicates the colorimetry information associated with the video on the HDMI link. For example, each value indicates the following:
00 2 =No data; 01 2 =SMPTE 170M or ITU601; 10 2 =ITU709; and 11 2 =reserved.
The aspect_ratio field indicates the picture aspect ratio associated with the video on the HDMI link. For example, each value indicates the following:
00 2 =No data; 01 2 4:3; 10 2 =16:9; and 11 2 =reserved.
The active_format_aspect_ratio field indicates the active format aspect ratio associated with the video on the HDMI link. For example, each value indicates the following:
1000 2 =Same as picture aspect ratio; 1001 2 =4:3 (Center); 1010 2 =16:9 (Center); 1011 2 =14:9 (Center); and other=per DVB AFD active format field.
The picture_scaling field indicates the non-uniform picture scaling associated with the video on the HDMI link. For example, each value indicates the following:
00 2 =No known non-uniform scaling; 01 2 =Picture has been scaled horizontally; 10 2 =Picture has been scaled vertically; and 11 2 =Picture has been scaled horizontally and vertically.
The video_id_code field indicates the video identification code for CEA Short Descriptors associated with the video on the HDMI link. And, the pixel-repetition field indicates the pixel repetition associated with the video on the HDMI link. For example, each value indicates the following:
0000 2 =No repetition (i.e., pixel sent once); 0001 2 =pixel sent 2 times (i.e., repeated once); 0010 2 =pixel sent 3 times; 0011 2 =pixel sent 4 times; 0100 2 =pixel sent 5 times; 0101 2 =pixel sent 6 times; 0110 2 =pixel sent 7 times; 0111 2 =pixel sent 8 times; 1000 2 =pixel sent 9 times; 1001 2 =pixel sent 10 times; and others=reserved.
Meanwhile, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x02 is equal to ‘1’, the current audio information used within the HDMI port is created by using the next newly defined audio information fields within the AUDIO_info{ } syntax. In other words, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x02 is equal to ‘1’, the current Auxiliary Video Information (AVI) InfoFrame used on the HDMI port is indicated. The newly defined audio information fields include a version field, an audio_coding_type field, an audio_channel_count field, a sampling_frequency field, a sample_size field, a max_bit_rate field, a speaker_allocation field, a down_mix field, and a level_shift_value field.
The version field indicates an AUDIO InfoFrame version. And, the audio_coding_type field indicates the audio coding type associated with the audio on the HDMI link. For example, each value indicates the following:
0000 2 =Refer to stream header; 0001 2 =IEC60958 PCM; 0010 2 =AC-3; 0011 2 =MPEG1 (Layers 1 & 2); 0100 2 =MP3 (MPEG1 Layer 3); 0101 2 =MPEG2 (multichannel); 0110 2 =AAC; 0111 2 =DTS; 1000 2 =ATRAC; and others=reserved.
The audio_channel_count field indicates the audio channel count associated with the audio on the HDMI link. For example, each value indicates the following:
000 2 =Refer to stream header; 001 2 =2ch; 010 2 =3ch; 011 2 =4ch; 100 2 =5ch; 101 2 =6ch; 110 2 =7ch; and 111 2 =8ch.
The sampling_frequency field indicates the sampling frequency count associated with the audio on the HDMI link. For example, each value indicates the following:
000 2 =Refer to stream header; 001 2 =32 kHz; 010 2 =44.1 kHz (CD); 011 2 =48 kHz; 100 2 =88.2 kHz; 101 2 =96 kHz; 110 2 =176.4 kHz; and 111 2 =192 kHz.
The sample_size field indicates the sample size associated with the audio on the HDMI link. For example, each value indicates the following:
00 2 =Refer to stream header; 01 2 =16 bit; 10 2 =20 bit; and 11 2 =24 bit.
The max_bit_rate field indicates the maximum bit rate associated with the audio on the HDMI link. The speaker_allocation field indicates the speaker allocation associated with the audio on the HDMI link. And, the down_mix field indicates the down mix associated with the audio on the HDMI link. For example, each value indicates the following:
0 2 =Permitted or no information about any assertion of this; and 1 2 =Prohibited.
The level_shift_value field indicates the level shift value associated with the audio on the HDMI link. Herein, the level_shift_value field uses the dB unit. Meanwhile, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x04 is equal to ‘1’, the current Source Product Description (SPD) information used within the HDMI port is created by using the next newly defined SPD information fields within the SPD_info{ } syntax. In other words, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x04 is equal to ‘1’, the current SPD InfoFrame used on the HDMI port is indicated. The newly defined SPD information fields include a version field, a source_device_info field, vendor_name_character1 to vendor_name_character8 fields, and product_description_char1 to product_description_char16 fields.
The version field indicates an SPD InfoFrame version. The source_device_info field indicates the source device information associated with the source product description format on the HDMI link. For example, each value indicates the following:
00 h =unknown; 01 h =Digital STB; 02 h =DVD; 03 h =D-VHS; 04 h =HDD Video; 05 h =DVC; 06 h =DSC; 07 h =Video CD; 08 h =Game; 09 h =PC general; and others=reserved.
The vendor_name_character1˜8 fields each indicates the vendor name character associated with the source product description format on the HDMI link. These fields correspond to a 7 bit ASCII code. And, the product_description_char1˜16 fields each indicates the product description character associated with the source product description format on the HDMI link. These fields also correspond to a 7 bit ASCII code. Meanwhile, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x08 is equal to ‘1’, the current MPEG information used within the HDMI port is created by using the next newly defined MPEG information fields within the MPEG info{ } syntax. In other words, when a logical product (or logical multiplication, logical AND) between the auxiliary_Information_status field value and 0x08 is equal to ‘1’, the current MPEG InfoFrame used on the HDMI port is indicated. Herein, the newly defined MPEG information fields include a version field, mpeg_bit_rate0 to mpeg_bit_rate3 fields, a field_repeat field, and a mpeg_frame field.
The version field indicates an MPEG source InfoFrame version. And, the mpeg_bit_rate0˜3 fields each indicates the MPEG bit rate associated with the MPEG source on the HDMI link. The MPEG bit rate is stored as 32 bits and is expressed in Hz units. The mpeg_bit_rate0 field includes the least significant byte, whereas the mpeg_bit_rate3 field includes the most significant byte. If the MPEG rate is unknown, or if the field is not applied, all of the bits within the mpeg_bit_rate0˜3 fields are set to ‘0’. For example:
If, 10 Mbps→10,000,000 Hz (dec.)→0x 00 98 96 80 (hex.) Upper, Lower Byte, mpeg_bit_rate0 0x80 Lower Byte; mpeg_bit_rate1 0x96; mpeg_bit_rate2 0x98; and mpeg_bit_rate3 0x00 Upper.
The field_repeat field indicates the field repeat for 3:2 pull-down associated with the MPEG source on the HDMI link. For example, each value indicates the following:
0 2 =New field (or picture); and 1 2 =Repeated field.
The mpeg_frame field indicates the MPEG frame associated with the MPEG source on the HDMI link. For example, each value indicates the following:
00 2 =unknown (no data); 01 2 =I Picture; 10 2 =B Picture; and 11 2 =P Picture.
Meanwhile, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x10 is equal to ‘1’, the current General Control (GC) information used within the HDMI port is created by using the next newly defined GC information fields within the GC_info{ } syntax. In other words, when a logical product (or logical multiplication, logical AND) between the auxiliary_information_status field value and 0x10 is equal to ‘1’, the current GC InfoFrame used on the HDMI port is indicated. The newly defined GC information fields include a version field, and a cp_byte field. The version field indicates a GC InfoFrame version. And, the cp_byte field indicates the cp byte associated with the general control packet on the HDMI link. For example, each value indicates the following:
0 2 =Set Audio/Video Mute; and 1 2 =Clear Audio/Video Mute.
As described above, all of the status information for the DVI links or the HDMI links that are connected to the host is created by using the DVI/HDMI Status Report Syntax. Herein, the number and content of the fields that are newly defined in FIG. 4 only correspond to a preferred embodiment of the present invention. Therefore, since variations and modifications may be made by the author (or designer) of the standard and of the system, the present invention is not limited to the proposed embodiments described herein. Furthermore, the contents defined for each value in each of the fields correspond only to the preferred embodiment of the present invention and are not limited to the embodiments described herein.
Referring to FIG. 4A to 4C , the host verifies all of the DVI and HDMI link statuses and creates a HDMI_DVI Status Report Syntax that is to be reported to the POD module. First of all, whether or not a DVI/HDMI link exists is indicated in the connection_status field value. Thereafter, when the connection_status field value is not equal to ‘0’, i.e., when at least one or more DVI/HDMI links exist, the number of DVI/HDMI links existing within the host is indicated in the connection_status field. Subsequently, the FOR loop is repeated as much as the number indicated in the connection_status field. Each time the FOR loop is performed, a status information of the DVI link or the HDMI link is created.
FIG. 5 illustrates an example of a digital cable TV receiver including a DVI/HDMI controller according to the present invention. The digital cable TV receiver broadly includes a host 100 , and a POD module 200 that can be mounted to or dismounted (or separated) from a slot of the host 100 . The host 100 may either be used to receive cable broadcast programs only or be used to receive all types of broadcast programs including cable broadcast programs, ground wave (or terrestrial) broadcast programs, and satellite broadcast programs. FIG. 5 illustrates an example of a cable digital television that can receive both cable and ground wave broadcast programs.
In addition, there are two types of data broadcast program transmission methods, wherein data broadcast programs such as stocks information or weather forecast are transmitted. More specifically, an Out Of Band (OOB) method and a DOCSIS Set-top Gateway (DSG) method are proposed as a method for upstream services within an open cable. The data broadcast program may be viewed at the moment a viewer views the television (TV) and selects a desired program. Alternatively, the data broadcast program may be viewed when the viewer directly interacts with the broadcast program or when the viewer selects the information he or she needs. The OOB method is most commonly used in the United States, and the DSG method is most commonly used in the Republic of Korea. However, in Korea, discussion is still under process as to which type of method is to be selected as the Korean standard. Herein, the types of method that are under discussion include the OOB-only method, the OOB/DSG combined method, the DSG-only method, etc.
The OOB method is a standard that defines a transmission standard between intersect equipments within a cable broadcast station (head-end) and a Set-Top box. The DSG method relates to a transmission method between a cable modem control system of a cable broadcast station and a DOCSIS-based cable modem within a Set-Top box. The DOCSIS refers to a digital cable TV standard adopted by CableLabs, which is a U.S. cable broadcast standard certification organization. The DOCSIS standard uses cable modem to allow data to be transmitted. The example of a digital cable TV receiver using the OOB/DSG combined method is shown in FIG. 5 . However, this is only one of the preferred embodiments of the present invention, and one of an OOB-only digital cable TV receiver and a DSG-only digital cable TV receiver may be used according to the present invention.
FIG. 6 illustrates a flow chart of process steps for creating and transmitting DVI/HDMI status information according to the present invention. Hereinafter, an embodiment according to the present invention will now be described with reference to FIG. 2 to FIG. 6 . More specifically, in the host 100 , a tuner 101 tunes only a specific channel frequency from ground wave Audio/Video (A/V) broadcasting, which is transmitted through an antenna, and cable A/V broadcasting, which is transmitted by In-band through a cable. Then, the tuned channel frequency is transmitted to a first demodulator 102 . Since each of the ground wave broadcasting and the cable broadcasting has a different transmission method, each of the decoding methods within the first demodulator 102 is also different from one another. In other words, the ground wave A/V broadcasting is demodulated to a Vestigial Sideband (VSB) Modulation method and transmitted accordingly, and the cable A/V broadcasting is demodulated to a Quadrature Amplitude Modulation (QAM) method and transmitted accordingly. Therefore, when the channel frequency tuned from the tuner 101 is a ground wave broadcast channel frequency, the tuned channel frequency is demodulated to a VSB method from the first demodulator 102 . Alternatively, when the channel frequency tuned from the tuner 101 is a cable broadcast channel frequency, the tuned channel frequency is demodulated to a QAM method from the first demodulator 102 .
In case of the ground wave broadcasting, the demodulated signal transmitted from the first demodulator 102 is transmitted to a demultiplexer 103 . And, in case of the cable broadcasting, the demodulated signal is transmitted to the demultiplexer 103 through the POD module 200 mounted on the slot. The POD module 200 includes a Conditional Access (CA) system for preventing high value-added broadcast contents from being copied and for providing restricted access. The POD module 200 is also referred to as a cable card. When a scramble occurs in the cable A/V broadcasting, the POD module descrambles the cable A/V broadcasting, which is then transmitted to the demultiplexer 103 . When the POD module 200 is not inserted in the slot, the cable A/V broadcasting demodulated from the first demodulator 102 is directly transmitted to the demultiplexer 103 . In this case, the scrambled cable A/V broadcasting cannot be descrambled, and therefore the viewers are unable to view the broadcast program normally.
The demultiplexer 103 receives the multiplexed signal and separates the multiplexed signal to a video signal and an audio signal. Thereafter, the demultiplexer 103 transmits the separated signals to a decoder 104 . The decoder 104 recovers the compressed A/V signal to its initial state by using a video decoding algorithm and an audio decoding algorithm, respectively, and then outputs the recovered signal for display. Meanwhile, a second tuner 105 tunes a specific channel frequency among the data broadcasting transmitted through cable by the DSG method and transmits the tuned channel frequency to a second demodulator 106 . The second demodulator 106 demodulates the DSG type data broadcasting, which is then transmitted to a CPU 110 . Moreover, a third tuner 107 tunes a specific channel frequency among the data broadcasting transmitted through cable by the OOB method and transmits the tuned channel frequency to a third demodulator 111 . The third demodulator 111 demodulates the OOB type data broadcasting by using a Quartenary Phase Shift Key (QPSK) method, which is then transmitted to the POD module 200 . More specifically, since the OOB type uses the QPSK transmission method, a receiving end also uses a QPSK type modulation.
Furthermore, when a bi-directional telecommunication between the cable broadcast station (or cable TV station) and the cable broadcast program receiver (or digital cable TV receiver) can be performed, the information (e.g., paid program subscription, Diagnostic information of the host, etc.) transmitted from the cable broadcast program receiver to the cable broadcast station is transmitted by one of the OOB method and the DSG method. This is why a switching unit 108 is provided herein. More specifically, when the OOB type transmission is used, user information or System Diagnostic information is transmitted to a modulator 109 through the POD module 200 and the switching unit 108 . Then, the information is modulated by using the QPSK method from the modulator 109 , which is then transmitted to the cable broadcast station through cable. On the other hand, when using the DSG type transmission, the information is transmitted to the modulator 109 through the CPU 110 and the switching unit 108 . Thereafter, the information is modulated by using a QAM-16 method from the modulator 109 , which is then transmitted to the cable broadcast station through cable.
Meanwhile, the CPU 110 parses the Diagnostic_req APDU, which is transmitted from the POD module 200 (S 201 ). Then, the CPU 110 verifies whether ‘0x08’ is included within the Diagnostic ID (S 202 ). When the 0x08 is included, the DVI/HDMI status is verified by using a DVI/HDMI controller 120 , and the verified result is created, as shown in FIGS. 4A to 4C , and is transmitted to the POD module 200 . More specifically, the DVI/HDMI controller 120 first verifies whether peripheral devices are connected to the host by DVI/HDMI link and also verifies the number of the connected peripheral devices, so as to set up (or determine) the connection_status field value and the connection_count field value. Subsequently, the DVI/HDMI controller 120 determines whether the connection_status field value is ‘0’ (S 203 ). When the connection_status field value is ‘0’, there are no peripheral devices connected to the host by DVI/HDMI link. Accordingly, the process step is skipped to Step 207 , thereby transmitting a Diagnostic_cnf APDU to the POD module 200 , which indicates that no DVI/HDMI status information is included.
In the above-described Step 203 , when the connection_status field value is not ‘0’, at least one peripheral device is connected to the host by DVI/HDMI link, and so the process step proceeds to Step 204 . Thereafter, a variable i is initialized to ‘0’ so as to determine whether the value of the variable i is lower (or smaller) than the connection_count field value (S 205 ). The variable i is a value that is compared with the connection_count field value in order to transmit all of the DVI/HDMI link status information of more than one peripheral devices to the POD module. Herein, the variable i is increased by ‘1’ each time the FOR loop is performed. Therefore, in the above-described Step 205 , when the value of the variable i is lower than the connection_count field value, this indicates that there still remain DVI/HDMI link status information which have not been transmitted to the POD module 200 . At this point, the process proceeds to Step 206 , wherein the connection_no field, the connection_mode field, the connection_type field, the host_HDCP_status field, the device_HDCP_status field, and the video format information are created. The video format information includes horizontal_lines information, vertical_lines information, scan_rate information, aspect_ratio information, and prog_inter_type information. Moreover, when the connection_mode field value is not equal to ‘0’, i.e., when the current status information is the status information for a HDMI link, an auxiliary_information_status field value is created, and the AVI information, the AUDIO information, the SPD information, the MPEG information, and the GC information that are associated with the HDMI link are also created in accordance with the auxiliary_information_status field value. In other words, the above-described Step 204 to Step 206 correspond to the FOR loop repetition statement of FIG. 4 .
Furthermore, in the above-described Step 205 , when the value of the i variable is determined to be lower than the connection_count field value, this indicates that all status information for the DVI/HDMI links, which will be transmitted to the POD module 200 , is created. And so, the process proceeds to Step 207 . The status information for all of the DVI/HDMI links of the host, which is created each time the FOR loop is performed, is included in the Diagnostic_cnf APDU, which is then transmitted to the POD module 200 .
As described above, the process of creating and transmitting DVI/HDMI status information may either be performed by using hardware or performed by using middleware or software. Also, the DVI/HDMI controller 120 may either be included in the CPU 110 or formed externally, as shown in FIG. 5 . In the above-described embodiment of the present invention, the POD module uses a Diagnostic ID in order to request the host to diagnose all statuses for the DVI/HDMI links. And, the host verifies all status information of the DVI links and the HDMI links and transmits the corresponding results to the POD module.
Meanwhile, in another embodiment of the present invention, the Generic Diagnostic Protocol may be expanded so that a Diagnostic ID is assigned for each of the DVI Diagnostic and the HDMI Diagnostic. Thus, a request for each of the DVI Diagnostic and the HDMI Diagnostic may be distinguished (or identified) from one another and separately transmitted to the POD module. Then, in accordance with the received Diagnostic ID, the host may verify only one of the DVI status information and the HDMI status information and transmit the verified result to the POD module. Table 3 and Table 4 show each Diagnostic item defined in the expanded Generic Diagnostic Protocol and the Diagnostic IDs assigned for each Diagnostic item.
TABLE 3
Diagnostic ID
Diagnostic
00
Set-Top memory allocation
01
Software version
02
Firmware version
03
MAC status
04
FAT status
05
FDC status
06
Current Channel Report
07
1394 Port
08
DVI status
0A~FF
Reserved for future use
TABLE 4
Diagnostic ID
Diagnostic
00
Set-Top memory allocation
01
Software version
02
Firmware version
03
MAC status
04
FAT status
05
FDC status
06
Current Channel Report
07
1394 Port
08
DVI status
0B~FF
Reserved for future use
More specifically, in Table 3 and Table 4, the Diagnostic ID and item marked in bold italic characters are newly defined within the Generic Diagnostic Protocol according to the present invention. In Table 3, when the Diagnostic ID is 0x08, the host verifies the DVI status and transmits the verified result to the POD module. On the other hand, when the Diagnostic ID is 0x09, the host verifies the HDMI status and transmits the verified result to the POD module. In Table 4, a new definition for verifying the status of all DVI/HDMI links by using a single Diagnostic ID is added to Table 3. At this point, ‘0A’ is assigned as the newly defined Diagnostic ID. In the above-described Table 3 and Table 4, the Diagnostic ID for the HDMI being assigned as ‘09’ and the Diagnostic ID for the DVI/HDMI being assigned as ‘0A’ are only details of a preferred embodiment of the present invention. The author (or designer) of the standard and of the system may choose to assign other reserved ID values other than ‘09’ and ‘0A’ as the Diagnostic ID, which is not limited to the values proposed in the above-described embodiments of the present invention. Furthermore, when the POD module requests only the HDMI status to be diagnosed, and when the host verifies the status information for all HDMI links only and transmits the verified results to the POD module, the DVI/HDMI controller of the digital cable TV receiver shown in FIG. 5 may be replaced with a HDMI controller.
FIGS. 7A to 7C illustrate an example of a HDMI Status Report Syntax of the Generic Diagnostic Protocol, which is created when the POD module requests a Diagnostic of the HDMI status. More specifically, the HDMI Status Report Syntax of FIGS. 7A to 7C is configured by deleting the connection_mode field shown in FIGS. 4A to 4C and by deleting the line for comparing whether the connection_mode field value is equal to ‘1’. Also, the description for each of the fields of the HDMI Status Report Syntax is identical to those described in FIGS. 4A to 4C and will, therefore, be omitted for simplicity. At this point, the connection_status field, the host_HDCP_status field, the Device_HDCP_status field, the video_format field, the horizontal_lines field, the vertical_lines field, the scan_rate field, the aspect_ratio field, and the prog_inter_type field creates only the information associated with the HDMI link.
FIG. 8 illustrates a flow chart of process steps for creating and transmitting HDMI status information according to another embodiment of the present invention. More specifically, the CPU 110 parses the Diagnostic_req APDU, which is transmitted from the POD module 200 (S 301 ). Then, the CPU 110 verifies whether ‘0x09’ is included within the Diagnostic ID (S 302 ). When the 0x09 is included, the HDMI status is verified, and the verified result is transmitted to the POD module 200 . In other words, whether or not peripheral devices are connected to the host by HDMI link is verified, and the number of the connected peripheral devices is also verified, so as to set up (or determine) the connection_status field value and the connection_count field value. Thereafter, whether or not the connection_status field value is ‘0’ is verified (S 303 ). When the connection_status field value is ‘0’, there are no peripheral devices connected to the host by HDMI link. Accordingly, the process step is skipped to Step 307 , thereby transmitting a Diagnostic_cnf APDU to the POD module 200 , which indicates that no HDMI status information is included.
In the above-described Step 303 , when the connection_status field value is not ‘0’, at least one peripheral device is connected to the host by HDMI link, and so the process step proceeds to Step 304 . Thereafter, a variable i is initialized to ‘0’ so as to determine whether the value of the variable i is lower (or smaller) than the connection_count field value (S 305 ). The variable i is a value that is compared with the connection_count field value in order to transmit all of the HDMI link status information of more than one peripheral devices to the POD module 200 . Herein, the variable i is increased by ‘1’ each time the FOR loop is performed. Therefore, in the above-described Step 305 , when the value of the variable i is lower than the connection_count field value, this indicates that there still remain HDMI link status information which have not been transmitted to the POD module 200 . At this point, the process proceeds to Step 306 , wherein the connection_no field, the connection_type field, the host_HDCP_status field, the device_HDCP_status field, and the video format information are created. Herein, the video format information includes horizontal_lines information, vertical_lines information, scan_rate information, aspect_ratio information, and prog_inter_type information. Thereafter, an auxiliary_information_status field value is created, and the AVI information, the AUDIO information, the SPD information, the MPEG information, and the GC information that are associated with the HDMI link are also created in accordance with the auxiliary_information_status field value. In other words, the above-described Step 304 to Step 306 correspond to the FOR loop repetition statement of FIG. 7 .
Meanwhile, in the above-described Step 305 , when the value of the i variable is determined to be lower than the connection_count field value, this indicates that all status information for the HDMI links, which will be transmitted to the POD module 200 , is created. And so, the process step proceeds to Step 307 . The status information for all of the HDMI links of the host, which is created each time the FOR loop is performed, is included in the Diagnostic_cnf APDU, which is then transmitted to the POD module 200 .
As described above, the present invention may be applied to all types of television receivers and Set-Top boxes supporting cable broadcast programs. Most particularly, the present invention can be applied to all types of digital cable TV receivers adopting the SCTE 28 standard. Meanwhile, preferred embodiments have been proposed in the description of the present invention. Therefore, when considering the technical difficulty of the present invention, those skilled in the art are fully capable of modifying the present invention so as to propose other embodiments of the present invention. Evidently, it will be apparent that such modifications do not depart from the scope and spirit of the present invention.
In the above described digital cable TV receiver, diagnosis method for the same, and data structure of the HDMI status report according to the present invention, the POD module may request the host to verify and report the HDMI status, and the host may verify the HDMI status information and transmit the verified result to the POD module. Thus, the host may transmit not only the DVI status information but also the HDMI status information to the POD module. Furthermore, the present invention expands an Diagnostic ID and a Diagnostic Status Report Syntax within a Generic Diagnostic Protocol defined in the SCTE 28 standard, so as to create the status information for all of the DVI links and the HDMI links for the connections within the host and to transmit the status information to the POD module, thereby facilitating the expansion and providing compatibility of the Diagnostic ID and Diagnostic Status Report Syntax, so that it can be applied to all types of digital cable TV receivers adopting the SCTE 28 standard.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this inventions provided they come within the scope of the appended claims and their equivalents.
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A host includes a plurality of High-Definition Multimedia Interface (HDMI) ports. A controller is configured to receive a source external to the host. The controller is further configured to collect HDMI information associated with more than one HDMI port in response to the request.
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FIELD OF THE INVENTION
[0001] This invention relates to ion exchange polymers and more particularly, to anion exchange polymers and materials.
BACKGROUND OF THE INVENTION
[0002] Ion exchange materials are commonly employed to treat and remove ionizable components from fluids for a variety of applications. Flow-through beds or flow-through devices for fluid treatment may employ exchange material or components in the form of grains, fabrics or membranes. The ion exchange functionality operates to transport one type of ion across the material in an electric field, while substantially or effectively blocking most ions of the opposite polarity. Anion exchange polymers and materials carry cationic groups, which repel cations and are selective to anions.
[0003] Anion exchange polymers may be prepared from tertiary amines, which are quaternized to provide anionic functionality. The quaternary ammonium compounds are crosslinked and polymerized to form anion exchange polymers. Typical methods for making anion exchange polymers require the use of alkyl halides for quaternizing the anion exchange polymer.
[0004] Alkyl halides are expensive and hazardous to use. It would be desirable to prepare improved anion exchange polymers having superior properties without using alkyl halides.
SUMMARY OF THE INVENTION
[0005] In one embodiment, an anion exchange polymer has the formula:
[0000]
[0000] wherein R is —[CH 2 —CH(OH)] 2 —W; R 1 is hydrogen or a C 1 -C 12 alkyl group; a is from about 0 to about 0.75, b and c are each independently, from about 0.25 to about 1.0; Z is oxygen or N—R 3 ; R 2 is —[CH 2 ] n -; R 3 is hydrogen or —[CH 2 ] m —CH 3 ; R 4 and R 5 are each, independently, —[CH 2 ] m —CH 3 ; X is selected from the group consisting of Cl, Br, I and acetate; W is a bridging group or atom; m is an integer from 0 to 20; n is an integer from 1 to 20; and Y is selected from the group consisting of
[0000]
[0000] wherein R 6 , R 7 and R 8 are each, independently, selected from the group consisting of hydrogen, —[CH 2 ] q —CH 3 and —CH(CH 3 ) 2 ; R 9 is —[CH 2 ] p ; p is a number from 3 to 6 and q is a number from 0 to 3.
[0006] In another embodiment, a method for making an anion exchange polymer comprises reacting a tertiary amine, an acid inhibitor and a polyepoxide to form a quaternary ammonium monomer and polymerizing the quaternary ammonium monomer in the presence of a catalyst.
[0007] In another embodiment, an ion exchange material comprises an anion exchange polymer having the formula:
[0000]
[0000] wherein R is —[CH 2 —CH(OH)] 2 —W; R 1 is hydrogen or a C 1 -C 12 alkyl group; a is from about 0 to about 0.75, b and c are each independently, from about 0.25 to about 1.0; Z is oxygen or N—R 3 ; R 2 is —[CH 2 ] n -; R 3 is hydrogen or —[CH 2 ] m —CH 3 ; R 4 and R 5 are each, independently, —[CH 2 ] m —CH 3 ; X is selected from the group consisting of Cl, Br, I and acetate; W is a bridging group or atom; m is an integer from 0 to 20; n is an integer from 1 to 20; and Y is selected from the group consisting of
[0000]
[0000] wherein R 6 , R 7 and R 8 are each, independently, selected from the group consisting of hydrogen, —[CH 2 ] q —CH 3 and —CH(CH 3 ) 2 ; R 9 is —[CH 2 ] p ; p is a number from 3 to 6 and q is a number from 0 to 3.
[0008] In another embodiment, a method for making an ion exchange material comprises reacting a tertiary amine, an acid inhibitor and a polyepoxide to form a quaternary ammonium monomer and polymerizing the quaternary ammonium monomer in the presence of a catalyst.
[0009] The various embodiments provide improved anion exchange polymers, methods for preparing the anion exchange polymers without using alkyl halides and for materials that are chemically resistant and non-fouling.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. The endpoints of all ranges reciting the same characteristic are independently combinable and inclusive of the recited endpoint. All references are incorporated herein by reference.
[0011] The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the tolerance ranges associated with measurement of the particular quantity).
[0012] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, or that the subsequently identified material may or may not be present, and that the description includes instances where the event or circumstance occurs or where the material is present, and instances where the event or circumstance does not occur or the material is not present.
[0013] The anion exchange polymer contains cationic groups. In one embodiment, an anion exchange polymer has the formula:
[0000]
[0000] wherein R is —[CH 2 —CH(OH)] 2 —W; R 1 is hydrogen or a C 1 -C 12 alkyl group; a is from about 0 to about 0.75, b and c are each independently, from about 0.25 to about 1.0; Z is oxygen or N—R 3 ; R 2 is —[CH 2 ] n -; R 3 is hydrogen or —[CH 2 ] m —CH 3 ; R 4 and R 5 are each, independently, —[CH 2 ] m —CH 3 ; X is selected from the group consisting of Cl, Br, I and acetate; W is a bridging group or atom; m is an integer from 0 to 20; n is an integer from 1 to 20; and Y is selected from the group consisting of
[0000]
[0000] wherein R 6 , R 7 and R 8 are each, independently, selected from the group consisting of hydrogen, —[CH 2 ] q —CH 3 and —CH(CH 3 ) 2 ; R 9 is —[CH 2 ] p ; p is a number from 3 to 6 and q is a number from 0 to 3.
[0014] In one embodiment, R 1 is a C 1 -C 6 alkyl group. In another embodiment, R 1 is methyl, ethyl, propyl, butyl or isobutyl.
[0015] In one embodiment, a is from about 0.25 to about 0.50. In another embodiment, b is from about 0.50 to about 0.75. In another embodiment, c is from about 0.50 to about 0.75.
[0016] In one embodiment, Z is ammonia, trimethylammonia or triethylammonia.
[0017] W is a bridging group or atom. In one embodiment, W is a hydrocarbon group, an inorganic group or inorganic atom. In one embodiment, W is a C 1 -C 30 alkyl group, C 1 -C 30 alkyl ether group, C 6 -C 30 aromatic group, C 6 -C 30 aromatic ether group or a siloxane. In another embodiment, W is a C 1 -C 6 alkyl group, C 1 -C 6 alkyl ether group, a C 6 -C 10 aromatic group or a C 6 -C 10 aromatic ether group. In another embodiment, W is methyl, ethyl, propyl, butyl, isobutyl, phenyl, 1,2-cyclohexanedicarboxylate, bisphenol A, diethylene glycol, resorcinol, cyclohexanedimethanol, poly(dimethylsiloxane), 2,6-tolylene diisocyanate, 1,3-butadiene or dicyclopentadiene.
[0018] In one embodiment, m is an integer from 0 to 10, including from 0 to 5. In another embodiment, n is an integer from 1 to 10, including from 1 to 5.
[0019] In another embodiment, a method for making an anion exchange polymer comprises reacting a tertiary amine, an acid inhibitor and a polyepoxide to form a quaternary ammonium monomer and polymerizing the quaternary ammonium monomer in the presence of a catalyst.
[0020] The tertiary amine may be an ethylenic tertiary amine. In one embodiment, the ethylenic tertiary amine is selected from the group consisting of dimethylaminopropylmethacrylamide (DMAPMA), dimethylaminopropylacrylamide (DMAPAA), diethylaminopropylmethacrylamide (DEAPMA), dimethylaminoethylmethacrylate (DMAEMA) and mixtures thereof. In another embodiment, the ethylenic tertiary amine monomer is DMAPMA.
[0021] The polyepoxide may be any type of polyepoxide having at least two epoxide groups. In one embodiment, the polyepoxide is a diglycidyl ether or a triglycidyl ether. Diglycidyl ethers include, but are not limited to, diethylene glycol diglycidyl ether, diglycidyl 1,2-cyclohexanedicarboxylate, N,N-diglycidyl-4-glycidyloxyaniline, bisphenol A diglycidyl ether, brominated bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, 1,4-butanediol diglycidyl ether, 1,4-butanediyl diglycidyl ether, 1,4-cyclohexanedimethanol diglycidyl ether, glycerol diglycidyl ether, resorcinol diglycidyl ether, bis[4-(glycidyloxy)phenyl]methane, bisphenol A propoxylate diglycidyl ether, dimer acid diglycidyl ester, ethylene glycol diglycidyl ether, brominated neopentyl glycol diglycidyl ether, diglycidyl ether-terminated poly(dimethylsiloxane), poly(ethylene glycol) diglycidyl ether, poly(propyleneglycol) diglycidyl ether, 1,2,3-propanetriol glycidyl ether and 1,3-butanediol diglycidyl ether. Triglycidyl ethers include, but are not limited to, tris(2,3-epoxypropyl)isocyanurate, trimethylolpropane triglycidyl ether, tris(4-hydroxyphenyl)methane triglycidyl ether 2,6-tolylene diisocyanate, tris(4-hydroxyphenyl)methane triglycidyl ether, glycerol propoxylate triglycidyl ether and trimethylolethane triglycidyl ether.
[0022] In another embodiment, the polyepoxide is a diepoxide. Diepoxides include, but are not limited to, 1,3-butadiene-diepoxide, 1,3-butadiene diepoxide, dicyclopentadiene dioxide, methyl cis,cis-11,12;14,15-diepoxyeicosanoate.
[0023] The epoxide quaternizes the tertiary amine to form a quaternary ammonium monomer. The quaternary ammonium monomer is also crosslinked by the epoxide to make the monomer water insoluble. Without crosslinking, the polymers would dissolve in water and would be ineffective for use in ion exchange materials. In one embodiment, the monomer is highly crosslinked. In another embodiment, the polymer is crosslinked in the range of from about 50 to about 100 percent. In another embodiment, the polymer is fully crosslinked.
[0024] Polymerization of the quaternary ammonium monomer to form the anion exchange polymer can occur simultaneously with the reaction for quaternizing and crosslinking the tertiary amine. The reaction of the tertiary amine and polyepoxide and the polymerization reaction may be carried out by heating the reactants and monomers to a suitable temperature and for a time sufficient for quaternizing and crosslinking the tertiary amine and for polymerizing the quaternary ammonium monomer. In one embodiment, the temperature range is from about 40° C. to about 150° C. In another embodiment, the temperature range is from about 60° C. to about 110° C. and in another embodiment, the temperature range is from about 85° C. to about 100° C. In one embodiment, the reaction time is from about 1 minute to about 2 hours. In another embodiment, the reaction time is from about 10 minutes to about 1 hour. In another embodiment, the reaction time is from about 20 minutes to about 45 minutes.
[0025] The quaternization is conducted in the presence of an acid inhibitor, which controls the polyepoxide from self polymerization. The acid inhibitor prevents the polyepoxide from self polymerizing by quenching the reaction. The amount of quenching is controlled by the amount of acid inhibitor used in the reaction. The acid inhibitor may be any type of acid. In one embodiment, the acid inhibitor is a mineral acid. In another embodiment, the acid inhibitor includes, but is not limited to, hydrochloric acid, methane sulfonic acid, sulfuric acid or phosphoric acid. The acid inhibitor is added in any amount suitable for quenching the polyepoxide. In one embodiment, the acid inhibitor is present in an amount of from about 75 percent by mole weight to about 125 percent by mole weight, based on the mole weight of the tertiary amine. In another embodiment, the acid inhibitor is present in an amount of from about 75 percent by mole weight to about 100 percent by mole weight, based on the mole weight of the tertiary amine.
[0026] The anion exchange polymer may be synthesized using a wide ratio range of the tertiary amine to the polyepoxide. In one embodiment, the ratio is from about 0.3 to about 1.5 moles of the tertiary amine to each equivalent mole of the polyepoxide. In another embodiment, the ratio is from about 0.5 to about 1.0 moles of the tertiary amine monomer per equivalent mole of the polyepoxide.
[0027] A catalyst is added to aid in polymerization. The catalysts may be spontaneously activated or activated by heat, electromagnetic radiation, electron beam radiation or by chemical promoters. The catalyst may be added in any amount suitable for aiding in polymerization. In one embodiment, the catalyst is in an amount of from about 0.1 to about 5.0 percent by weight of the reaction mixture.
[0028] The catalyst may be any type of catalyst suitable for polymerizing the quaternary ammonium monomer. In one embodiment, the catalyst is a peroxide. The peroxide includes, but is not limited to, methyl ethyl ketone peroxide and dibenzoyl peroxide. In another embodiment, the catalyst is a water soluble or oil soluble azo initiator. The azo initiator includes, but is not limited to, 2,2′-azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride, 2,2′-azobis(N,N′-dimethylene isobutyramidine)dihydrochloride, 2,2′-azobis(2-methylpropionamidine)dihydrochloride, 2,2′-azobis[N-(2-carboxyethyl)-2-methylpropionamidine]hydrate, 2,2′-azobis {2-[1-(2-hydroxyethyl)-2-imidazolin-2-yl)propane], 2,2′-azobis[2-methyl-N-(2-hydroxyethyl)propionamide] and dimethyl 2,2′-azobis(2-methylpropionate).
[0029] The term “chemical promoters” as used herein refers to a substance, which increases the rate of polymerization either by itself or in combination with another catalyst. For example, methyl ethyl ketone peroxide can function as a catalyst itself, but its rate of initiation can be greatly increase by small amounts of transition metal salt chemical promoters, such as, for example, cobalt naphthenate. Similarly, dibenzoyl peroxide can function as a catalyst itself, but its action be accelerated by a dimethylaniline chemical promoter. The UV radiation polymerization agents can become more efficient in the presence of chemical promoters, which are photoinitiators or chemical compounds that generate free radicals. Non-limiting examples of photoinitiating chemical promoters include benzophenone, benzyl, antraquinone, eosin and methylene blue.
[0030] In one embodiment, the components are combined in the presence of a solvent. Any solvent is suitable for use in this embodiment, so long as the solvent is not itself polymerizable and the components are soluble in it. Solvents suitable in this embodiment include, but are not limited to, water, polyethylene glycols, dimethylsulfoxide, 2-pyrrolidone, N-methyl pyrrolidone and mixtures thereof.
[0031] The amount of solvent is added in any amount suitable for solubilizing the components. In one embodiment, the amount of solvent is from about 10 to about 90 percent by weight based on the total weight of the reaction mixture. In another embodiment, the amount of solvent is from about 20 to about 70 percent by weight based on the total weight of the reaction mixture. In another embodiment, the amount of solvent is from about 25 to about 50 percent by weight based on the total weight of the reaction mixture.
[0032] The components are combined and reacted in any conventional manner. The order of addition is not critical and the components may be added in any order.
[0033] An example of a reaction forming a quaternary ammonium monomer by reacting DMAPMA with a polyepoxide and hydrochloric acid (HCl) is shown below:
[0000]
[0034] Additionally, other ethylenic monomers may be added to the polymerization mixture to increase or decrease the ion exchange capacity of the resulting ion exchange polymer. Examples of ethylenic monomers that lower the ion exchange capacity include, but are not limited to, methacrylamine, N-methylmethacrylamide, N-vinyl pyrrolidinone and N-vinyl caprolactam. Examples of ethylenic monomers that raise the ion exchange capacity include, but are not limited to, methacrylamidopropyl trimethylammonium chloride (MAPTAC) and trimethylammoniumethyl methacrylate chloride (TMAEMC).
[0035] These ethylenic monomers may be added to the reaction mixture with the other reactants and may be added in any order with the reactants. The ethylenic monomers may be added in any amount suitable for affecting the ion exchange capacity of the ion exchange polymer. In one embodiment, the ethylenic monomer is added in an amount of from about 0 to about 50 molar percent of the tertiary amine. In another embodiment, the ethylenic monomer may be added in an amount of from about 10 to about 40 molar percent of the tertiary amine. In another embodiment, the ethylenic monomer may be added in an amount of from about 20 to about 40 molar percent of the tertiary amine.
[0036] The anion exchange polymer may be used to form ion exchange materials. In one embodiment, an ion exchange material comprises an anion exchange polymer having the formula:
[0000]
[0000] wherein R is —[CH 2 —CH(OH)] 2 —W; R 1 is hydrogen or a C 1 -C 12 alkyl group; a is from about 0 to about 0.75, b is and c are each independently, from about 0.25 to about 1.0; Z is oxygen or N—R 3 ; R 2 is —[CH 2 ] n -; R 3 is hydrogen or —[CH 2 ] m —CH 3 ; R 4 and R 5 are each, independently, —[CH 2 ] m —CH 3 ; X is selected from the group consisting of Cl, Br, I and acetate; W is a bridging group or atom; m is an integer from 0 to 20; n is an integer from 1 to 20; and Y is selected from the group consisting of
[0000]
[0000] wherein R 6 , R 7 and R 8 are each, independently, selected from the group consisting of hydrogen, —[CH 2 ] q —CH 3 and —CH(CH 3 ) 2 ; R 9 is —[CH 2 ] p ; p is a number from 3 to 6 and q is a number from 0 to 3.
[0037] In one embodiment, R 1 is a C 1 -C 6 alkyl group. In another embodiment, R 1 is methyl, ethyl, propyl, butyl or isobutyl.
[0038] In one embodiment, a is from about 0.25 to about 0.50. In another embodiment, b is from about 0.50 to about 0.75. In another embodiment, c is from about 0.50 to about 0.75.
[0039] In one embodiment, Z is ammonia, trimethylammonia or triethylammonia.
[0040] W is a bridging group or atom. In one embodiment, W is a hydrocarbon group, an inorganic group or inorganic atom. In one embodiment, W is a C 1 -C 30 alkyl group, C 1 -C 30 alkyl ether group, C 6 -C 30 aromatic group, C 6 -C 30 aromatic ether group or a siloxane. In another embodiment, W is a C 1 -C 6 alkyl group, C 1 -C 6 alkyl ether group, a C 6 -C 10 aromatic group or a C 6 -C 10 aromatic ether group. In another embodiment, W is methyl, ethyl, propyl, butyl, isobutyl, phenyl, 1,2-cyclohexanedicarboxylate, bisphenol A, diethylene glycol, resorcinol, cyclohexanedimethanol, poly(dimethylsiloxane), 2,6-tolylene diisocyanate, 1,3-butadiene or dicyclopentadiene.
[0041] In one embodiment, m is an integer from 0 to 10, including from 0 to 5. In another embodiment, n is an integer from 1 to 10, including from 1 to 5.
[0042] In one embodiment, the ion exchange material may be anion exchange resin beads or an anion exchange membrane.
[0043] In another embodiment, a method for making an ion exchange material comprises reacting a tertiary amine, an acid inhibitor and a polyepoxide to form a quaternary ammonium monomer and polymerizing the quaternary ammonium monomer in the presence of a catalyst.
[0044] An anion exchange membrane may be formed by any method known in the art. In one embodiment, the membrane is formed by reinforcing a fabric with the anion exchange polymer. A liquid mixture of the reactants can be applied to the fabric by casting the liquid monomer mixture onto the fabric or by soaking the fabric in the liquid mixture using individual pieces of fabric, multiple pieces of fabric arranged in stacks or with fabric from a roll in a continuous process. When heat is applied, the reaction between the reactants and polymerization will occur to form a crosslinked anion exchange membrane supported by a fabric.
[0045] In another embodiment, the membrane is formed by imbibing a porous plastic film, such as polyethylene, polypropylene or Teflon®, with the anion exchange polymer. A liquid mixture of the reactants can be applied to the porous plastic film by casting the liquid monomer mixture onto the porous plastic film or by soaking the porous plastic film in the liquid mixture. When heat is applied, the reaction between the reactants and polymerization will occur to form a crosslinked anion exchange membrane supported by a porous plastic film.
[0046] The anion exchange monomers can also be polymerized into a solid mass, processed and pulverized into small particles. The small particles can then be blended in an extruder and heated with a melted plastic, such as polyethylene or polypropylene. The plastic and ion exchange mixture can then be extruded into thin sheets of ion exchange membranes.
[0047] Exchange resin beads may be produced by suspending the mixture of the reactants in a water immiscible organic media and heating to form ion exchange beads. When heat is applied, the reaction between the reactants and polymerization will occur. Beads may also be produced by a vibratory spray mechanism.
[0048] In order that those skilled in the art will be better able to practice the present disclosure, the following examples are given by way of illustration and not by way of limitation.
EXAMPLES
Example 1
[0049] DMAPMA (30.6 g, 0.18 mole), hydrochloric acid (15.4 g, 0.16 mole), 1,2,3-propanetriol glycidyl ether (GE100) (23.6 g, 0.09 mole) and 28.0 g of water were mixed and stirred for one hour. 1.4 g of a catalyst, 2,2′-azobis(N,N′-dimethylene isobutyramidine) dihydrochloride supplied by Wako Chemicals USA, Dallas, Tex. (VA044), was added and the mixture was spread onto acrylic cloth between two Mylar sheets and sandwiched between glass plates. The resulting assembly was heated to 85° C. for 30 minutes. The sandwich was separated and the resulting anion exchange membrane was placed into water.
[0050] The following membrane properties were obtained:
[0051] Cap (meq/g)=2.67
[0052] Water content (%)=43.8
[0053] Resistivity (ohm-cm 2 )=11.1
[0054] Thickness (cm)=0.063
[0055] The anion exchange capacity was expressed as milligram-equivalents per gram of dry anion exchange resin in the nitrate form (i.e., not including fabric). The water content was expressed as percent by weight of the wet anion exchange resin in the nitrate form (i.e., not including fabric). The areal resistance of a square centimeter of membrane in the chloride form was measured in 0.01N NaCl at 1000 Hz.
Example 2
[0056] DMAPMA (30.6 g, 0.18 mole), hydrochloric acid (15.4 g, 0.16 mole), 1,2,3-propanetriol glycidyl ether (GE100) (23.6 g, 0.09 mole), N-Vinyl caprolactam (9.4 g, 0.068 mole) and 28.0 g of water were mixed and stirred for one hour. 1.4 g of a catalyst, 2,2′-azobis(N,N′-dimethylene isobutyramidine) dihydrochloride supplied by Wako Chemicals USA, Dallas, Tex. (VA044), was added and the mixture was spread onto acrylic cloth between two Mylar sheets and sandwiched between glass plates. The resulting assembly was heated to 85° C. for 30 minutes. The sandwich was separated and the resulting anion exchange membrane was placed into water.
[0057] The following membrane properties were obtained:
[0058] Cap (meq/g)=2.35
[0059] Water content (%)=42.9
[0060] Resistivity (ohm-cm 2 )=15.4
[0061] Thickness (cm)=0.067
[0062] The anion exchange capacity was expressed as milligram-equivalents per gram of dry anion exchange resin in the nitrate form (i.e., not including fabric). The water content was expressed as percent by weight of the wet anion exchange resin in the nitrate form (i.e., not including fabric). The areal resistance of a square centimeter of membrane in the chloride form was measured in 0.01N NaCl at 1000 Hz.
[0063] While typical embodiments have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and scope herein.
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A novel anion exchange polymer is provided. A method of making the anion exchange polymer includes reacting a tertiary amine, an acid inhibitor and a polyepoxide to form a quaternary ammonium monomer and polymerizing the quaternary ammonium monomer in the presence of a catalyst. The exchange polymer is prepared without using alkyl halides and can be used to make improved ion exchange materials that are chemically resistant and non-fouling.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/314,237, filed Sep. 28, 1994, which is now abandoned.
FIELD OF THE INVENTION
The invention concerns a roller blind system with lateral carrier members for a draw-up mechanism, a mounting or the like, and with lateral guide rails for the roller blind shuttering. The guide rails can each be connected to a respective lateral carrier member, by two or more connecting elements which are different or which can be adjusted differently. The connecting elements are separate from the guide rails and the carrier members, and are respectively provided for connecting a guide rail and a carrier member. The connecting elements can be selected or adjusted in dependence of in the respectively desired relative position of the guide rail and the carrier member.
DESCRIPTION OF THE PRIOR ART
In roller blind systems in accordance with the state of the art, lateral carrier members (cover caps) carry the draw-up or raising mechanism, or a mounting for the winding shaft, of a roller blind shuttering or shield arrangement. Provided integrally on those lateral carrier members are downwardly projecting connecting elements, by means of which the lateral carrier members can be fitted onto lateral guide rails. The lateral guide rails are, for example, screwed to the door or window frame, and serve to guide the roller blind shuttering. The disadvantage of such a connecting element which is formed integrally with the carrier member is that the draw-up element of the draw-up mechanism, for example a belt or a crank handle, can only be extended out of the roller blind casing structure either to the right or to the left from the connecting element. Relative to the outside edge of the guide rail, therefore, that arrangement always involves a spacing in respect of the draw-up elements towards the right or towards the left. In particular, it is not possible for those draw-up elements to be extended out of the roller blind casing structure without a lateral spacing relative to the outside edge of the guide rail (apart from using complicated belt direction-changing mechanisms or a universal joint arrangement which is of an expensive and complicated construction). If the draw-up element is to be extended laterally outside the carrier members, it is additionally necessary to displace the winding-up mechanism outwardly and to provide an additional cover means, which, in turn, represents increased cost.
SUMMARY OF THE INVENTION
Therefore, the object of the invention is to provide a roller blind system of the general kind set forth in the opening part of this specification, with which the relative lateral position as between the carrier members and the respective guide rails can be adapted in a simple manner to the respective conditions involved.
In accordance with the invention, in a roller blind system of the general kind set forth in the opening part of this specification, the relative lateral position as between guide rails and carrier members is adjustable by way of the separate connecting elements.
As, in accordance with the invention, the connecting element is no longer formed integrally with the lateral carrier members, it is possible by the use of different connecting elements or adjustable connecting elements easily to adapt the relative lateral position as between a respective lateral carrier member and the lateral guide rail connected thereto to the respective conditions involved, in which case the carrier members and the guide rails themselves can, in principle, always by of the same configuration for such adaptation. By way of adaptation of the relative lateral position as between carrier member and guide rail, it is possible for the draw-up element (for example belt or crank handle), which extends from the draw-up mechanism which is fixed to the carrier member, to be adjusted in respect of its position relative to the outside edge of the guide rail. In particular, it is possible for the draw-up elements to be passed out of the roller blind casing structure without a lateral spacing relative to the outside edge of the guide rail, without expensive direction-changing mechanisms being required. It is particularly desirable, in regard to easy adaptability to the respective conditions concerned and replacement as required of the parts involved, if the separate connecting elements can be respectively connected releasably to the carrier member and/or releasably to the guide rail.
It is particularly advantageous if a plurality of different separate connecting elements are already available for the fitter or planner of a specific roller blind. Then, depending on the local conditions involved, it is only necessary to select for each carrier member or for each guide rail a specific one of those separate connecting elements, and to use it for connecting the guide rail and the carrier member. The connecting elements of such a set of connecting elements may be, for example, of an I-shaped or Z-shaped profile, wherein the Z has two vertical limbs and a horizontal limb. The lateral displacement between the carrier member and the guide rails can then be readily adapted by way of the length of the horizontal limb.
In principle, however, it is also possible for the separate connecting element to be of a two-part or multi-part structure, wherein at least two parts are adjustable relative to each other. This also permits fine adaptation of adjustment on site.
Besides sets of different separate connecting elements the roller blind system according to the invention may advantageously include a plurality of different left-hand and right-hand guide rails, the connecting region of which, however, is always of the same configuration so that it matches the separate connecting elements. This makes it possible to provide, in the manner of a modular system, for adaptation to different conditions in the region of the guide rails. For example, adjustments may be made according to the nature and thickness of the roller blind shuttering or shield arrangement, the nature of the fixing to the door frame or to the wall etc, while the same type of separate connecting elements can be used for all guide rails.
That problem can be solved in terms of structure by a two-part or multi-part guide rail. One part has a connecting region which is always of substantially the same design configuration, for the separate connecting element. The second part is connected to the first part, and can be adapted to the respective conditions involved.
The modularity of the roller blind system according to the invention can relate not only to different separate connecting elements and different guide rails which match, but also a plurality of different carrier members which can be selectively fixed to the guide rails. The different carrier members, in turn, have connecting regions or mounting means of the same kind which match all separate connecting elements. Overall, therefore, it is possible to construct a roller blind system which is modular in three aspects, and in which a plurality of different carrier members, a plurality of different or adjustable connecting elements, and a plurality of different guide rails are available, which can be combined together as desired to permit simple adaptation to the respective requirements involved.
Further advantages and particulars of the invention are described in greater detail with reference to the following specific description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front plan view of a roller blind system according to the present invention.
FIG. 2 is a side plan view of a lateral carrier member according to the present invention.
FIG. 3 is a sectional view of the lateral carrier member of FIG. 2 taken along lines A--A.
FIG. 4 is a top plan view of the lateral carrier member of FIG. 2.
FIG. 5 is a side view of a lateral cover according to the present invention.
FIGS. 6 and 7 are front views of a section of a roller blind system according to the present invention showing separate embodiments for the connection of a lateral carrier member to a guide rail by means of a connecting element.
FIG. 8a is a front view of a profiled connecting element according to the present invention.
FIG. 8b is a sectional view of the connecting element of FIG. 8a taken along line A--A.
FIG. 8c is a top plan view of a of the connecting element of FIG. 8a which is straight in respect of its longitudinal extent.
FIGS. 9a-9c are side views of three separate embodiments of integral connecting elements according to the present invention.
FIG. 10a is a side view of and adjustable connecting element according to the present invention.
FIG. 10b is a sectional view of the adjustable connecting element of FIG. 10a taken along line B--B.
FIG. 10c is a top diagrammatic plan view of the adjustable connecting element of FIG. 10a.
FIG. 11 is a top sectional view of a first embodiment of a guide rail according to the present invention.
FIG. 12 is a top sectional view of a second embodiment of a guide rail according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The roller blind shown in FIG. 1 has two lateral carrier members 1 which carry a mounting 2 or a draw-up or raising mechanism 3. A winding shaft with axis 4 can be driven by way of the draw-up mechanism 3 and a draw-up element (not shown), and, thus, a roller blind shuttering (also not shown) can be wound up. The roller blind shuttering is guided in lateral guide rails 5 which are fixed, for example, by means of fixing screws 6 to a door or window frame. The carrier members 1 are releasably connected to the guide rails 6 by way of separate connecting elements 7. In FIG. 1 the separate connecting elements are illustrated only diagrammatically by broken lines. A closer description thereof is set forth in relation to FIG. 5 through 10c.
If the winding shaft is not enclosed by a roller blind casing structure, it may be desirable, for the purposes of enhancing stability, if the two carrier members 1 are connected together by a connecting bar 8.
The roller blind shown in FIG. 1 is, in principle, suitable both as a built-in roller blind and also as a finished or ready-made roller blind, in which respect all operationally important elements can be the same in both cases. In the case of a built-in roller blind, the carrier members 1 are fitted in an already existing compartment or opening in the window or door lintel member, and possibly downwardly faced. The entire draw-up mechanism together with the carrier members and the winding shaft is, therefore, scarcely visible. In that case the two carrier members can be arranged completely unencased in the receiving compartment or opening. If, however, the roller blind is to be used as a so-called ready-made roller blind which is typically subsequently fitted above windows or doors in such a way as to be visible from the outside, it is easily possible to mount an end cover 9 externally at each carrier member 1, without altering the other structurally and operationally important elements. Furthermore, a roller blind casing structure wall may be provided between the two covers 9 in order to conceal the winding shaft, the mounting 2, and the draw-up mechanism 3 in the interior. It is also possible for different kinds of covers 9 to be fixed on the outside to the respective carrier member, for the same roller blind system, with the same or similar carrier members 1.
The carrier members 1 may be, for example, of the configuration shown in FIGS. 2 through 4. The carrier members 1 illustrated therein are integral and comprise stamped sheet metal. That means that they are easy and inexpensive to produce. In order to enhance stability the carrier member 1 have angled legs at the edge. They also permit easy fixing to a wall forming the roller blind casing structure, between two lateral carrier members 1. On the left and on the right in FIGS. 2 and 4, the carrier members 1 have profile channels 1b for enhancing stability. The profile channel 1b which is at the right in FIGS. 2 and 4 also serves to receive a connecting element 7, as is shown, for example, as element 20 in FIGS. 8a through 8c. The connecting element 7 serves to connect the carrier member 1 to the guide rails 5. In order to provide for a stable connection of the connecting element 7 to the carrier member 1, two lugs 10 are stamped out in the carrier member 1 and are bent inwardly and downwardly within the profile channel 1b. The connecting element 7 has openings at the spacing of the two lugs 10 and can thus be inserted from below into the lugs.
At a region 1d which is set back relative to the end faces 1c, the carrier member shown in FIGS. 2 through 4 has a plurality of through openings 11. The draw-up mechanism, the mounting or the like can then be screwed from the outside through the through openings 11 to the carrier member 1, in which case the screw heads do not project beyond the faces 1c. That makes it possible for simple flat cover plates 9 to be mounted to the end faces 1c, if that is advantageous for visual or technical reasons. The cover plate 9 can preferably be screwed or glued to the carrier member 1, but releasable connections are certainly also conceivable and possible.
It is possible for the roller blind system to be of a modular structure in regard to the carrier members. In other words, the region of the profile channel 1b and the stamped-out lugs are always of the same configuration in different carrier members to that they always fit the same separate connecting elements 7. However the remainder of the configuration of the carrier member may vary greatly, for example in regard to size for adaptation to different winding diameters. However, even in the case of one and the same carrier member, by virtue of the numerous pre-bored through openings 11, it is possible to fix different kinds of draw-up mechanisms, mountings or the like, without altering the carrier member.
An embodiment of a flat cover plate 9 is shown in FIG. 5.
FIGS. 6 and 7 show how a different relative position as between the guide rail 5 and the carrier member 1 can be achieved by way of different separate connecting elements 7, 7' with the structure otherwise being the same. It is possible in that way to adapt the lateral spacing between a draw-up element 12 (for example a draw-up or raising belt) and the outside edge 5a of the guide rail, depending on local conditions. In FIG. 6 the spacing d is approximately zero, that is to say the draw-up element 12 extends substantially along the outside edge 5a of the guide rail 5. That is possible by virtue of a connecting element 7 which is of a Z-shaped profile and which is fitted both in the carrier member 1 and also in the guide rail 5, and which is releasably connected thereto. The releasable push-in connection is only diagrammatically shown in FIGS. 6 and 7. A larger spacing between the draw-up element 12 and the guide rail 5 is easily achieved by using a separate connecting element 7' which is also Z-shaped but which, as shown in FIG. 7, has a longer horizontal leg.
In the embodiment shown in FIGS. 8a through 8c the separate connecting element 20 is overall straight, but it is profiled in cross-section (see in particular FIG. 8c) in order to increase stability. The connecting element may comprise, for example, metal or reinforced plastic material. In the embodiment shown in FIGS. 8a through 8c the connecting element 20 has two openings 20a which are suitable for being engaged into the lugs 10 in FIG. 3 from below. The connecting element 20 then lies snugly and fully in the profile channel 1b, as shown in FIG. 4.
Simple configurations of I-shaped 21 and Z-shaped 22, 23 connecting elements are shown in FIGS. 9a through 9c.
While the connecting elements shown hitherto were of a one-piece configuration and thus permit inexpensive manufacture, FIGS. 10a through 10c show a somewhat more expensive design. The connecting element 24 illustrated there is of a two-part configuration, wherein two L-shaped parts are assembled overall to form a Z-shaped connecting element. The horizontal leg 24a of the one part and the horizontal leg 24b of the other part overlap in the middle region, the degree of overlap being adjustable. In that way it is possible to adjust the effective length of the horizontal limb of the connecting element which overall is of a Z-shaped profile. A screw can serve for fixing the relative position of the legs 24a and 24b, the screw being screwed through both legs 24a and 24b, for example at the location indicated by a cross 13 in FIG. 10c.
Besides a set of different separate connecting elements or adjustable connecting elements, and possibly beside various carrier members which match, the roller blind system according to the invention may also have different kinds of guide rails in order to provide for optimum adaptation to the respective conditions involved. The guide rails are then distinguished in that they have a connecting region 5c which is always of the same configuration, irrespective of the rest of the structure of the guide rail, and which, therefore, always matches the same or similar separate connecting elements (see FIGS. 11 and 12). FIG. 11 shows an integral embodiment of a guide rail 5. The separate connecting element 7 can be inserted into the region 5c from above. The region 5d serves to guide a actual roller blind.
FIG. 12 shows a two-part embodiment of the guide rail 5'. The first part 5a' has the connecting region 5c' for the connecting element 7, while the second part 5b' which is fixed thereto has the guide 5d for the actual roller blind shuttering. The two-part configuration shown in FIG. 12 advantageously makes it possible to fit different kinds of further parts 5b' to one and the same basic part 5a' with connecting region 5c', depending on the roller blind thickness etc.
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A roller blind system with a roller blind draw-up or mounting assembly supported by lateral carrier members. Lateral guide rails for guiding the roller blind shuttering are connected to the lateral carrier members by separate connecting elements. The separate connecting elements facilitate selection or adjustment of the respective lateral positions of the guide rails and carrier members.
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[0001] This application is a continuation-in-part of patent application entitled A MODULAR GUARD SYSTEM AND APPARATUS FOR A POWER SAW Ser. No. 11/284,214, filed Nov. 21, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to power tools and, more particularly, to power table saws.
[0003] Power table saws typically have guard systems that either attach to the undercarriage of the table saw, to the rear of the table saw or attach to some structure above the table saw. In each of these configurations there are typically three components, namely, a splitter or riving knife, kickback prevention devices, (often called kickback dogs) and a blade guard that covers the blade. A riving knife is a safety device that reduces the likelihood of a kick-back event where a work piece is somehow caught or bound up during a cutting operation and the inertia of the blade throws the work piece back toward the user. A riving knife is typically considered to function similarly to a spreader or splitter on a blade guard assembly, but does not extend above the top of the blade.
[0004] With all known commercial table saw guard configurations, the end user cannot separate the riving knife from the other components. There are times when this is desirable based on the type of cut being made.
[0005] There are two basic types of cuts that are generally made with a table saw and those are through cuts and non-through cuts. During a through cut, the blade is protruding through the entire thickness of the work piece, and in this type of cut there are few problems with current table saw guard configurations. However, when making a non-through cut, the user must remove the guard system if the guard system is of the type which is attached to the undercarriage or the rear of the table saw. These mounting configurations are typically utilized on most portable and bench top models that are presently commercialized. Because there is a need to remove the guard system during non-through and other special types of cuts and because special wrenches or the like are often necessary to do so, many users simply leave the guard system off.
SUMMARY OF THE INVENTION
[0006] A preferred embodiment of the present invention is directed to a modular saw guard system for a power saw of the type which has a table top, a rotatable circular saw blade, the table top having an opening through which the saw blade can extend, the system comprising a riving knife mounted to the saw rearwardly of the blade and having a top surface and a predetermined thickness that is greater than the thickness of the blade body and less than the thickness of the kerf of the blade, the riving knife having at least one aperture near the top surface, a blade guard and kickback prevention mechanism that is releasably mounted to the riving knife, the mechanism having a blade guard portion above the blade and being adjustable to enable a work piece to be moved into cutting position by the blade and a kickback prevention portion configured to engage a work piece as it is being cut by the blade and apply resistance to prevent the work piece from being expelled in the reverse direction,
[0007] the mechanism further comprising a mounting member configured to fit on and be releasably attached to the riving knife, the blade guard portion being pivotally attached to the mounting member, the kickback prevention portion being pivotally attached to the mounting member, a lever mechanism for holding the mounting member to the riving knife and for releasing the mounting member for removal therefrom, the lever mechanism including a movable pin member for engaging the aperture of the riving knife.
DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of the front right side of the preferred embodiment of a modular guard system of the present invention;
[0009] FIG. 2 is a perspective view of the front left side of the system shown in FIG. 1 , with portions removed;
[0010] FIG. 3 is another perspective view of front right side of the mounting channel and kickback prevention mechanism portion of the system shown in FIG. 1 ;
[0011] FIG. 4 is an enlarged perspective view of a portion of the mounting channel and kickback prevention mechanism shown in FIG. 3 ;
[0012] FIG. 5 is a perspective of the right side of the riving knife of the system shown in FIGS. 1 and 2 ;
[0013] FIG. 6 is a plan view of the right side of the system shown in FIG. 1 , particularly illustrating the blade guard mechanism hinge in its operating position;
[0014] FIG. 7 is a plan view of the right side of the system shown in FIG. 1 , particularly illustrating the blade guard mechanism hinge in its raised non-operating position;
[0015] FIG. 8 is an exploded perspective of a portion of the blade guard and kickback prevention mechanism shown in FIG. 1 ;
[0016] FIG. 9 is a perspective view of the right side of a portion of blade guard and kickback prevention mechanism shown in FIG. 8 , and particularly illustrating a mounting channel configured to fit on and be releasably attached to the riving knife;
[0017] FIG. 10 is a perspective view of the right side of a portion of blade guard and kickback prevention mechanism shown in FIG. 8 , and particularly illustrating a lever mechanism for holding the mounting channel to the riving knife and for releasing the mounting channel; and
[0018] FIG. 11 is a plan view of the right side of a portion of blade guard and kickback prevention mechanism shown in FIG. 8 , and particularly illustrating a movable pin member for engaging the aperture of the riving knife;
[0019] FIG. 12 is a simplified side view of an upper blade guard portion that attaches to the blade guard mechanism hinge.
DETAILED DESCRIPTION
[0020] The preferred embodiment of the present invention comprises a modular guard system that has a riving knife mechanism, a blade guard mechanism and a kickback prevention mechanism, all of which can be either quickly adjusted, attached and/or removed. However, the riving knife mechanism must be attached to the table saw in a generally extended position if the blade guard mechanism or the kickback prevention mechanism is used, because these latter two mechanisms are attached to the riving knife mechanism.
[0021] A quick attachment mechanism for the riving knife is shown and described in the aforementioned application entitled A MODULAR GUARD SYSTEM AND APPARATUS FOR A POWER SAW Ser. No. 11/284,214, filed Nov. 21, 2004, which is specifically incorporated by reference herein. Because the embodiments described herein have a riving knife with a very similar lower mounting configuration as is shown and described in the above application, the description of the quick attachment mechanism is not provided here.
[0022] With the modular configuration of the embodiments of the present system, the end user is more likely to use the riving knife and the blade guard and kickback prevention mechanism for a particular task being carried out on the table saw, rather than the typical choice a user now has, which is that of attaching or removing all of these components as part of a single guard system. While the illustrated embodiments of the present invention are shown in connection with a power table saw, it should be understood that the system mechanisms can be utilized in other tools and environments, and that such other applications should be considered to be within the spirit and scope of the present invention. For example, embodiments of the present invention may be used with saws that are known as combo saws and flip saws that are marketed in Europe and possibly elsewhere.
[0023] While the modular design of the preferred embodiment of the present invention permits the removal of the riving knife mechanism together with the blade guard and the kickback prevention mechanism, the design is not meant to encourage such removal. In fact, what is encouraged is the use of these mechanisms at all times whenever practicable. However, the reality of decades of historical use of table saws is that commercial artisans as well as experienced woodworkers want to and do use table saws to make specialty cuts, including plunge cuts, cove cuts and dado cuts, for example. A plunge cut can be made by placing a work piece on the saw with the blade retracted, turning on the motor and cranking the blade upwardly to make a cut more or less in the middle of the work piece. A dado cut is one made with a dado blade that makes a wide cut, and is often used to cut a slot in a work piece, i.e., a non-through cut. A cove cut is a specialty non-through cut, where a work piece is guided by a jig of some type to move the work piece across the blade at an angle (and cutting only an eighth of an inch depth or less per pass) thereby using the curvature of the blade to cut and make a concave surface in the work piece.
[0024] These specialty cuts cannot be made with known conventional riving knifes, blade guards and kickback dogs being attached. Since commercial artisans and woodworkers remove them for such specialty tasks, the preferred embodiment of the present invention is configured to overcome many of the disadvantages of many conventional designs. One important feature is the elimination of the need to completely remove the riving knife mechanism to make some of the specialty cuts described above. For example, It will not need to be removed for a dado cut. It may need to be removed for a cove cut if it goes too deep, and similarly for a plunge cut. If the blade guard and kickback prevention mechanism is detached from the riving knife, the riving knife can be easily retracted out of the way. After such specialty cuts are completed, the riving knife can then be easily adjusted to its extended position where the blade guard mechanism kickback prevention mechanism can be quickly attached. Another benefit of the adjustable riving knife is that it maintains it alignment relative to the blade and therefore does not have to be realigned when it is adjusted to its extended positions
[0025] Turning now to the drawings and particularly FIGS. 1-8 , there is shown a major portion of a modular saw guard system, indicated generally at 20 , that includes a riving knife 22 , a blade guard and kickback prevention mechanism, indicated generally at 24 . The blade guard and kickback prevention mechanism 24 has a quick release assembly 26 that enables it to be easily mounted on and removed from the riving knife 22 .
[0026] The riving knife 22 is adjustable so that its elevation relative to the blade can be changed. When it is used as a standard guard, the blade guard and kickback prevention mechanism 24 is attached to it and the system 20 is then easily attached to a designated mounting post which not shown but is located below the top T of the table (see FIG. 6 ) as is well known to those skilled in the art, and either moves up and down with the movement of the blade when it has an undercarriage mount, or stays in position relative to the top of the table when it is in a rear tool mount position.
[0027] When the system is used as a splitter, the blade guard and kickback prevention mechanism 24 can be removed quickly by using its quick release assembly 26 , and the saw can now perform standard through cuts with the added safety of the riving knife 22 in position. The removal of the blade guard and kickback prevention mechanism is desired on some cuts due to the need for the operator to have more visual guidance, and to avoid any undesirable scratches or markings on the material being cut from the kick back arms. In this position, the riving knife 22 rides directly behind the blade, and is higher than the top of the blade.
[0028] When used as a riving knife for linear moving undercarriage mounts only, the blade guard and kickback prevention mechanism 24 are removed from the riving knife 22 and the riving knife is mounted in an intermediate position where it is operated as a conventional riving knife, as opposed to a separator or splitter. In this position, the top of the riving knife is below the top edge or reach of the blade by a distance that is preferably between 3 and 5 millimeters. In this position, the user has the added security of the riving knife operating as a splitter which prevents the two cut work piece parts from closing on one another behind the blade which can bind the blade and create a kickback condition. It can also be used in the non-through cut mode where the top of the riving blade mechanism will penetrate into the partial cut line. In this regard, it should be understood that the riving knife 22 is mounted to a motor and arbor gear box assembly (not shown but also well known to those skilled in the art) that drives the blade and is vertically as well as angularly adjustable. Since the elevation and angle of riving knife 22 changes as the motor and arbor gear box assembly changes, the position of the riving knife 22 is constant relative to the blade.
[0029] The riving knife 22 is preferably a steel stamping and has an elongated generally curved thin base portion as shown in FIG. 5 , with a center slot 30 that extends from the bottom to the center portion of its height. There are two apertures 32 and 34 which are located on opposite sides of the slot 30 , for attaching the riving knife 22 to the mounting post of the saw. The knife 22 also has an aperture 36 positioned near its substantially flat top surface 38 and a slot, indicated generally at 40 , which has a vertical portion 42 defining an opening that merges with a forwardly (i.e., toward the blade) extending portion 44 that define a shelf 46 for retaining the rear end of blade guard and kickback prevention mechanism 24 .
[0030] In this regard, and referring to FIGS. 1-4 , 6 and 7 , the blade guard and kickback prevention mechanism 24 has an elongated U-shaped mounting channel 48 that has a top portion 50 and spaced apart legs 52 and 54 that extend downwardly from the top portion.
[0031] As is best shown in FIG. 9 , an extension 56 from the leg 54 has a transverse first portion 58 a vertical portion 60 and return portion 62 , with portions 58 and 62 having apertures 64 for receiving a hinge pin. A second extension 66 extends outwardly from the leg 54 and then vertically and it has aperture 68 that is aligned with apertures 70 in the legs 54 and 52 . The apertures 68 and 70 are provided to receive a locking pin for locking the channel 48 to the riving knife 22 . Apertures 71 are provided in each of the legs 52 and 54 for attachment to kickback arms and apertures 72 are provided for pivotally supporting the blade guard portion of the blade guard and kickback prevention mechanism 24 . The legs 52 and 54 have curved end portions 74 that terminate in transverse stop surfaces 76 for limiting movement of a plate guard hinge 78 when the blade guard is moved upwardly into a non-protecting, non-operative position.
[0032] As is apparent from the foregoing discussion, and as best shown in FIG. 3 , the U-shaped channel 48 supports the plate guard hinge 78 which has a lower mounting portion 80 that has two spaced apart legs 82 with apertures for receiving a pair of cylindrical bushings 84 that fit in these apertures and in apertures 72 in the sidewalls 52 and 54 . The bushings 84 are preferably held together with a rivet 86 that is installed into apertures in the bushings, with the reduced diameter portions of the bushings being sized to closely fit in the apertures 72 of the mounting channel 48 . The hinge 78 has a pair of transverse flanges 88 which have apertures 90 which are sized to receive attachment pins, rivets, screws, bolts or other connecting means that permit pivoting movement (not shown) for attaching an upper guard 92 (see FIG. 12 ) that has an aperture 94 for receiving a connector such as a rivet, bolt or the like for attaching the hinge 78 to the upper guard 92 . The upper guard 92 is preferably made from a clear polycarbonate or other plastic material and covers the blade during cutting operations.
[0033] The quick release assembly 26 enables the U-shaped channel 48 to be easily and quickly attached and removed from the riving knife 22 . Referring to FIGS. 1, 3 , 4 , 10 and 11 , the assembly 26 includes a release lever 102 having a free end portion 104 that presents a handle for an operator, with the lever 102 having a mounting end comprising two spaced mounting portions 106 , each of which have an aperture 108 for receiving a hinge pin 110 that pivotally connects the release lever 102 to the U-shaped channel 48 . Midway between the ends of the release lever 102 is an elongated slot 112 in which a release pin 114 is provided.
[0034] As best shown in FIG. 11 , the release pin 114 has a reduced diameter portion 116 and it has an aperture 118 which a locking pin 120 is press fit into. The reduced diameter portion 116 defines a shoulder 122 which contacts the interior surface of the release lever 102 . The pin 114 is positioned in apertures 68 and 70 when it is in locking position. However, when the release member lever 102 is pulled away from the riving knife 22 , the release pin disengages from aperture 36 in the riving knife 22 .
[0035] When the blade guard and kickback prevention mechanism 24 is mounted on the riving knife 22 , the assembly 26 is biased to remain secured to the riving knife 22 . As best shown in FIGS. 4 and 10 , this is done by a torsion spring 124 that has one end 126 bearing upon the sidewall 54 and the other end biased against a bridge portion 128 of the release lever 102 .
[0036] The kickback prevention functionality is provided by a pair of arms 130 that have one or more points 135 in the lower surface thereof that are configured to engage the work piece and prevent it from being expelled back toward the operator if a kickback condition arises. The arms 130 are pivotable around bushings 132 and a rivet 134 is installed between the two bushings 132 . As best shown in FIG. 8 , the rightward bushing 132 has a reduced diameter left portion 133 that is sized to preferably snugly fit aperture 71 in the legs 52 and 54 of the channel 48 and the openings in plates 142 and 144 . The diameter of this portion 133 also corresponds to the width of the portion 42 and the height of portion 44 of the slot 40 of the riving knife 22 . The length of the portion 133 is sufficient to extend across the gap between the legs 52 and 54 and also to be seated in the apertures 71 of both legs. Alternatively, the bushings 132 as well as bushings 84 may be complimentary in construction so that they can be press fit together without the use of a connecting pin.
[0037] The kickback arms 130 have an aperture 136 on one end thereof together with an end ear 138 that extends away from the aperture 136 that is configured to engage a stop pin 140 to limit the movement of the arms 130 in the downward direction. The apertures 136 of the arms 130 are sized to fit the cylindrical bushings 132 . Also, torsion springs (not shown) are provided and fit around each bushing 132 that have one end that bear against the stop pin 140 and an opposite end that bear against the back edge of each of the arms 130 .
[0038] When the blade guard and kickback prevention mechanism 24 is to be mounted to the riving knife 22 , the channel 48 is placed over the flat portion 38 so that the portion 133 of the bushing that extends between the legs 52 and 54 fits into the slot 40 and is moved forwardly into the horizontal portion 44 so that it is held captive by the shelf 46 . When it is this forward position, the release pin 114 of the assembly 26 is aligned with the aperture 36 of the riving knife 22 and can be inserted to lock the blade guard and kickback prevention mechanism 24 in place. It should be understood that the channel 48 will not seat horizontally unless and until the operator pulls the handle 104 away from the channel 48 to enable the pin 114 to clear the riving knife 22 . Once the channel is properly seated, the operator can release the handle 104 and the spring 124 will drive the pin 114 into the apertures 70 and 36 .
[0039] Removal of the blade guard and kickback prevention mechanism 24 merely requires the operator to pull the handle 104 outwardly to remove the pin 114 from the aperture 36 , which permits sliding the blade guard and kickback prevention mechanism 24 rearwardly (i.e., to the right as shown in FIG. 1 , for example) so that the bushing 132 can clear the shelf 46 and the mechanism separated from the riving knife 22 .
[0040] It is desirable to have the thickness of the riving knife 22 be a predetermined thickness that is greater than the thickness of the blade body and less than the thickness of the kerf of the blade, (the kerf being the width of cut made by the saw blade). The blade guard and kickback prevention mechanism 24 of the preferred embodiment of the present invention allows the upper guard hinge 78 , upper guard 92 and kickback arms 130 to be used with the U-shaped channel 48 when knives of different thicknesses are used. This is achieved by the use of shims 142 and 144 that are positioned on the inside of the legs 52 and 54 . They are retained by set screws (not shown) that fit within apertures 138 in the sidewalls 52 and 54 that can be adjusted to position the spacing between the shims 142 and 144 to accommodate riving knifes 22 of different thicknesses. The shims have apertures sized and aligned with apertures in the legs 52 and 54 where necessary so that the functionality or operability of the system is not impaired.
[0041] While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
[0042] Various features of the invention are set forth in the appended claims.
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A preferred embodiment of the present invention is directed to a modular saw guard system for a power saw of the type which has a table top, a rotatable circular saw blade, the table top having an opening through which the saw blade can extend, the system comprising a riving knife mounted to the saw rearwardly of the blade and having a top surface and at least one aperture near the top surface, a blade guard and kickback prevention mechanism that is releasably mounted to the riving knife, the mechanism comprising a mounting channel configured to fit on and be releasably attached to the riving knife, the blade guard portion being pivotally attached to the mounting channel, the kickback prevention portion being pivotally attached to the mounting channel; and a lever mechanism for holding the mounting channel to the riving knife and for releasing the mounting channel for removal therefrom, the lever mechanism including a movable pin member for engaging the aperture of the riving knife.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of British Patent Application No. 0506564.4 filed Mar. 31, 2005, the subject matter of which is being incorporated herein by reference.
Field of the Invention
This invention relates to identifying a photoelectric sensor array size and in particular a CCD sensor array size. In one embodiment the invention relates to a method of identifying a photoelectric sensor array and in particular a CCD sensor array.
BACKGROUND OF THE INVENTION
Where a variety of different types or sizes of sensor may be connected to an imaging system it is very desirable to determine the number of pixels and lines of a connected sensor array to determine an appropriate clocking scheme. Preferably, not only a size of the array making up the sensor is determined, but also a type of the sensor is identified as a known sensor type, in order to apply, for example, predetermined optimal bias voltages and gain for an output signal. For example, in dental x-ray imaging, a dental surgeon may select one of say three x-ray sensors with differing numbers of pixels dependent, for example, on an area to be x-rayed or the size of a patient's oral cavity. At present, with a manual system, a dental surgeon has disadvantageously to divert his attention from a patient to key into a computer keyboard of an imaging system a type of sensor connected to the imaging system. It is preferable if the imaging system automatically identifies a type of sensor connected to the imaging system. It is known to use an EPROM in association with a sensor, for example connected in series in a connector to the sensor, to provide an identifying signal to an imaging system to identify the type, and possibly a serial number, of the sensor. However, use of an EPROM adds undesirable cost and complexity to the sensor and is dependent on recognition by the imaging system of the identifying signal.
It would also be desirable for an imaging system to be able to detect if a sensor connected to the imaging system has a major fault or to detect that no sensor array is connected.
Moreover, having determined an array size it is very desirable to be able to determine an actual identity of a connected sensor, particularly where more than one sensor of a given array size may be connected to an imaging system. For example, defect maps are typically provided with each sensor, indicating locations of atypical pixels so that readings from the atypical pixels can be corrected and it is necessary to know which sensor is connected in order to use a corresponding defect map. Thus, for example, U.S. Pat. No. 6,618,084-B1 discloses a method of determining the location of defective pixels in a sensor array, storing these locations in a memory associated with the sensor, for example on the same chip as a CMOS sensor, and making corrections for readings, or a lack of a reading, from defective pixels. In circumstances where a plurality of sensors may be connected to an imaging system, it is advantageous instead to store maps of the defects centrally, either in the imaging system or in a central database accessible remotely, and to identify the sensor connected to the imaging system so that a corresponding defect map may be used to correct an image generated by the connected sensor. It is preferable if the imaging system automatically identifies a sensor connected to the imaging system. It is known to use an EEPROM in association with a sensor, for example in series in a connector to the sensor, to provide an identifying signal to an imaging system to identify the sensor. However, use of an EEPROM adds undesirable cost and complexity to the sensor and is dependent on recognition by the imaging system of the identifying signal.
In summary, a known method of improving quality of a CCD image comprises storage of dark and bright/flat field image data, and the correction of dark and bright defects in subsequent images by appropriate processing using the stored data. In order to do this, known CCD drive or imaging systems either require: a fixed, single CCD array sensor with only one corresponding set of stored dark and flat field image data, manual selection of a particular CCD serial number, from a set of serial numbers, in order to retrieve the appropriate dark and flat field data or automatic selection of a particular CCD serial number by reading an EEPROM incorporated into a CCD connector, in order to retrieve the appropriate dark and flat field data.
It would be advantageous to be able to identify a sensor uniquely and automatically from a set of sensors to apply corrections, without the use of a EEPROM.
It would also be advantageous to be able to identify a sensor uniquely for warranty purposes, for example, to determine whether a particular sensor is covered by a particular manufacturer's or supplier's warranty.
SUMMARY OF THE INVENTION
According to a first embodiment of a first aspect of the invention, there is provided size determining means to determine a number of pixels in at least one dimension of a sensor array of photoelectric devices, comprising: readout register means for receiving charge accumulated in the sensor array; clock means to apply clock cycle pulses to the readout register means to read out charge from the readout register means for a predetermined number of clock cycles known to exceed a number of pixels in the at least one dimension of the sensor array; discontinuity detection means to determine a first discontinuity in the readout charge, representing a last active pixel in the at least one dimension of the sensor array; and counter means to count clock cycles between a first active pixel and the first discontinuity to determine a number of active pixels in the at least one dimension of the sensor array.
Conveniently, the discontinuity detection means is to determine a second discontinuity in the readout charge, representing the first active pixel in the at least one dimension of the sensor array; and to count clock cycles between the first discontinuity and the second discontinuity to determine a number of active pixels in the at least one dimension of the sensor array.
Particularly, the size determining means further comprises comparison means to use the determined number of pixels to identify a type of the sensor array from a predetermined set of array types.
Advantageously, the size determining means is to integrate dark current charge in the sensor array for a predetermined period of time and to transfer charge from active pixels of the sensor array into the readout register means.
Alternatively, the size determining means is to integrate dark current charge in the readout register means for a predetermined period of time
Advantageously, the size determining means is arranged repeatedly to apply clock cycle pulses to the readout register means for different durations of the predetermined period of time and to obtain an average number of active pixels in the at least one dimension of the sensor array.
Conveniently, the size determining means is to determine a first or second discontinuity by making a comparison of a moving average of accumulated charge in preceding pixels with an instantaneous value.
Conveniently, the photoelectric devices comprise CCD devices.
Alternatively, the photoelectric devices comprise CMOS devices.
According to a second embodiment of the first aspect of the invention, there is provided size determining means to determine a number of pixels in a line of a sensor array of photoelectric devices, comprising: readout register means for receiving charge accumulated in the sensor array; clock means to apply clock cycle pulses to the readout register means to read out charge from the readout register means for a predetermined number of clock cycles known to exceed a number of pixels in the readout register; discontinuity detection means to determine a first discontinuity in the readout accumulated charge, representing a last active pixel in the line of the array; and counter means to count clock cycles between a first active pixel and the first discontinuity to determine a number of active pixels in the line of the array.
Conveniently, the discontinuity detection means is arranged to determine a second discontinuity in the readout accumulated charge, representing a first active pixel in the line; and the counter means is arranged to count clock cycles between the first discontinuity and the second discontinuity to determine a number of active pixels in the line of the sensor array.
According to a third embodiment of the first aspect of the invention, there is provided size determining means to determine a number of lines of a sensor array of photoelectric devices, comprising: readout register means for receiving charge accumulated in the sensor array; clock means to apply clock cycle pulses to the readout register means to read out charge from the readout register means for at least one pixel for each line of the sensor array for a predetermined number of clock cycles known to exceed a number of lines in the sensor array; discontinuity detection means to determine a first discontinuity in the readout accumulated charge, representing a last active line of the sensor array; and counter means to count clock cycles between a first pixel and the first discontinuity to determine a number of active lines of the array.
Conveniently, the discontinuity detection means is arranged to determine a second discontinuity in the readout accumulated charge, representing a first active line of the array; and the counter means is arranged to count clock cycles between the first discontinuity and the second discontinuity to determine a number of active lines of the sensor array.
Advantageously, the size determining means is arranged additionally to label the photoelectric sensor array, by accumulating charge in at least a portion of the sensor array; and further comprising: read-out means to read out the accumulated charge to form an image; feature extraction means to determine, from the image, features of the sensor array comprising at least one of locations of atypical pixels and relative gray levels corresponding to the atypical pixels, in the at least a portion of the sensor array; signature generation means to generate a storable signature of the sensor array from the features of the sensor array; storage means for storing the storable signature; and comparison means to compare the stored signature with a subsequently generated signature for subsequent identification of the sensor array.
Conveniently, the size determining means is arranged to accumulate charge from a dark current.
Advantageously, the size determining means is arranged to increase dark current by at least one of adjusting bias levels applied to the sensor array, increasing a temperature of the sensor array and applying adapted clocking waveforms.
Conveniently, the size determining means is arranged to determine locations of atypical pixels by subtracting a baseline black level and a dark current floor from the image.
Advantageously, the size determining means is arranged to subtract a baseline black level and dark floor current by forming a first image over a first integration time and forming a second image over a second integration time longer than the first integration time and subtracting the first image from the second image.
Advantageously, the size determining means is arranged to subtract a baseline black level and dark floor current by forming an original image, Gaussian blurring the original image to form a blurred image and subtracting the blurred image from the original image.
Conveniently, the size determining means is arranged to blur the image by Gaussian blurring the image with a filter of radius 16 pixels.
Conveniently, the size determining means is arranged to determine the relative gray levels of atypical pixels by applying a gray level threshold at a level at which a predetermined plurality of pixels have gray levels exceeding the threshold and by successively raising the threshold to the gray level of each of the predetermined plurality of pixels to determine the relative gray level of each of the plurality of atypical pixels.
Conveniently, the size determining means is arranged to determine the relative gray levels of atypical pixels by applying a gray level threshold at a level at which a predetermined plurality of pixels have gray levels exceeding the threshold and by determining a difference in gray level of each of the atypical pixels compared with an average gray level of pixels adjacent to each of the atypical pixels respectively.
Conveniently, the size determining means is arranged to generate a signature by generating a map of the determined locations of the atypical pixels of the at least a portion of the sensor array.
Conveniently, the size determining means is arranged to generate a signature by generating a signature from the determined locations of the atypical pixels and relative gray levels of the atypical pixels.
Conveniently, the size determining means is arranged to generate a signature, by generating a histogram from the relative gray levels of the atypical pixels.
Conveniently, the size determining means is arranged to rank the atypical pixels are in order of gray level.
Conveniently, the size determining means is arranged to generate a signature by fitting a polynomial equation to dark signal non-uniformity of the image.
Conveniently, the size determining means is arranged to store the storable signature by storing associable with the storable signature at least one of a serial number of the sensor, a date of manufacture of the sensor, and a warranty period for the sensor.
Conveniently, the size determining means is arranged to store the storable signature by storing associable with the storable signature at least one of drive biases suitable for use with the sensor and image correction information including at least one of dark field, flat field and blemish correction image files.
Conveniently, the size determining means is arranged to store the storable signature in a database.
Conveniently, the size determining means is arranged to store the storable signature in a database remote from an imaging system to which the sensor is connectable, such that the database is accessible to the imaging system over a communications network.
Conveniently, the size determining means is further arranged to generate a new signature of the sensor array; and to match the new signature of the sensor array with the stored signature to identify the sensor array.
Conveniently, the size determining means is further arranged to retrieve at least one of a serial number of the sensor, a date of manufacture of the sensor, and a warranty period for the sensor associable with the stored signature.
Conveniently, the size determining means is further arranged to retrieve at least one of optimum drive biases suitable for use with the sensor and image correction information including at least one of dark field, flat field and blemish correction image files associable with the storable signature.
According to a second aspect of the invention, there is provided an imaging system comprising size determining means to determine a number of pixels in at least one dimension of a sensor array of photoelectric devices, comprising: readout register means for receiving charge accumulated in the sensor array; clock means to apply clock cycle pulses to the readout register means to read out charge from the readout register means for a predetermined number of clock cycles known to exceed a number of pixels in the at least one dimension of the sensor array; discontinuity detection means to determine a first discontinuity in the readout charge, representing a last active pixel in the at least one dimension of the sensor array; and counter means to count clock cycles between a first active pixel and the first discontinuity to determine a number of active pixels in the at least one dimension of the sensor array.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is aschematic drawing of a first sensor array to which the method of the invention may be applied;
FIG. 2 is a trace of an output signal from the sensor array of FIG. 1 ;
FIG. 3 is a schematic drawing of a second sensor array to which the method of the invention may be applied;
FIG. 4 is a trace of an output signal from the sensor array of FIG. 3 ;
FIG. 5 is a averaged trace of an output signal from the sensor array of FIG. 3 using a clock count corresponding to a predetermined number of pixels/line, as in the prior art;
FIG. 6 is a averaged trace of an output signal from the sensor array of FIG. 3 using a clock count greater than a number of pixels/line, according to the invention;
FIG. 7 is a averaged trace of an output signal from the sensor array of FIG. 3 using a clock count corresponding to a predetermined number of lines in the array, as in the prior art;
FIG. 8 is a averaged trace of an output signal from the sensor array of FIG. 3 using a clock count greater than a number of lines in the array, according to the invention;
FIG. 9 is a schematic diagram of a circuit, for use in the invention, for determining a number of pixels in a line of the array of FIG. 3 from the averaged output trace of FIG. 6 ;
FIG. 10 is a schematic diagram of a circuit, for use in the invention, for determining a number of lines in the array of FIG. 3 from the averaged output trace of FIG. 8 ;
FIG. 11 is a flowchart of the method of the invention;
FIG. 12 is a schematic drawing of a further known photoelectric array suitable for use with the invention.
FIG. 13 is a dark image produced by a sensor array, before processing the image according to an embodiment of the present invention;
FIG. 14 is a plot of gray values of the image of FIG. 13 after processing according to the embodiment of the present invention to reveal dark signal (DS) spikes;
FIG. 15 is a close-up of a high amplitude DS spike, numerous low amplitude spikes and DS background of the plot of gray values of FIG. 14 ;
FIG. 16 is close-up of edge effects of the plot of gray values of FIG. 14 ;
FIG. 17 is a plot of positions of largest amplitude DS spikes in a plot of gray values similar to that of FIG. 14 ;
FIG. 18 is a relative histogram of relative amplitudes of atypical pixels in the plot of FIG. 14 ; and
FIG. 19 is a dark signal non-uniformity (DSNU) row profile of distance in pixels as abscissa and gray value as ordinates of the plot of FIG. 14 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Throughout the description, identical reference numerals are used to identify like parts.
Referring to FIGS. 1 , 2 and 11 , charge from a CCD array 10 is integrated, step 1101 , in darkness for a time that allows sufficient dark current to accumulate to be reliably measured, e.g. an average dark current of 1% of full well capacity, for an Advanced Inverted Mode Operation (AIMO) device, clocked in AIMO mode, this is approximately 10 seconds at room temperature. One line, for example a first line 11 , of CCD charge is transferred in direction of arrow-headed lines 15 to a register 12 and read out, in direction of arrow-headed line 16 , for example to a charge detector amplifier, not shown, applying, step 1102 , a plurality of clock cycles that exceeds a supposed maximum number of pixels/line for the subject CCD array, e.g. for a known dental x-ray sensor CCD family, more than 1262 clock cycles. In this manner, so-called “virtual pixels” 121 will be read after a last of the actual pixels 111 of the first line 11 of array 10 . These virtual pixels 121 will gain some dark current charge during their passage through the register 12 . Transfer of a succeeding line 13 into the register 12 is delayed while the register 12 is read for the virtual pixels 121 associated with a currently-read line 11 . Referring to FIG. 2 , data 20 read from the current line 11 is analysed to detect, steps 1103 , 1104 , any significant discontinuities 21 , 22 in the output signal, for example by subtraction of a moving average from an instantaneous signal. If a detected discontinuity 21 , 22 in dark current is less distinct than sufficient definitively to establish presence of a discontinuity, due, for example, to non-uniformity of dark current over the CCD array, further measurements may be made to resolve the ambiguity. For example, an average length of line may be determined over several lines of the array 10 , or when counting a number of lines in a manner described herein below, rather than a number of pixels per line, averaged over several columns of pixels. An alternative continuous transfer clocking scheme, for example Time-Delay Integration (TDI) mode, automatically averages dark current over all the lines of the array 10 . Alternatively, data generated by dark currents may be collected several times for a range of integration periods, which would at least tend to cancel out temperature sensitivity of dark current. Finally, a fuzzy logic approach may be used, wherein a specific sensor type is determined according to measured pixels per line, and/or lines per field, falling within a predetermined range, for example it may be sufficient to identify a type of sensor if it is determined that a number of pixels per line is between 1200 and 1300. This requires prior knowledge of all CCD sensors which will be used with an imaging system, but often this is the case.
Referring to FIG. 2 , a first detected discontinuity 21 indicates a transition from blank elements to image elements. A second discontinuity 22 indicates a transition from image elements to blank elements. A number of clock cycles between the first discontinuity and the second discontinuity is counted, step 1105 , and corresponds to a number of active pixels for a sensor array under test, and may be sufficient to identify a particular device type within a family, by comparing, step 1106 , the pixel count with known pixel counts of know arrays. Alternatively, if clocking does not begin before a first active pixel 112 , only the second discontinuity 22 is detected and the number of pixels per line corresponds to a number of clocking pulses between a first detected pixel 112 and the second discontinuity 22 .
If no discontinuity 21 , 22 is detected, it is evident that the CCD array has a major fault, or that no CCD array is connected.
Referring to FIGS. 3 and 4 , the method may be extended to determine a number of run-off pixels at an end of a line in an array 30 having such run-off pixels 34 . Typically additional pixels are provided in the image area for dark reference and over-scanning purposes. Thus, as shown in FIG. 12 , a typical array 120 may have 8 leading blank elements 126 and 8 terminal blank elements 122 in the register 1202 and 16 leading and trailing dark reference pixels 123 , 124 in each row or line of the array and 3 terminal dark reference rows 125 . Referring again to FIG. 3 , these run-off pixels 34 do not generate charge from illumination, as does an illuminated main image portion 35 of the array, but still collect dark current themselves. Further discontinuities 43 , 44 may therefore be detected in the data 40 read from the register, towards an end of a pixel line 31 , in addition to discontinuities 41 , 42 indicating boundaries of the array. Alternatively, only dark current collected in the readout register 32 may be read, with no transfer from an image portion 35 , so that there is measurable dark current present in all register elements, including register elements corresponding to runoff elements 34 . A detected number of runoff elements 34 could be used as additional information to identify a known sensor array 30 , or to help define a clocking scheme, without knowledge of a specific connected sensor.
Alternatively, or where determining a number of pixels in a line is not sufficient to identify a known sensor type uniquely, the number of lines in an array 10 , 30 may similarly be determined, for example by reading a first pixel 112 , 312 in the first line 11 , 31 and in each other line and clocking past a supposed maximum number of lines to determine a discontinuity in an output signal after the last actual pixel 192 , 392 has been read.
The method step of counting pixels, step 1105 , in a line may be better understood by reference to FIGS. 5 , 6 and 12 . In a known method of reading an array output from an array 120 , as illustrated in FIG. 5 , an averaged output 50 from the array is clocked for a plurality of clock cycles corresponding to a known number of pixels/line and an output 51 , 52 , 53 corresponding only to blank and dark elements at the ends of each row exists between output 54 corresponding to active pixels in a first row and output corresponding to active pixels 55 in a succeeding row. Referring to FIG. 6 , on the other hand, an averaged video output 60 in an array clocked according to the invention with a plurality of clock signals exceeding a plurality of pixels/line, has an output 66 corresponding to the virtual or null pixels as well as outputs 61 , 62 corresponding to blank pixels and reference pixels between an output 64 corresponding to active pixels in a first row and output 65 corresponding to active pixels in a succeeding row.
Referring to FIG. 9 , the V os output 60 is amplified by an amplifier 91 before being input to a first input of a comparator 92 . A reference voltage V ref , corresponding to a voltage midway between maximum and minimum amplitudes of the averaged output V os is input to a second input of the comparator 92 to output a signal V out , which is high when V os exceeds V ref , to a counter 93 which is clocked at the pixel clocking rate. The counter 93 counts pixel clock cycles while V out is high to output the number of active pixels in one or more rows.
The method step of counting lines or rows in an array may be better understood by reference to FIGS. 7 , 8 and 10 . In a known method of reading an array output from an array 120 , as illustrated in FIG. 7 , an averaged output 70 from the array is clocked for a plurality of clock cycles corresponding to a known number of lines or rows and an output 71 corresponding only to a vertical shift period exists between output 74 corresponding to active pixels in a first row and output 75 corresponding to active pixels in a succeeding row. Referring to FIG. 8 , on the other hand, an averaged video output 80 in an array clocked according to the invention with a plurality of clock signals exceeding a plurality of rows or lines, has an output 86 corresponding to the virtual or null pixels as well as output 71 corresponding to the vertical shift between an output 84 corresponding to active pixels in a first row and output 85 corresponding to active pixels in a succeeding row.
Referring to FIG. 10 , the V os output 80 is amplified by an amplifier 101 before being input to a first input of a comparator 102 . A reference voltage V ref , corresponding to a voltage midway between maximum and minimum amplitudes of the averaged output V os is input to a second input of the comparator 102 to output a signal V out , which is high when V os exceeds V ref , to a counter 103 which is clocked at the row clocking rate. The counter 103 counts row clock cycles while V out is high to output the number of active rows.
It will be understood that the method is also applicable to CCD arrays in which pixels are in arrangements other than a standard rectangular array.
It will be further understood that the method is also applicable to other sensor types such as CMOS device sensors.
Whilst dark current is a convenient way of gathering signal charge, since it is inherent in silicon of the array, array size can also be determined if signal charge is generated in the array 10 , 30 by some other technique, for example, light could briefly be produced over the area of the sensor, by pulsing an LED or opening a shutter, or, for a dental x-ray sensor with a phosphor, by stimulating the phosphor, by light or by passing an electric current through the phosphor.
Having determined the size of an array as an initial procedure, it may be desirable to identify a particular sensor of that array size.
Referring to FIG. 13 , which shows a dark image 200 produced by a sensor array, a dark current variation of an imaging sensor is characteristic of a particular sensor because the dark current variation is associated with local crystal dislocations in bulk material from which an array of devices of the sensor is constructed. Using suitable signal and software processing, single pixel dark current high points 221 , 222 , hereinafter called dark current spikes, DS (dark signal) spikes or spikes, as shown in FIG. 14 , and area non-uniformity of dark current 223 , hereinafter called dark signal non-uniformity (DSNU), can be used to identify a particular imaging sensor uniquely from a number of sensors.
Although dark current spikes may be used to identify an array, in principle, a given image sensor can be identified according to the invention by non-uniformity of a number of different electro-optical aspects of its array, for example, dark signal spikes, dark signal columns, dark signal non-uniformity, fixed traps, signal level dependent traps, photo-response spots, photo-response columns and photo-response non-uniformity. However, the invention is primarily described herein based on x,y mapping of non-uniformities of the dark signal in order to identify a given image sensor.
To obtain a dark image 200 , as shown in FIG. 13 , charge generated in a CCD array is integrated in darkness for a sufficient time to accumulate a dark image containing moderately high dark current and a number of hot pixel/dark current spikes 221 , 222 , for example an average dark current of 2% of full well capacity—for an Advanced Inverted Mode Operation (AIMO) device for 5 seconds at 37° C. A resulting image 200 is read out from the array and stored.
Before each use of the sensor in which it is required to identify the sensor, a dark image is again obtained. A general correlation may be expected between the measured dark current image and the previously stored dark current image, with which the measured image may be matched. A matching technique need not be applied to the whole array, but to any predetermined stored portion. For example, a dark current profile of say a first 50 pixels and 50 lines may be matched with a corresponding portion of the previously acquired dark current image. This reduces required mathematical processing and, assuming all sensors to be identified are larger than the portion, say 50 pixels×50 lines, permits matching a sensor without having first to determine an array size of the sensor.
A matching technique need not be applied to the whole array, but to the detection of the most significant atypical pixels, e.g. in terms of single pixel deviation in amplitude from nearest neighbours. In one embodiment, this means detecting the brightest, say 50, pixels in a dark image.
If a selected portion of the sensor fails to produce any match, or fails to produce a unique match, other portions or the whole sensor are subsequently compared.
Various matching techniques may be used to seek to match a stored image to a measured image. The ratio of dark current in a captured image to an original image can be used as an estimator for a scaling factor or a figure of merit as to how close the correlation is expected to be. However, wherever possible, single distinctive pixels are searched out. For example, a threshold is applied to the image at a grey level, A, just above a mean grey level for the whole image, and detected atypical pixels plotted in an x-y table. Alternatively, a maximum grey level of the whole image is detected, then a threshold, B, applied such that 100 ‘bright’ atypical pixels detected and plotted in an x-y table. The use of relative pixel amplitudes is preferred in order to avoid strong dependence on imager temperature. Theoretically, only one previously stored dark current image is needed for each CCD array to be identified. The thresholded images should be a good match to the ones previously stored for the same CCD. Alternatively, only one measured image could be matched against multiple stored images, but that would require storing several dark current images for each CCD array.
An extension of the thresholding method uses dark current images for a range of integration times and thresholds them all at a same level. This may provide extra information to help identification as lower level white defects will then be mapped.
Three basic embodiments are described as examples of suitable processing:
1 Detection of x & y coordinates of spikes and their ranking by amplitude;
2 Calculation of a histogram with bins of relative spike amplitude; and
3 Fitting of a polynomial equation to medium and large area DSNU.
Practically, the first embodiment, detection of x & y coordinates of spikes and their ranking by amplitude, is preferred.
In all cases, the output of the processing is used to construct a concise dark signal (DS) signature in terms of a series of numbers for a particular sensor, e.g. relative amplitude (spike 1) , x coordinate (spike 1) , y coordinate (spike 1) . . . X coordinate (spike N) , y coordinate (spike N) , relative amplitude (spike N)
Generation of DS Signatures
In order to generate a DS signature, an imager signal due to dark current must be significantly higher, for example more than three times greater, than readout noise of the imager.
It is also necessary that the dark signal is not so high as to saturate the imager or signal processor, nor so high as to cause significant clipping of DS spikes or imager blooming from DS spike sites.
An integration time for the dark image must be a sufficient time to collect a reasonable amount of dark current. However, in order to hasten signature generation, and to reduce time required for an adequate amount of dark current to build up, it is advantageous temporarily to increase a normal imager dark current by one or more of the following methods:
adjusting bias levels (usually by reducing a substrate voltage); increasing device temperature; or changing clocking waveforms applied to the imager, e.g. if an AIMO CCD is being used, using Non-Inverted Mode Operation (NIMO) waveforms.
Once the sensor has been identified, normal values of the parameters are used for imaging.
Detection of x,y Coordinates of Spikes
Bottom-Up Method
In a bottom-up first embodiment, once a dark image 200 has been generated, a baseline black level and dark current floor are subtracted to allow discrimination of DS spikes 221 , 222 . This can be done, for example, by one of the following methods:
forming a first image over a very short integration time, e.g. 1 ms, taking a second image at a longer integration time, e.g. 1 s, and subtracting the first image from the second; or taking an original image at a long integration time, e.g. 1 s and Gaussian blurring this image, e.g. with a filter of radius 16 pixels, and subtracting the blurred image from the original image in order to reveal DS spikes.
The whole area average of the image, with baseline previously subtracted, is calculated. A gray level threshold operation is carried out for the image. The threshold is raised from zero gray level until a number of spikes 221 , 222 detected is reduced to a number of the order of 100. The gray level threshold is raised further until the lowest of the 100 spikes is just lower than the threshold. The first spike amplitude is then calculated from the formula (current threshold−whole area average). The process is repeated until the positions and amplitudes of all spikes have been measured and recorded.
FIG. 17 shows an exemplary plot 250 of positions of largest amplitude DS spikes 221 in a plot of gray values, for which the x,y coordinates are determined.
Top-Down Method
In a top-down second embodiment, a threshold operation is carried out for the image. The gray level threshold is reduced from peak white counts until the number of spikes detected is of the order of 100. For each spike detected, the peak amplitude and a local area average of around five pixels radius, centred on the spike, is measured. The amplitude of each spike is then calculated as (peak amplitude—local area average).
Column Defect and Edge Effects
Referring to FIG. 16 , an algorithm for counting the spikes 220 should be insensitive to shading 230 at the edges of the image 200 , which can be caused by charge leakage. It should also be insensitive to column defects, not shown, where a number (e.g. >10) sensor defects are joined together in a column defect. In preference, the algorithm counts single pixel DS spikes 221 , 222 in areas that are known not to be influenced by edge effects 230 or column effects.
Calculation of Histogram with Bins of Relative Spike Amplitude
In a third embodiment, a histogram is calculated from the relative amplitudes of the spikes. The spikes are ranked in order of brightest to least bright pixel, as shown in the following table.
Spike Position
Grey
Relative
Spike Ref
X
Y
Value
Amplitude
1
981
821
522
1.00
2
845
203
440
0.70
3
717
80
403
0.56
4
164
721
400
0.55
5
863
596
394
0.53
6
737
705
389
0.51
7
51
71
386
0.50
8
593
263
363
0.41
9
1273
377
352
0.37
10
631
652
343
0.34
11
1083
594
340
0.33
12
521
290
338
0.32
13
1265
27
332
0.30
14
322
857
308
0.21
15
1322
910
287
0.13
16
1314
238
271
0.07
17
226
230
264
0.05
18
74
92
257
0.02
19
699
637
256
0.02
20
1171
775
256
0.02
21
1346
530
251
0.00
From this table a dark signal signature may be derived from the relative amplitudes and (x,y) coordinates of the spikes ranked in order of relative amplitude:
DS Signature=(1.0, 981, 821, 0.7, 845, 203, 0.56, 717, 80 . . . 0.0, 1346, 530)
Further aspects of the image may be used to check the correctness of the Spike Position table. For example:
X max: 1368: maximum pixel number in the x direction for the known sensor Y max: 936: maximum pixel number in the y direction for the known sensor Grey max: 4096: number of bits of the A to D Standard deviation: 3.36 Mean: 182: check that no spike is less than (mean+3×std dev=192.1) Max: 522: check no spike exceeds this value
A table of x,y coordinates and spike amplitude results from the embodiment described above. In this third embodiment, this data is re-ordered to construct a histogram 260 , see FIG. 18 , with spikes 261 from lowest to highest relative spike amplitude 262 . Alternatively, the data is allocated to relative spike amplitude ranges or bins to construct a frequency histogram with say 20 bins from lowest to highest relative spike amplitude. The use of relative spike amplitudes is important in order to avoid a necessity of scaling spike amplitude with temperature.
In a related embodiment, relative spike amplitudes may be serially calculated on the fly.
Fitting of Polynomial Equation to Medium and Large Area DSNU
In a fourth embodiment, a polynomial equation is fitted to medium or large area DSNU 223 . A first image is formed over a very short integration time, e.g. 1 ms, and a second image formed over a longer integration time, e.g. 1 s and the first image is subtracted from the second image.
Row Profile
Column binning may be used, i.e. combining data from adjacent pixels in a column direction, in order to reduce effects of noise. Typically column binning will be 10 to 100 pixels high. A polynomial equation is fitted to the resulting row profile 270 , as shown in FIG. 19 .
Column Profile
Alternatively, row binning may be used, i.e. combining data from adjacent pixels in a row direction, in order to reduce effects of noise. Typically row binning will be 10 to 100 pixels high.
A linear equation is fitted to the dark current ramp that results from pixels read out later from the array that contains greater dark signal. This dark current ramp is subtracted from the image. A polynomial equation is fitted to the column profile.
Use of DS Signatures to Identify an Imager
The probability of the x,y coordinates of spikes identifying a particular imager increases rapidly with the number of spikes. Although around 100 spikes are mapped for each device, a match on a first 10 to 50 spikes will usually be sufficient. If matching all 100 spikes is inconclusive, further matching using one or both of the third embodiment of using histograms and the fourth embodiment of fitting polynomials can also be used.
When an imaging device of unknown serial number is connected to the imaging system, a dark image is first generated, which is then processed to give the DS signature. This DS signature is then compared with local or remote databases/lookup tables in order to identify the device uniquely.
Once identified, the device can then be associated with information such as date of manufacture, warranty remaining, optimum drive biases required etc. It can also be associated with image correction information such as dark field, flat field and blemish correction image files.
Once the processing has been implemented at both the point of manufacture and the point of use, the system is more economical to run, less prone to errors, e.g. resulting from repetitive programming, and more flexible than other systems that, for example, use a serial EEPROM attached to the imaging device to store serial number data.
The DS signature method of the invention is usable in combination with conventional printed labelling or EEPROM identification as a backup or check to confirm that an imager does have the correct serial number. The DS signature is intrinsic to the imaging device alone.
The DS signature is compact, and is generated by a method which can be easily automated, is fast, and does not require the storage of large image files to identify a particular imager uniquely.
Once a particular CCD serial number has been identified, the stored dark field and bright field image data is used to correct subsequent images by appropriate processing in a known manner.
It will be understood that the method is applicable to CCD arrays in which pixels are in patterns other than a standard rectangular array.
It will be further understood that the method is also applicable to other sensor types such as CMOS device sensors.
Whilst dark current is a convenient way of gathering signal charge, since it is inherent in silicon of the array, an array may be identified if signal charge is generated in the array by some other technique, for example, light could briefly be produced over the area of the sensor, by pulsing an LED or opening a shutter, or, for a dental x-ray sensor with a phosphor, by stimulating the phosphor, by light or by passing an electric current through the phosphor.
It will be understood that where a plurality of sensor arrays are to be used with an imaging system, as, for example, in a dental surgery, maps of atypical pixels of all the sensor arrays to be used with the imaging system may be stored in the imaging system. Alternatively, maps of atypical pixels may be stored centrally in a database and the maps accessed over a communications network, for example the maps may be stored on a website and accessed using the Internet. Alternatively, or in addition, a manufacturer may have a map database of all devices manufactured in a given time period so that any device returned to the manufacturer, for example as being defective during a warranty period, may be uniquely identified, for example to determine whether the device is covered by warranty or to identify a manufacturing batch number, for example, for a possible product recall or quality control investigation.
Although an embodiment of the invention has been described in terms of pixels which are atypical by virtue of their dark current, it will be understood that the invention is equally applicable to the location of any distinctive pixels within the array which may be consistently mapped.
Alternative embodiments of the invention can be implemented as a computer program product for use with a computer system, the computer program product being, for example, a series of computer instructions stored on a tangible data recording medium, such as a diskette, CD-ROM, ROM, or fixed disk, or embodied in a computer data signal, the signal being transmitted over a tangible medium or a wireless medium, for example microwave or infrared. The series of computer instructions can constitute all or part of the functionality described above, and can also be stored in any memory device, volatile or non-volatile, such as semiconductor, magnetic, optical or other memory device.
Alternative embodiments of the invention can be implemented as a computer program product for use with a computer system, the computer program product being, for example, a series of computer instructions stored on a tangible data recording medium, such as a diskette, CD-ROM, ROM, or fixed disk, or embodied in a computer data signal, the signal being transmitted over a tangible medium or a wireless medium, for example microwave or infrared. The series of computer instructions can constitute all or part of the functionality described above, and can also be stored in any memory device, volatile or non-volatile, such as semiconductor, magnetic, optical or other memory device.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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In a size determining system, a number of pixels in a dimension of a sensor array of photoelectric devices is determined. A readout register is arranged to receive charge accumulated in the dimension of the sensor array. A clock is connected to apply clock cycle pulses to the readout register to read out the charge from the readout register for a predetermined number of clock cycles known to exceed a supposed maximum number of pixels in the dimension of the sensor array. A discontinuity detector is operative to determine a first discontinuity in the readout charge, representing a last active pixel in the dimension of the sensor array. A counter is arranged to count clock cycles between a first active pixel and the first discontinuity to determine a number of active pixels in the dimension of the sensor array.
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FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and a method for converting megaco protocol; and, more particularly, to an apparatus and a method for executing protocol conversion to enable megaco protocol-applied internet phone terminals, a media gate way and a media gateway controller to communicate with SIP, H.323 or MGCP protocol-applied internet phone terminals, a gatekeeper, a proxy server, a media gateway and a media gateway controller on an internet phone network where various internet phone protocols are used.
DESCRIPTION OF RELATED ARTS
[0002] Presently, various internet phone protocols are used for media gateways, media gateway controllers, gate keepers, proxy servers and internet phone terminals which are the equipments that enable internet phone services on an internet phone network. Such internet phone protocols include: a megaco protocol which is a standard protocol of international telecommunications union—telecommunication standardization sector (ITU-T) and internet engineering task force (IETF); an H.323 protocol of ITU-T; a session initiation protocol (SIP) and a media gateway control protocol (MGCP) of IETF.
[0003] Referring to FIGS. 1A to 1 B, conventional internet phone networks utilizing an H.323 protocol and an SIP protocol are illustrated. Herein, FIG. 1A illustrates an internet phone network utilizing an H.323 protocol, and FIG. 1B illustrates an internet phone network utilizing an SIP protocol.
[0004] The H.323 protocol and the SIP protocol are peer-to-peer structured protocols with subscribers' terminal-oriented communicational structures. Therefore, the subscribers' terminals, in other words, internet phone terminals are generally required to include a majority of additional service functions. This causes limitations such as increasing internet phone terminal costs and a need for upgrading the internet phone terminals every time a new additional service function is added. Also, although there are no limitations in direct communications between the internet phone terminals, there are limitations of unstable services of billing, security and quality of service (QoS) in a business model environment wherein an internet telephony service provider (ITSP) operator provides internet phone services.
[0005] Referring to FIGS. 2A to 2 B, examples of conventional internet phone network utilizing a megaco protocol and an MGCP protocol are illustrated. Herein, FIG. 2A illustrates an internet phone network utilizing a megaco protocol, and FIG. 2B illustrates an internet phone network utilizing a MGCP protocol.
[0006] The megaco protocol is a master-slave structured protocol. An internet phone terminal of a subscriber of an internet phone network utilizing a megaco protocol operates in a slave mode which operates in the same manner as a conventional telephone terminal of a public switching telephone networks (PSTN) subscriber (an analog telephone). As a result, the ITSP operator can identify and control conditions of every subscriber's phones through a megaco media gateway controller and execute more efficient internet phone services. Furthermore, all of the additional service functions are concentrated at the media gateway controller, resulting in a much lowered cost to add a new additional service for the internet phone network utilizing the megaco protocol, when compared with the internet phone networks utilizing the H.323 or the SIP protocols.
[0007] On the other hand, the MGCP protocol was developed prior to the megaco protocol, and it has the same master-slave structure as the megaco protocol. MGCP protocol is superior to the megaco protocol in stability, but it only supports limited functions of voice-oriented functions when compared with the megaco protocol. The megaco protocol is structured to support multimedia functions such as video, audio and voice functions, and therefore, it will be much more frequently applied to the next generation network (NGN) than the conventional H.323, SIP, and MGCP protocols.
[0008] The ITSP operators, presently providing internet phone services, select the internet phone protocols, establish the internet phone networks, and provide the internet phone services according to each of their own business models. Consequently, an ITSP operator uses one of the H.323 protocol internet phone network, the SIP protocol internet phone network and the MGCP protocol internet phone network.
[0009] If an existing ITSP operator plans to switchover to an internet phone network utilizing the megaco protocol, it must either replace all of the subscribers' internet phone terminals for H.323/SIP/MGCP protocols with internet phone terminals for the megaco protocol simultaneously, or replace its gate keeper/proxy server/MGCP media gateway controller with a megaco media gateway controller. However, this process causes limitations in services for the subscribers with high costs.
[0010] In conclusion, it can be an alternative plan and a new business model for establishing the megaco protocol internet phone network to: have the subscribers use the existing H.323/SIP/MGCP internet phone terminals; install and operate the megaco media gateway controller first; and replace all of the existing H.323/SIP/MGCP internet phone terminals with the megaco internet phone terminals later, instead of replacing all of the existing H.323/SIP/MGCP internet phone terminals with the megaco internet phone terminals or installing the megaco media gateway controller.
[0011] Also, for the ITSP operators that desire a complete control of their subscribers of the existing megaco protocol internet phone network, or the ITSP operators that do not wish to spend too much on replacing pro-protocol relay equipments such as a proxy server, it will be a good business model to replace only the subscribers' H.323/SIP internet phone terminals with the megaco internet phone terminals.
[0012] To realize the various business models mentioned above, an equipment for executing protocol conversion between the megaco protocol and the H.323/SIP/MGCP protocols is required.
[0013] Meanwhile, a media gateway controller that executes conversion between an SIP internet phone protocol and a megaco internet phone protocol is proposed in an article by B. Marsic et al., entitled “IMS to PSTN/CS interworking,” Proceedings of the 7 th International Conference on Telecommunications, June, pp. 701-704, 2003.
[0014] However, the above antecedent treatise only suggests a method for converting a protocol between a megaco protocol and a certain internet phone protocol (an SIP protocol), and it does not fundamentally resolve the limitations mentioned above.
SUMMARY OF THE INVENTION
[0015] It is, therefore, an object of the present invention to provide an apparatus and a method for converting megaco protocol enabling execution of communications between objects which use different protocols by: searching destination objects and protocol conversion functions by utilizing databases according to condition modes of objects which transmitted protocol packets; and executing protocol conversion.
[0016] In accordance with an aspect of the present invention, there is provided an apparatus for converting a megaco protocol to a different protocol, including: a plurality of first protocol execution means for receiving a plurality of different protocol packets, executing operations according to the received protocols, analyzing the received protocols, and generating protocol execution parameters; a megaco protocol execution means for receiving a megaco protocol packet, executing operations according to the received protocol, analyzing the received protocol, and generating protocol execution parameters; databases for storing connection information between the objects and protocol conversion functions; and a protocol conversion means for interworking between the first protocol execution means and the megaco protocol execution means, searching for destination objects and the protocol conversion functions in the database, and converting the generated protocol execution parameters to protocol types of the destination objects, based on condition modes of objects which transmitted the protocol packets.
[0017] In accordance with another aspect of the present invention, there is provided a method for megaco protocol conversion, including the steps of: receiving a protocol packet and generating protocol execution parameters; searching an object information database entry by utilizing the generated protocol execution parameters; verifying an object condition mode of the searched object information database entry; verifying a protocol type of a destination object by utilizing the generated protocol execution parameters, based on the verified object condition mode; and converting the generated protocol execution parameters to the verified protocol type of the destination object by utilizing parameter conversion functions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other objects and features of the present invention will become better understood with respect to the following description of the specific embodiments given in conjunction with the accompanying drawings, in which:
[0019] FIGS. 1A to 1 B are diagrams illustrating conventional internet phone networks utilizing H.323 and SIP protocols;
[0020] FIGS. 2A to 2 B are diagrams illustrating conventional internet phone networks utilizing megaco and MGCP protocols;
[0021] FIG. 3 is a diagram illustrating a megaco protocol conversion apparatus in accordance with a first embodiment of the present invention;
[0022] FIG. 4 is a diagram illustrating an object information database shown in FIG. 3 ;
[0023] FIG. 5 is a diagram illustrating a terminal information database shown in FIG. 3 ;
[0024] FIG. 6 is a diagram illustrating a megaco protocol execution parameter conversion function database shown in FIG. 3 ;
[0025] FIG. 7 is a flow-chart illustrating an example of a megaco protocol conversion method in accordance with a second embodiment of the present invention;
[0026] FIGS. 8A to 8 B are diagrams illustrating examples of internet phone networks with applications of megaco protocol conversion apparatuses in accordance with a third embodiment of the present invention; and
[0027] FIGS. 9A to 9 B are diagrams illustrating other examples of internet phone networks with applications of megaco protocol conversion apparatuses in accordance with a forth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] An apparatus and a method for converting megaco protocol in accordance with a specific embodiment of the present invention will be described in detail with reference to the accompanying drawings, which is set forth hereinafter.
[0029] FIG. 3 is a diagram illustrating an example of a megaco protocol conversion apparatus in accordance with a specific embodiment of the present invention.
[0030] Referring to FIG. 3 , the megaco protocol conversion apparatus in accordance with the present invention includes: X k number of protocol execution units 310 where ‘k’ is a number bigger than or equal to 1 , and less than or equal to ‘n’ (1≦k≦n); a megaco protocol execution parameter conversion unit 320 ; a megaco protocol execution unit 330 ; a megaco master mode control unit 340 ; a megaco slave mode control unit 350 ; a terminal information database 360 ; an object information database 370 ; and a megaco protocol execution parameter conversion function database 380 .
[0031] The X k number of protocol execution units 310 execute internet phone protocols of H.323, SIP and MGCP that are different from a megaco protocol. That is, the X k number of protocol units 310 : receive X k number of protocol packets from adjacent objects which use the same type of protocols as the X k number of protocols such as internet phone terminals, a gate keeper, a proxy server, a media gateway controller and a media gateway; analyze the received X k number of protocol packets and execute appropriate protocol operations according to the present conditions of the X k number of protocols; and transmit corresponding protocol execution parameters, e.g., condition information and packet parameters to the megaco protocol execution parameter conversion unit 320 .
[0032] Furthermore, the X k number of protocol execution units 310 : receive the protocol execution parameters necessary for operations from the megaco protocol execution parameter conversion unit 320 to execute appropriate protocol operations; and transmit the X k number of protocol packets to adjacent objects which use the same type of protocols as the X k number of protocols such as internet phone terminals, a gate keeper, a proxy server, a media gateway controller and a media gateway.
[0033] On the other hand, the megaco protocol execution parameter conversion unit 320 interworks between the X k number of protocol execution units 310 and the megaco protocol execution unit 330 , and executes protocol conversion. At this point, for protocol conversion, the megaco protocol execution parameter conversion unit 320 identifies the mode of the objects which transmitted the protocol packets to the megaco protocol execution parameter conversion unit 320 , as either master or slave, based on the transmitted protocol packets. Then, the megaco protocol execution parameter conversion unit 320 identifies other objects which correspond to the objects connected to the megaco protocol conversion apparatus in accordance with the specific embodiment of the present invention. At this time, the megaco protocol execution parameter conversion unit 320 utilizes: the terminal information database 360 ; the object information database 370 ; and the megaco protocol execution parameter conversion function database 380 .
[0034] FIG. 4 is a diagram illustrating the object information database 370 shown in FIG. 3 .
[0035] Referring to FIG. 4 , the object information database 370 includes: an object information database entry 410 ; an object connection identifier 420 to distinguish connection relations between master mode objects such as a media gateway controller, a gate keeper and a proxy server and slave mode objects such as internet phone terminals and a media gateway; an object IP address 430 ; an object condition mode 440 to distinguish the mode of an object as master or slave; and an object protocol type 450 to distinguish protocol type of the object.
[0036] FIG. 5 is a diagram illustrating a terminal information database shown in FIG. 3 .
[0037] Referring to FIG. 5 , the terminal information database 360 includes: a terminal information database entry 510 ; a terminal phone number or termination identifier 520 to identify a subscriber's information of a terminal; an object connection identifier 530 to distinguish connection relations between master mode objects such as a media gateway controller, a gate keeper and a proxy server and slave mode objects such as internet phone terminals and a media gateway; a terminal IP address 540 ; and a terminal protocol type 550 to distinguish protocol type of the terminal.
[0038] FIG. 6 is a diagram illustrating a megaco protocol execution parameter conversion function database shown in FIG. 3 .
[0039] Referring to FIG. 6 , conversion functions are stored in the megaco protocol execution parameter conversion function database 380 . The conversion functions are for converting megaco protocol execution parameters to internet phone protocol execution parameters other than the megaco protocol, or converting internet phone protocol execution parameters other than the megaco protocol to megaco protocol execution parameters in reverse. The megaco protocol execution parameter conversion function database 380 also includes: a megaco protocol execution parameter conversion function database entry 610 ; an input protocol type 620 ; an output protocol type 630 ; and a megaco protocol execution parameter conversion function 640 .
[0040] Referring to FIGS. 4 to 6 , the megaco protocol execution parameter conversion unit 320 is described in detail as follows.
[0041] The megaco protocol execution parameter conversion unit 320 receives protocol execution parameters from either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 , and identifies the object information database entry 410 from the object information database 370 by utilizing the object IP address as an index. Also, the megaco protocol execution parameter conversion unit 320 verifies condition mode of an object which transmitted protocol packets, as master or slave from the object information database entry 410 .
[0042] If the object condition mode is master, it is concluded that object condition mode is slave for an object which counters the object which transmitted the protocol packets, that is, a destination object whereto the protocol packets must be transmitted. In other words, an internet phone terminal is the destination object whereto the protocol packets are to be transmitted. Then, the megaco protocol execution parameter conversion unit 320 searches for the terminal information database entry 510 and verifies the protocol type from the terminal information database 360 by utilizing the terminal phone number or termination identifier 520 and the object connection identifier 420 from the protocol execution parameters which were received from either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 .
[0043] Also, the megaco protocol execution parameter conversion unit 320 converts the protocol parameters to protocols of the slave mode object by utilizing the terminal protocol type 550 and the terminal IP address 540 from the searched terminal information database entry 510 and the received protocol execution parameters from either the X k number of protocol execution unit 310 or the megaco protocol execution unit 330 . That is, the megaco protocol execution parameter conversion function database entry 610 is searched from the megaco protocol execution parameter conversion function database 380 by utilizing the protocol execution parameters received from either the X k number of protocol units 310 or the megaco protocol execution unit 330 as an input index, and utilizing the protocol type searched from the terminal information database entry 510 as an output index. Then, the protocol execution parameters received from either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 which correspond to the input index, are converted to protocol execution parameters of the protocol searched from the terminal information database entry 510 which correspond to the output index. Herein, the searched megaco protocol execution parameter conversion functions are used.
[0044] Meanwhile, if the megaco protocol execution parameter conversion unit 320 verifies the condition mode of the object as slave which transmitted the protocol packets from the object information database entry 410 , it is concluded that object condition mode is master for an object which counters the object which transmitted the protocol packets, that is, a destination object whereto the protocol packets must be transmitted. In other words, the master mode objects include a media gateway controller, a proxy server and a gate keeper. Hence, the megaco protocol execution parameter conversion unit 320 searches for an object information database entry in master mode from the object information database 370 , by utilizing the object connection identifier 420 of the object information database entry 410 as an index.
[0045] Furthermore, the megaco protocol execution parameter conversion unit 320 verifies the protocol type of the master mode object from the searched object information database entry in master mode. Also, the megaco protocol execution parameter conversion unit 320 searches for the megaco protocol execution parameter conversion function database entry 610 from the megaco protocol execution parameter conversion function database 380 , by utilizing the protocol type of the protocol execution parameters received from either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 as an input index, and utilizing the protocol type of the above-mentioned master mode object as an output index. Moreover, the megaco protocol execution parameter conversion unit 320 converts the protocol execution parameters corresponding to the input index which were received from either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 , to the protocol execution parameters of the above-searched master mode object protocol corresponding to the output index by utilizing the searched megaco protocol execution parameter conversion functions.
[0046] The megaco protocol execution unit 330 executes megaco internet phone protocols. That is, the megaco protocol execution unit 330 : receives the megaco protocol packet from an adjacent object that uses the megaco protocol, such as an internet phone terminal, a media gateway controller, an a media gateway; analyzes the received megaco protocol packet; executes appropriate operations according to the present condition of the protocol; and transmits the protocol execution parameters such as the condition information and the packet parameters to the megaco protocol execution parameter conversion unit 320 .
[0047] Also, the megaco protocol execution unit 330 receives the necessary protocol execution parameters for the protocol execution module to operate from the megaco protocol execution parameter conversion unit 320 . Then, the megaco protocol execution unit 330 executes appropriate protocol operations and transmits the megaco protocol packet to an adjacent object that use the megaco protocol such as an internet phone terminal, a media gateway controller and a media gateway.
[0048] The megaco master mode control unit 340 controls the megaco protocol execution unit 330 to operate in master mode. The megaco master mode control unit 340 operates in a case where an internet phone terminal utilizes the megaco protocol. The megaco master mode control unit 340 administers connection information such as master-slave connection start information, master-slave connection end information and master-slave change information between the megaco master mode control unit 340 and the internet phone terminal.
[0049] The megaco slave mode control unit 350 controls the megaco protocol execution unit 330 to operate in slave mode. The megaco slave mode control unit 350 operates in a case where a media gateway controller utilizes the megaco protocol. The megaco slave mode control unit 350 administers connection information such as master-slave connection start information, master-slave connection end information and master-slave change information between the megaco slave mode control unit 350 and the media gateway controller.
[0050] FIG. 7 is a flow-chart illustrating a megaco protocol conversion method in accordance with an embodiment of the present invention.
[0051] Referring to FIG. 7 , at step 710 , a protocol packet is received firstly through the X k number of protocol execution units 310 or the megaco protocol execution unit 330 .
[0052] Subsequently, at step 720 , the received packet is analyzed and protocol execution parameters are generated. Then, at step 730 , an object information database entry is searched from the object information database 370 by utilizing an object IP address information from the generated protocol execution parameters at step 720 as an index.
[0053] Afterwards, the object condition mode searched in object information database entry at step 730 is verified as master or slave at step 740 .
[0054] If the object condition mode is master, a terminal information database entry is searched at step 750 from the terminal information database 360 by utilizing a terminal phone number or termination identifier of the above-generated protocol execution parameters at the step 720 and an object connection identifier of the above-searched object information database entry at step 730 as indexes.
[0055] After that, protocol type of the terminal information database entry searched at step 750 is verified at step 770 .
[0056] Next, a megaco protocol execution parameter conversion function database entry is searched at step 780 from the megaco protocol execution parameter conversion function database 380 utilizing the protocol type of the above-generated protocol execution parameters as an input index, and the protocol type of the above-verified terminal information database entry as an output index.
[0057] Subsequently, protocol execution parameters of the protocol which correspond to the input index are converted to protocol execution parameters of the protocol which correspond to the output index at step 790 , utilizing megaco protocol execution parameter conversion functions of the megaco protocol execution parameter conversion function database entry.
[0058] Afterwards, a protocol is executed with the above-converted protocol execution parameters through either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 at step 800 , and then the protocol packet is transmitted to an adjacent object at step 810 .
[0059] Meanwhile, if the object condition mode is slave in the reference numeral 740 stage, an object information database entry of a master mode object is searched at step 760 from the object information database by utilizing an object connection identifier of the object information database entry which was searched at step 730 as an index. The object identified as slave corresponds to an internet phone terminal. This above process is to find information of a media gateway controller, a gate keeper and a proxy server.
[0060] Next, protocol type of the object information database entry is verified at step 770 . Then, a megaco protocol execution parameter conversion function database entry is searched at step 780 from the megaco protocol execution parameter conversion function database 380 , utilizing the protocol type of the above-generated protocol execution parameters as an input index, and the protocol type of the above-searched object information database entry as an output index.
[0061] Afterwards, the protocol execution parameters of the protocol which correspond to the input index are converted to the protocol execution parameters of the protocol which correspond to the output index by utilizing the megaco protocol execution parameter conversion functions at step 790 .
[0062] After that, a protocol is executed with the above-converted protocol execution parameters through either the X k number of protocol execution units 310 or the megaco protocol execution unit 330 at step 800 , and then the protocol packet is transmitted to an adjacent object at step 810 .
[0063] FIGS. 8A to 8 B are diagrams illustrating examples of internet phone networks with applications of megaco protocol conversion apparatuses in accordance with the present invention.
[0064] FIG. 8A is a diagram illustrating an example of a conventional H.323 internet phone network whereon a megaco protocol conversion apparatus is applied to connect megaco internet phone terminals in accordance with the specific embodiment of the present invention. FIG. 8B is a diagram illustrating another example of a conventional SIP internet phone network whereon a megaco protocol conversion apparatus is applied to connect megaco internet phone terminals in accordance with the specific embodiment of the present invention.
[0065] FIG. 9A to 9 B are diagrams illustrating other examples of internet phone networks with applications of megaco protocol conversion apparatuses in accordance with the specific embodiment of the present invention.
[0066] FIG. 9A is a diagram illustrating an example of a megaco internet phone network whereon a megaco protocol conversion apparatus is applied to connect existing SIP internet phone terminals in accordance with the specific embodiment of the present invention. FIG. 9B is a diagram illustrating another example of a megaco internet phone network whereon a megaco protocol conversion apparatus is applied to connect existing MGCP internet phone terminals in accordance with the specific embodiment of the present invention.
[0067] The above described embodiment of the present invention may be embodied in program and can be stored in recordable media such as CD-ROMs, RAMs, ROMs, floppy disks, hard disks and magnetic optical disks. Since the process can be easily practiced by those skilled in the art, it will not be described further herein.
[0068] In a case where it is desired to use an SIP, an H.323 or an MGCP protocol internet phone network as a megaco protocol applied network, the above described embodiment of the present invention reduces subscribers' terminal equipment replacement cost and testing cost needed for equipment replacement because there is no need to change subscribers' SIP, H.323 or MGCP protocol internet phone terminals to megaco protocol internet phone terminals.
[0069] Furthermore, the above described embodiment of the present invention reduces purchasing cost of high-capacity megaco protocol media gateway controller equipment and testing cost needed for equipment installation, to supply internet phone services to subscribers with megaco protocol internet phone terminals only.
[0070] Also, the above described embodiment of the present invention is designed in a modularized structure with expandability, and reduces time and cost for transplanting a new internet phone protocol into a megaco protocol conversion apparatus.
[0071] The present application contains subject matter related to the Korean patent application No. KR 2004-0095291, filed in the Korean Patent Office on Nov. 19, 2004, the entire contents of which being incorporated herein by reference.
[0072] While the present invention has been described with respect to certain specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.
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An apparatus and a method for megaco protocol conversion is provided. The apparatus includes: a plurality of first protocol execution means for receiving a plurality of different protocol packets, executing operations according to the received protocols, analyzing the received protocols, and generating protocol execution parameters; a megaco protocol execution means for receiving a megaco protocol packet, executing operations according to the received protocol, analyzing the received protocol, and generating protocol execution parameters; databases for storing connection information between the objects and protocol conversion functions; and a protocol conversion means for interworking between the first protocol execution means and the megaco protocol execution means, searching for destination objects and the protocol conversion functions in the database, and converting the generated protocol execution parameters to protocol types of the destination objects, based on condition modes of objects which transmitted the protocol packets.
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TECHNICAL FIELD
[0001] The present invention relates in general to memory circuits, and more particularly, to dynamic random access memory cells and a method for forming the same.
BACKGROUND OF THE INVENTION
[0002] Random access memory (“RAM”) cell densities have increased dramatically with each generation of new designs and have served as one of the principal technology drivers for ultra large scale integration (“ULSI”) in integrated circuit (“IC”) manufacturing. However, in order to accommodate continuing consumer demand for integrated circuits that perform the same or additional functions and yet have a reduced size as compared with available circuits, circuit designers continually search for ways to reduce the size of the memory arrays within these circuits without sacrificing array performance.
[0003] With respect to memory ICs, the area required for each memory cell in a memory array partially determines the capacity of a memory IC. This area is a function of the number of elements in each memory cell and the size of each of the elements. For example, FIG. 1 illustrates an array 100 of memory cells 110 for a conventional dynamic random access memory (DRAM) device. Memory cells 110 such as these are typically formed in adjacent pairs, where each pair is formed in a common active region 120 and share a common source/drain region that is connected to a respective digit line via a digit line contact 124 . The area of the memory cells 110 are said to be 8F 2 , where F represents a minimum feature size for photolithographically-defined features. For conventional 8F 2 memory cells, the dimension of the cell area is 2F×4F. The dimensions of a conventional 8F 2 memory cell are measured along a first axis from the center of a shared digit line contact 124 (½F), across a word line 128 that represents an access transistor (1F), a storage capacitor 132 (1F), an adjacent word line 136 (1F), and half of an isolation region 140 (½F) separating the active region 120 of an adjacent pair of memory cells (i e., resulting in a total of 4F). The dimensions along a second perpendicular axis are half of an isolation region 150 on one side of the active region 120 (½F), the digit line contact 124 (1F), and half of another isolation region 154 on the other side of the active region 120 (½F) (i.e., resulting in a total of 2F).
[0004] In some state-of-the-art memory devices, the memory cells for megabit DRAM have cell areas approaching 6F 2 . Although this is approximately a 25% improvement in memory cell area relative to conventional 8F 2 memory cells, as previously described, a further reduction in memory cell size is still desirable. Therefore, there is a need for a compact memory cell structure and method for forming the same.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a semiconductor memory cell structure. The memory cell is formed on a surface of a substrate and includes an active region formed in the substrate, an epitaxial post formed on the surface of the substrate over the active region. The epitaxial post has at least one surface extending outwardly from the surface of the substrate and another surface opposite of the surface of the substrate. A vertical transistor is formed in the epitaxial post having a gate structure that is formed adjacent to at least a portion of all the outwardly extending surfaces of the epitaxial post. The memory cell further includes a memory cell capacitor formed on an exposed surface of the epitaxial post.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a simplified top plan view of conventional memory cells.
[0007] [0007]FIG. 2A is a simplified top plan view of memory cells according to an embodiment of the present invention, and FIG. 2B is a simplified cross-sectional view of a pair of memory cells according to the embodiment shown in FIG. 2A.
[0008] [0008]FIG. 3 is a simplified cross-sectional view of a semiconductor substrate that can be processed to form the memory cell of FIG. 2, in accordance with an embodiment of the present invention.
[0009] [0009]FIG. 4 is a simplified cross-sectional view of the substrate of FIG. 3 at a later point in processing, in accordance with an embodiment of the present invention.
[0010] [0010]FIG. 5 is a simplified cross-sectional view of the substrate of FIG. 4 at a later point in processing, in accordance with an embodiment of the present invention.
[0011] [0011]FIG. 6 is a simplified cross-sectional view of the substrate of FIG. 5 at a later point in processing, in accordance with an embodiment of the present invention.
[0012] [0012]FIG. 7 is a simplified cross-sectional view of the substrate of FIG. 6 at a later point in processing, in accordance with an embodiment of the present invention.
[0013] [0013]FIG. 8 is a simplified cross-sectional view of the substrate of FIG. 7 at a later point in processing, in accordance with an embodiment of the present invention.
[0014] [0014]FIG. 9 is a simplified cross-sectional view of the structure of FIG. 2B at a later point in processing, in accordance with an embodiment of the present invention.
[0015] [0015]FIG. 10 is a simplified cross-sectional view of a pair of memory cell according to an alternative embodiment.
[0016] [0016]FIG. 11 is a functional block diagram of a memory circuit that includes memory cells according to an embodiment of the present invention.
[0017] [0017]FIG. 12 is a functional block diagram of a computer system including a memory device according to the embodiment shown in FIG. 11.
[0018] As is conventional in the field of integrated circuit representation, the lateral sizes and thicknesses of the various layers are not drawn to scale, and portions of the various layers may have been arbitrarily enlarged or reduced to improve drawing legibility.
DETAILED DESCRIPTION OF THE INVENTION
[0019] [0019]FIG. 2A is a top plan view of an array of memory cells 200 according to an embodiment of the present invention. As shown in FIG. 2A, capacitors have not been illustrated in order to avoid unnecessarily obscuring the other structures of the memory cell 200 . The dimensions of the cell 200 are 4F 2 . That is, the cell 200 measures 2F along a first axis, starting with half of a digit line contact (½F), and extending over an epitaxial post on which a capacitor is formed (1F) and half of an isolation region (½F). Along a second perpendicular axis, the cell 200 measures 2F, starting with half of an isolation region (½F), and extending over the digit line contact (1F), and half of another isolation region (½F). FIG. 2B is a simplified cross-sectional view of the memory cell 200 (FIG. 2A) along A-A at a stage of processing. A more detailed description of the memory cell 200 will be provided with respect to FIGS. 3 through 10, which illustrate the memory cell 200 at various stages of processing.
[0020] [0020]FIG. 3 is a simplified cross-sectional view of the memory cell 200 (FIG. 2) at a stage of processing. Formed in a p-type substrate 204 is an n-type active region 206 in which a pair of memory cells 200 are formed. The active region 206 is isolated from adjacent active regions by isolation regions 202 . The active region 206 and the isolation regions 202 can be formed using conventional methods, for example, conventional masking, deposition, implant and drive-in processes. Following the formation of the isolation regions 202 and the active region 206 , a layer of insulating material is deposited onto the substrate 204 , masked and etched to form sacrificial structures 208 a - c on the substrate 204 . The insulating material from which the sacrificial structures 208 a - c are formed is silicon nitride, or alternatively, as will be explained in more detail below, other insulating material to which subsequent etch processes are selective.
[0021] [0021]FIG. 4 is a simplified cross-sectional view of the structure shown in FIG. 3 at a later point in processing, in accordance with an embodiment of the present invention. An insulating material is deposited over the substrate 204 and the sacrificial structures 208 a - c and subsequently etched back using an anisotropic etch process. Suitable etch processes are known in the art. Sidewalls 210 a - c , 212 a - c are formed as a result of the deposition and etch back processes. The insulating layer can be formed from a silicon-oxide material, and the etch back process should be selective to the silicon nitride of the sacrificial structures 208 a - c . A p-type epitaxial layer is formed on the exposed regions of the substrate 204 , and etched to selectively form epitaxial “posts” 220 , 222 within the trench region between the sacrificial nitride structures 208 a , 208 b , and 208 b , 208 c , respectively. As will be described in more detail below, the epitaxial posts 220 , 222 represent the material in which vertical access transistors (i.e., word lines) will be formed and to which memory cell capacitors are electrically coupled.
[0022] [0022]FIG. 5 is a simplified cross-sectional view of the structure shown in FIG. 4 at a later point in processing, in accordance with an embodiment of the present invention. An etch process selective to the nitride sacrificial structures 208 a - c and the epitaxial posts 220 , 222 is performed to remove the oxide sidewalls 210 a - c , 212 a - c . Gate oxide 230 is then formed over the epitaxial posts 220 , 222 and the exposed regions of the substrate 204 . The material of the sacrificial structures 208 a - c is such that oxide does not form thereon during the formation of the gate oxide 230 .
[0023] [0023]FIG. 6 is a simplified cross-sectional view of the structure shown in FIG. 5 at a later point in processing, in accordance with an embodiment of the present invention. A polysilicon layer is formed over the structure of FIG. 5 followed by a masking and etch process to selectively remove portions of the polysilicon layer. An anisotropic etch back process is then performed to remove additional portions of polysilicon layer in order to form gates 240 , 242 of vertical transistors 250 , 252 , respectively. The etch back process recesses the gates 240 , 242 to below the height of the epitaxial posts 220 , 222 , respectively. Although shown in cross-section in FIG. 6, the gates 240 , 242 surround the respective posts 220 , 222 . This is apparent from FIG. 2A, which illustrates that the gate 242 is part of a continuous polysilicon wordline that is formed around each of the epitaxial posts associated with the memory cells of that row.
[0024] [0024]FIG. 7 is a simplified cross-sectional view of the structure shown in FIG. 6 at a later point in processing, in accordance with an embodiment of the present invention. An insulating layer is formed over the structure shown in FIG. 6 and subsequently etched back to form a relatively planar surface. Although a conventional chemical-mechanical polishing process can be used for the etch back step, it will be appreciated that other suitable etch back processes may be used as well. The etch back process results in the formation of insulating spacers 256 to isolate the gates 240 , 242 of the vertical transistors 250 , 252 . The insulating layer 258 , and consequently, the insulating spacers 256 , can be formed from a silicon oxide material, or other material, that is selective to a silicon nitride etch process.
[0025] [0025]FIG. 8 is a simplified cross-sectional view of the structure shown in FIG. 7 at a later point in processing, in accordance with an embodiment of the present invention. An etch process is used to remove the silicon nitride sacrificial structures 208 a - c to leave the epitaxial posts 220 , 222 , the vertical transistors 250 , 252 , and the insulating spacers 256 . An insulating material is then deposited over the remaining structure and anisotropically etched back to form sidewalls 260 that isolate the gates 240 , 242 of the vertical transistors 250 , 252 , respectively. As shown in FIG. 2B, a dielectric interlayer 264 is subsequently deposited over the existing structure and etched back to form a planar surface on which digit lines and storage capacitors can be formed. Still with reference to FIG. 2B, a via 270 is formed through the dielectric interlayer 246 to expose a portion the active region 206 . A conductive material 272 is subsequently deposited over the structure and in the via 270 to electrically contact the active region 206 . The conductive material 272 is masked and etched to form a digit line contact.
[0026] [0026]FIG. 9 is a simplified cross-sectional view of the structure shown in FIG. 2B at a later point in processing, in accordance with an embodiment of the present invention. A second dielectric interlayer 274 is deposited over the structure, and using conventional methods, container shaped memory cell capacitors 280 are formed in the second dielectric interlayer 274 and have a first capacitor plate 282 electrically coupled to a respective epitaxial post 220 , 222 . The first capacitor plate 282 can be formed from a highly doped polysilicon material, however, it will be appreciated that other suitable materials may be used as well. Following the formation of the first capacitor plates 282 of the memory cell capacitors 280 , dopants from the highly doped polysilicon layer are diffused into the respective epitaxial post 220 , 222 by heating the substrate 204 . As a result, lightly doped conductive regions 284 are created in the epitaxial posts 220 , 222 in a region adjacent the insulating spacers 256 . The lightly doped conductive regions 284 provide a conductive path between a memory cell capacitor 280 and the respective gate 240 , 242 of the vertical transistors 250 , 252 . Thus, when a vertical transistor is activated, the memory cell capacitor 280 can be electrically coupled to the active region 206 .
[0027] Although embodiments of the present invention have been described as including container shaped memory cell capacitors 280 , it will be appreciated that alternative capacitor structures can also be used as well without departing from the scope of the present invention. For example, conventional stacked capacitor structures electrically coupled to the epitaxial posts 220 , 222 could be used in an alternative embodiment of the present invention. Alternatively, capacitors having a first capacitor plate with multiple polysilicon layers, that is, a “finned” capacitor, could also be used. Moreover, other modifications can be made to the memory cell capacitors 280 as well and still remain within the scope of the present invention. An example of such a modification includes forming memory cell capacitors 280 having a rough surface such as a hemispherical silicon grain (HSG) layer (not shown). Consequently, the present invention is not limited to the specific embodiments described herein.
[0028] [0028]FIG. 10 illustrates a pair of memory cells 1000 according to an alternative embodiment of the present invention. Whereas memory cells 200 (FIG. 9) includes a digit line contact formed from a conductive material 272 , the memory cell 1000 includes a buried digit line 1006 . Formation of the buried digit line 1006 is well known in the art and can be formed using conventional processing methods.
[0029] It will be appreciated that the description provided herein is sufficient to enable those of ordinary skill in the art to practice the invention. Selecting specific process parameters, including temperature, doping levels, thicknesses, and the like, are well within the understanding of those ordinarily skilled in the art. Particular details such as these have been omitted from herein in order to avoid unnecessarily obscuring the present invention. It will be further appreciated that additional processing steps can be performed in fabricating the memory cells 200 without departing from the scope of the present invention. For example, in forming the isolation regions 202 , an implant process can be performed to create a junction region below the isolation region 202 to minimize leakage currents between adjacent active regions. Another example of such a modification is performing an implant step prior to deposition of the conductive material 272 to create a highly doped region in the active region 206 to promote conductivity to the digit line contact.
[0030] [0030]FIG. 11 is a functional block diagram of one embodiment of a memory circuit 60 , which includes memory banks 62 a and 62 b . These memory banks each incorporate a memory array according to an embodiment of the present invention. In one embodiment, the memory circuit 60 is a synchronous DRAM (SDRAM), although it may be another type of memory in other embodiments.
[0031] The memory circuit 60 includes an address register 64 , which receives an address from an ADDRESS bus. A control logic circuit 66 receives a clock (CLK) signal receives clock enable (CKE), chip select (CS), row address strobe (RAS), column address strobe (CAS), and write enable (WE) signals from the COMMAND bus, and communicates with the other circuits of the memory device 60 . A row-address multiplexer 68 receives the address signal from the address register 64 and provides the row address to the row-address latch-and-decode circuits 70 a and 70 b for the memory bank 62 a or the memory bank 62 b , respectively. During read and write cycles, the row-address latch-and-decode circuits 70 a and 70 b activate the word lines of the addressed rows of memory cells in the memory banks 62 a and 62 b , respectively. Read/write circuits 72 a and 72 b read data from the addressed memory cells in the memory banks 62 a and 62 b , respectively, during a read cycle, and write data to the addressed memory cells during a write cycle. A column-address latch-and-decode circuit 74 receives the address from the address register 64 and provides the column address of the selected memory cells to the read/write circuits 72 a and 72 b . For clarity, the address register 64 , the row-address multiplexer 68 , the row-address latch-and-decode circuits 70 a and 70 b , and the column-address latch-and-decode circuit 74 can be collectively referred to as an address decoder.
[0032] A data input/output (I/O) circuit 76 includes a plurality of input buffers 78 . During a write cycle, the buffers 78 receive and store data from the DATA bus, and the read/write circuits 72 a and 72 b provide the stored data to the memory banks 62 a and 62 b , respectively. The data I/O circuit 76 also includes a plurality of output drivers 80 . During a read cycle, the read/write circuits 72 a and 72 b provide data from the memory banks 62 a and 62 b , respectively, to the drivers 80 , which in turn provide this data to the DATA bus.
[0033] A refresh counter 82 stores the address of the row of memory cells to be refreshed either during a conventional auto-refresh mode or self-refresh mode. After the row is refreshed, a refresh controller 84 updates the address in the refresh counter 82 , typically by either incrementing or decrementing, the contents of the refresh counter 82 by one. Although shown separately, the refresh controller 84 may be part of the control logic 66 in other embodiments of the memory device 60 . The memory device 60 may also include an optional charge pump 86 , which steps up the power-supply voltage V DD to a voltage V DDP . In one embodiment, the pump 86 generates V DDP approximately 1-1.5 V higher than V DD . The memory circuit 60 may also use V DDP to conventionally overdrive selected internal transistors.
[0034] [0034]FIG. 12 is a block diagram of an electronic system 1212 , such as a computer system, that incorporates the memory circuit 60 of FIG. 11. The system 1212 also includes computer circuitry 1214 for performing computer functions, such as executing software to perform desired calculations and tasks. The circuitry 1214 typically includes a processor 1216 and the memory circuit 60 , which is coupled. to the processor 1216 . One or more input devices 1218 , such as a keyboard or a mouse, are coupled to the computer circuitry 1214 and allow an operator (not shown) to manually input data thereto. One or more output devices 1220 are coupled to the computer circuitry 1214 to provide to the operator data generated by the computer circuitry 1214 . Examples of such output devices 1220 include a printer and a video display unit. One or more data-storage devices 1222 are coupled to the computer circuitry 1214 to store data on or retrieve data from external storage media (not shown). Examples of the storage devices 1222 and the corresponding storage media include drives that accept hard and floppy disks, tape cassettes, and compact disk read-only memories (CD-ROMs). Typically, the computer circuitry 1214 includes address data and command buses and a clock line that are respectively coupled to the ADDRESS, DATA, and COMMAND buses, and the CLK line of the memory device 60 .
[0035] 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. For example, the memory cell 200 has been illustrated as having epitaxial posts with a rectangular or quadrilateral cross-sectional area. However, the epitaxial posts can be formed having a generally circular cross-sectional area or a generally polygonal cross-sectional area as well. Accordingly, the invention is not limited except as by the appended claims.
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A semiconductor memory cell structure and method for forming the same. The memory cell is formed on a surface of a substrate and includes an active region formed in the substrate, an epitaxial post formed on the surface of the substrate over the active region. The epitaxial post has at least one surface extending outwardly from the surface of the substrate and another surface opposite of the surface of the substrate. A gate structure is formed adjacent to at least a portion of all the outwardly extending surfaces of the epitaxial post, and a capacitor formed on an exposed surface of the epitaxial post.
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The invention is a result of a contract with the Department of Energy (Contract No. W-7405-ENG-36).
BACKGROUND OF THE INVENTION
This invention relates generally to a method for producing hydrocarbons from hydrocarbon-containing hydrates and relates more particularly to an economical method for such production.
Methane and other hydrocarbons are known to react with liquid water (or brine) or ice to form solid hydrocarbon hydrates. These compounds are believed to exist in very large quantities in Arctic regions in gas-bearing sediments which lie between about 1000 and a few thousand feet below the earth surface. Therefore, these hydrates represent an enormous potential resource of hydrocarbons.
The Russians in particular have been keenly interested in recovering hydrocarbons from these vast reserves. As outlined by W. J. Cieslewicz, in "Some Technical Problems and Developments in Soviet Petroleum and Gas Production," The Mines Magazine, November, 1971, on page 15, several different methods of converting hydrate gas back into the gaseous state directly in the formation which were under study by the date of that paper included (1) artificially reducing the formation pressure, (2) increasing the formation temperature, and (3) pumping of catalysts into the formation. Regarding the first of these methods, that method (according to the paper) can be used only in deposits with high permeability; and a very large pressure reduction is necessary, particularly in gas deposits containing heavier hydrocarbon components. Regarding the second of these methods, according to that paper, the method can be accomplished by pumping water, steam, or hot gases into the deposit. And, regarding the third of these methods, of the many chemical substances tried by the date of that paper, methanol produced the best results in bringing about the release of free gas from the hydrate.
By the early 1970's, as disclosed in a series of five Russian papers, the Russians suggested injecting pressurized materials into a gas-producing well located below an in situ hydrate zone in the Messoyakha field in order to prevent the formation of or to free the area around the well-bore from hydrates which form and plug the well. The Messoyakha field is unique in that it is the only known field that has located within the same reservoir a (lower) free gas zone and an (upper) hydrate zone. They proposed injecting hydrate inhibitors (e.g., methanol or ethylene glycol or calcium chloride solutions or mixtures thereof) into the reservoir by means of hydraulic fracturing. In N. V. Cherskii et al., "Methods of Locating, Opening Up, and Exploiting Productive Horizons Containing Crystal Hydrates of Natural Gas (On the Example of the Messoyakhskoe Field)," Institute of Physical and Engineering Problems of the North, Academy of Sciences of the USSR, Siberian Division, Yakut Branch, Publishing House "Nauka," Novosibirsk, 1972, pp. 112-119, (on page 6 of the translation by Associated Technical Services, Inc.) the following was stated: "The most effective method of preventing hydrate formation in the bottom-hole zone and destroying previously formed hydrates is to inject inhibitor (preferably methanol) into the reservoir by means of hydraulic fracturing. Forced injection of methanol into the bottom-hold zone of the productive formation of two wells of the Messoyakhskoe field gave a six-fold increase in production." The largest documented single treatment volume recited in any of the five articles was the injection of 1374 gallons (in a series of treatments with a cumulative volume of 5284 gallons in 100 days) of 25% by weight CaCl 2 solution into the free-gas zone of the Messoyakha field, as was described in S. A. Arshinov et al., "Hydrate-Free Production of Wells in Messoyakhsii Gas Field," Gazovoe Delo, No. 12, 1971, pp. 3-5 (at page 2 of the English translation by H. Altmann, June 1972). Such small volume treatments would be designed to dissolve hydrates occuring immediately adjacent to the well-bore and thus to perform near well-bore cleanup.
However, in a report issued by the Gas Research Institute covering a Gas Hydrate Workshop held in Denver, Colorado on February 1, 1979, at page 41 the statement was made that workers in some quarters felt that pressure reduction or the injection of alcohol or glycol probably would not prove viable for the recovery of natural gas from in situ hydrates for both technical and economic reasons; on the other hand, a more likely means was considered to be the injection of heat. Water (or brine) according to that report may be injected into the formation; and the hotter the water, the less will be required. Therefore, geothermal sources were a distinct possiblity.
The same article continued on page 43 that underground or in situ recovery of gas from hydrates should be environmentally acceptable, whereas mining--even if feasible--would be less so. For every molecule of methane in the hydrate form, 6, 7, or more molecules of water may occur; and this would present problems of dilution for solvent additives, as well as possible contamination of the waters remaining.
The article (on page 43) also considered the need for fracturing or rubblizing the hydrate-bearing formation, as an adjunct of production. The article pointed out that hydrate formations have little or no natural permeability and that techniques are needed to create flow channels in order to increase contact with the recovery agent. However, fracture by explosive or hydraulic methods was stated to be not regarded as a promising method of creating permeability. For explosive methods, (according to the article) the heat of explosion would liberate water which would be expected to refreeze unless temperatures could be sustained by the introduction of circulating water or gases. Hydraulic methods might be more satisfactory, according to the article, with the fracture sustained by sand particles. Thus, holding a crack open was still a goal.
And, as recently as June 16, 1981, in an article entitled, "Gas Imprisoned in Permafrost," Vol. 9, no. 115, in The Energy Daily, at page 4, the following conclusion regarding the effective stimulation of hydrate reservoirs was stated, "So far, no economic method has been devised for freeing the gas from its permafrost prison." Therefore, despite what has been known in the prior art, a need still exists for an economical method of producing hydrocarbons from hydrocarbon-containing hydrates.
SUMMARY OF THE INVENTION
An object of this invention is an economical method for producing hydrocarbons from hydrocarbon-containing hydrates.
Another object of this invention is a method of producing methane (or natural gas) at a fast rate, over an extended period of time, and in an economical and safe manner.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention, as embodied and broadly described herein, the method of this invention comprises: producing hydrocarbons from a hydrate formation after a spearhead (described below) has been injected into the formation by (a) mixing a hot, "supersaturated" brine comprising: (1) water, (2) at least one salt selected from the group consisting of calcium chloride (CaC1 2 ), calcium bromide (CaBr 2 ), and mixtures thereof, and (3) at least one polymer viscosifier which is compatible with the salt(s) described above and which has a shear thinning rheology; and then (b) injecting a volume of at least about 10,000 gallons of that mixture at pressures of about 1 psi per foot of depth (below the earth surface) into a well-bore located within the hydrate formation, so as to produce a controlled, massive hydrofracture in the formation extending at least about 100 feet from the well-bore. The hot "supersaturated" brine will melt the hydrates and will release high-pressure gas, which in turn will help to extend the fracture even farther into the formation. Note that in this document the term "supersaturated" brine refers to a saturated or nearly saturated brine at elevated temperature which will become supersaturated as the hot brine starts to cool. A significant amount of excess salt will precipitate from the bring during cooling. Because as much salt as is practicable will be used, the high salt concentrations in the produced flow path (which will effectively be salt packs) will continue to melt hydrates for an extended period of time, even if the salts are diluted considerably, due to the properties of the particular chosen salt(s).
In a preferred embodiment, although the spearhead can be any of a variety of fluids the spearhead is preferably a hot brine of water and CaC1 2 and/or CaBr 2 having no undissolved salt and thus having a lower salt concentration than the mixture recited above. In the spearhead, there need be no viscosifier because no solids will be present.
Although salts have long been used to lower the melting point of ice, although they have been used to melt hydrates which have formed in pipelines, and although they have at least been proposed for use (together with methanol or ethylene glycol) to fracture in the area of a well-bore in order to maintain the gas production of a well which was located below (not in) a naturally occurring hydrate zone, it is believed that a hot brine has never previously been injected into a naturally occurring hydrate formation for the purpose of fracturing the formation and melting the hydrates in order to produce hydrocarbons. Additionally, although it has been suggested in several publications to inject hot, naturally occurring geothermal brines into hydrate deposits, these brines would not have the composition of the brines required in the present invention and these brines would be injected primarily for the benefit of their thermal energy, not their salt content. This injection would be a long-term process, not a one-time fracture stimulation (as usually used in the present invention).
It is believed that the particular brine fluids recited above have not previously been used for fracturing hydrates. In conventional hydraulic fracturing, large volumes of liquids under high pressures are pumped into a reservoir in order to create long fractures in the rock; and generally, a proppant material such as sand will be pumped into the fracture so that when the hydraulic pressure is released the sand will be trapped between the hard faces of the fracture and will keep the fracture open, providing a high-permeability flow path for the reservoir fluids. However, in the present invention, although not recognized (apparently) by others attempting to recover hydrocarbons from hydrates, in order to create a long high-premeability flow path it is required only that the hydrates be melted; and adding a proppant material such as sand is neither required nor desired. The fracture will have little or no permeability if hydrate or ice is allowed to reform, so the melting must continue for a relatively long time period. By the method of the invention, as the hydrates are merely melted, sand which is often present in hydrate formations will be permeable once the hydrates are melted. The produced hydrocarbon gases will easily flow through the permeable path thus produced. Although in the Gas Research Institute reference (cited above) hydraulic methods were mentioned for fracturing, the creation of a relatively permanent, high-permeability flow path merely by melting (as opposed to introducing proppant materials for sustaining a fracture) was clearly not addressed. And in the Russian literature, fracturing was mentioned in well-bore cleanup operations in free-gas zones, rather than for stimulating hydrate zones. It is believed that the method of the present invention is new and unobvious.
Although dense calcium chloride or calcium bromide brines with small amounts of polymer viscosifier have been used routinely as completion and workover fluids along the Gulf Coast and as low-invasion coring fluids for pressure coring, it is believed that the method of the invention of producing hydrocarbons by using such brines is patentably distinct from such work.
By using calcium chloride, or calcium bromide, or a mixture therof to prepare the slurry which is to be injected into the hydrate formation, several advantages arise. Both of these salts release much heat when they are dissolved in water due to the values of their heats of hydration. As the temperature of the solution increases, more of the salt can be dissolved and a very dense supersaturated solution can be obtained. Additionally, both of these materials form very low freezing point brines, as has been known in the art and as disclosed in the article by Rakowsky and Garret, "Low-Temperature Electrolytes," Journal of the Electrochemical Society, Vol. 10, No. 3, March, 1954, pp. 117-19. A brine made up of about 6.5 mole percent of calcium chloride has a freezing point of about -67° F. (about -55° C.); and a brine made up of about 7.2 mole percent of calcium bromide has a freezing temperature of about -117° F. (about -83° C.). And, furthermore, even if those recited concentrations are diluted considerably (as would occur during the melting of hydrates while hydrocarbons are produced in the formation in the method of the invention), a brine of calcium bromide having about 2 mole percent salt and a brine of calcium chloride having about 3 mole percent salt will both have a freezing temperature of about 10° F. Because the temperatures in most hydrate formations will not drop lower than about 10° F., brines having concentrations of salts of calcium bromide greater than about 2 mole percent calcium bromide or a calcium chloride brine having a mole percent greater than about 3 mole percent calcium chloride will be satisfactory for use in the invention. These figures were obtained form a graph displayed in the Rakowsky and Garrett reference cited above; and that graph is hereby incorporated herein by reference.
Yet another advantage of these two salts for use in the invention is that they are both quite economical. The cost of the salt and its transportation to the production site represent the only expected significant costs which should arise in the practice of the invention. The equipment used to mix the fluids and to pump them into the well is routinely used by the oil industry and is readily available. The invention, therefore, is expected to provide an economical method for producing hydrocarbons from naturally occurring hydrate reservoirs.
Additionally, another advantage of using the salts recited above (unlike materials such as methanol which have been tried in the prior art) is that the salts are safe to use, are not flammable, and will tend to stay in place in the reservoir and will not merely flow out of the reservoir.
Yet another advantage is that although these salts are very corrosive at high temperatures, there is no significant corrosion at temperatures below 32° F.
A further advantage is that once the fracture is initially opened, as the hydrate decomposes, its structure will change (e.g., the hydrate will form water and free gas); and the gas which has formed will help to extend the crack. Additionally, the method will be self-driven, once the slurry has been introduced into the formation; the heat of hydration will continue to provide heat for melting as more of the hydrate dissolves.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the practice of the invention, either calcium chloride or calcium bromide or a mixture thereof can be used to form the slurry which is to be injected into the hydrate formation after the spearhead is injected. The salt will be used in amounts which are as large as practicable.
Also required in the practice of the invention is at least one viscosifier which is chemically compatible with the dense brines with which it is to be mixed. The viscosifier should have desirable rheological properties, including non-Newtonian shear thinning behavior and good proppant-suspension properties. Examples of suitable viscosifiers include hydroxyethyl cellulose (i.e., HEC) and xanthum gum (i.e., XC), which are water soluble, easily pumpable, and able to suspend large quantities of salt.
The viscosifier should be used in sufficient amounts to prevent the salt from settling too quickly and possibly causing a "screen-out" (in which the proppant fills in the well-bore and plugs it up, rather than being carried out into the fracture).
The spearhead can be any of a variety of fluids, and there need be no viscosifier in the spearhead. However, it is preferred to use a hot brine of water and CaC1 2 and/or CaBr 2 , due to the properties of these salts (described above). The spearhead will be injected into the well in a volume of about 1000 gallons at an initial pressure sufficient to begin a fracture in the formation (i.e., about 1 psi per foot of depth of the formation below the earth surface). After the fracture has begun, the fluid pressure needed to continue the fracture decreases for a period of time and then increases.
The slurry or dense brine will be produced in the following way. First, water and some of the salt will be mixed together, resulting in a hot solution (having a temperature as high as about 150°-200° F.). Due to the high temperatures, large quantities of additional salt can be dissolved in the fluid. Then, polymer viscosifier will be added, along with more salt. The concentration of the final mixture will be in excess of about 10 mole percent salt and in excess of about 1 lb of viscosifier per barrel of brine; and the mixture will be needed in volumes of at least about 10,000 gallons.
If desired, other ingredient(s) can be present in the mixture in a total small amount (for example, 5-20 weight percent). Such additives can include, for example, alcohol(s) and/or glycol(s) and/or additional amounts of other salts(s). These can be present with the mixture of water, CaC1 2 and/or CaBr 2 , and viscosifier, provided that the ingredients are all chemically compatible with one another.
Then, the hot, supersaturated salt slurry will be pumped at high rates (preferably at least about 100 gallons/min.) into the hydrate zone, creating a long fracture that is packed with salt (with additional salt dropping out of solution as the mixture cools). Additionally, if desired, more salt can be added to the fracture so as to produce a salt pack which will remain for long periods of time (on the order of many days) in the fracture. Even if the salt forms a solid wedge within the fracture, the melting will still proceed and the production of hydrates will continue. This is a significant difference from conventional fracturing, where the presence of a solid wedge (such as ice or hydrate-plugged sand) would terminate the production of a well. In this invention, therefore, salt storage for prolonged prevention of freezing is intended, rather than to use the salt as a proppant. Thus, this goal of this invention is very different from the goals of the prior art addressed above.
It is believed that the method of this invention will be useful with most types of hydrate formations which will be encountered. However, because the dissociation pressures will decrease as the content of heavier hydrocarbons in a hydrate formation become higher, there could be some combination of temperature and pressure at which the method might not work well. For example, if the propane content in the hydrates were too high, the pressure might not be high enough to drive the produced propane-rich gas to the well.
Generally, the pipe and packer assembly will be removed after the slurry has been introduced into the formation; and then other equipment will be inserted for removing the produced fluids and hydrocarbon gases. Alternatively, if desired, the same pipe could be used to remove the produced gases.
It will not be necessary to move the position of the pipe during production because the high pressures of the produced hydrocarbon gases will move the gases into the pipe.
As is standard procedure in well production, the pressure around the well must be lowered in order to produce the product gases. This can be done by any suitable means.
In order to fracture the hydrate and to provide a path length of at least about 100 feet (which is believed to be required for economic production of hydrocarbons), the slurry should be pumped into the formation at an initial pressure which would at least be high enough to fracture the reservoir (i.e., about 1 psi per foot of depth below the earth surface).
The volume of slurry which should be used should be at least about 10,000 gallons. This is roughly an order of magnitude greater than the largest single treatment volume of inhibitor which was stated as having been used by the Russians in the Messoyakha field (as described in the Arshinov et al. article, cited above). This is also roughly an order of magnitude greater than the volume of methanol which was injected by Imperial Oil Limited in the Mackenzie Delta of Canada (as described in C. Bily et al., "Naturally Occurring Gas Hydrates in the Mackenzie Delta, N.W.T.," Bulletin of Canadian Petroleum Geology, vol. 22, No. 3 (September, 1974) at page 349. And in the present invention volumes up to several hundred thousand gallons will preferably be used.
Although the salt itself may not form a permeable salt pack within the fracture, it is believed that the method of production of the invention will still be operable even if a nonpermeable salt pack occurs.
The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. This description sets forth the best mode presently contemplated for the practice of the invention. It is intended that the scope of the invention be defined by the claims appended hereto.
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A method of recovering natural gas entrapped in frozen subsurface gas hydrate formations in arctic regions. A hot supersaturated solution of CaCl 2 or CaBr 2 , or a mixture thereof, is pumped under pressure down a wellbore and into a subsurface hydrate formation so as to hydrostatically fracture the formation. The CaCl 2 /CaBr 2 solution dissolves the solid hydrates and thereby releases the gas entrapped therein. Additionally, the solution contains a polymeric viscosifier, which operates to maintain in suspension finely divided crystalline CaCl 2 /CaBr 2 that precipitates from the supersaturated solution as it is cooled during injection into the formation.
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FIELD OF INVENTION
[0001] The present invention relates to offshore mooring systems. More specifically it relates to a subsea, remotely operated tension adjusting system for mooring lines where the lines comprise chain sections.
INTRODUCTION AND BACKGROUND
[0002] Definitions and Abbreviations
[0003] The abbreviations used in this document are:
[0004] DFF Design Fatigue Factor
[0005] EOL End of Life
[0006] ESD Emergency Shut Down
[0007] FPSO Floating Production Storage and Offloading
[0008] FSO Floating Storage and Offloading
[0009] FSU Floating Storage Unit
[0010] HPU High Pressure Unit
[0011] HS Hot Spot
[0012] MBL Minimum Breaking Load
[0013] MLBE Mooring Line Buoyancy Element
[0014] MSL Mean Seawater Line
[0015] MTF Mechanical Transfer Function
[0016] ROV Remotely Operated Vehicle
[0017] STL Submerged Turret Loading
[0018] STP Submerged Turret Production
[0019] SWL Safe Working Load
[0020] TBD To Be Determined
[0021] WROV Work ROV
[0022] The definitions used in this document shall be understood as follows:
[0023] Buoy: Complete STL/STP Buoy comprising:
[0024] Buoyancy Cone, Bearings, Turret, ESD valves, Buoy part of Hydraulic and Signal Connectors, Riser hang-offs and connections, Mooring connections and Pick-up Assembly.
[0025] Connecting device: Chain connecting device that is permanently/fixed located in the mooring line; also simply ‘Connector’
[0026] Operating device: Tool to operate the connecting device during tension adjusting operation; attachable to and detachable from the connecting device.
[0027] Tensioning system: System comprising connecting device and operating device; also called ‘tensioner’.
[0028] Mooring System: Complete mooring system comprising: Anchors, Chain, Wire, Polyster Rope, Mooring Line Buoyancy Elements and Connections.
[0029] Riser System: Flexible riser and umbilical system from seabed to vessel.
[0030] Riser: Flexible riser for transfer of liquids and gases.
[0031] Subsea System: Field related system comprising: Mooring, Buoy and Riser/umbilical System.
[0032] Umbilical: Flexible umbilical for power/hydraulic and signal lines.
[0033] Mooring systems in deep and ultradeep waters often require use of polyester ropes, because of weight issues and vessel offset limitations. One drawback with polyester ropes is however that it creeps over time when subject to continuous loading. It also creeps when it experiences loads higher than it has seen earlier. Part of this creep can be mitigated by stretching the rope to a high tension during the offshore installation campaign, but for practical reasons (installation vessel capabilities and safety) there is an upper limit on how much tension that can be applied. Hence, re-tensioning of polyester systems will most likely be required regularly over the design life of the field.
[0034] Buoys do often not have any re-tensioning possibility, because that feature would grow the size and the complexity of the Buoy. Re-tensioning has therefore been done as a combination of tensioning during installation (to typically 20-30% of the MBL for the polyester rope), and by opening the line, cutting chain and closing the line again, if later re-tensioning is required. The latter operation may however be expensive, as it typically requires large vessel(s) with significant winch/crane capacity, ROV, weather limitations, long planning due to limited number of vessels that can do the operation, etc.
[0035] There exists thus a need for a new tensioning system in order to simplify and reduce the cost/risk of the present tension adjusting methodology.
SUMMARY
[0036] The present invention is a mooring line tension adjusting system comprises a connecting device, connecting and locking two adjacent chain sections of a mooring line, and an operating device, moving one of the chain sections inside the connecting device to change the tension of the mooring line. The system has the inventive feature that the operating device is remotely attachable to the connecting device before a tensioning operation and detachable from the connecting device after the tensioning operation.
[0037] One of the parts comprised in the system is a connecting device, comprising a first connection arrangement for a first chain and a second connection arrangement for a second chain wherein the first connection arrangement provides a permanently fixed connection of said first chain and the second connection arrangement provides a connection which can be modified by an operating device. The connecting device comprises a first docking element—for instance a pin—enabling the operating device to firmly attach to the connecting device prior to performing a tension adjusting operation.
[0038] The second part of the system is an operating device with a second docking element being compatible with the first docking element, enabling the operating device to firmly attach to the connecting device to perform a tension adjustment operation.
[0039] A further aspect of the invention is a method for tensioning the mooring line with the tension adjusting system disclosed above. The method comprises
[0040] a. positioning a surface vessel above the mooring line, slightly to the side of a connecting device, where two sections of the mooring line are connected by the connecting device;
[0041] b. attaching one end of a first chain or similar elongated element to one of two attachment points provided on a guide at an lower end of the operating device and attaching a first weight bar to the second end of the first chain;
[0042] c. attaching a second chain or similar element, longer than the first chain to a second attachment point on the guide at the lower end of the operating device and attaching a second weight bar to the second end of the second chain;
[0043] d. attaching a lifting/handling equipment to a third attachment point at an upper end of the operating device;
[0044] e. connecting an umbilical to a power system of the operating device, and to an power supply system on board of the surface vessel;
[0045] f. overboarding the operating device with the umbilical and accessories and lower it slightly above the same depth as the connecting device mounted into the mooring line;
[0046] g. moving the vessel such that the second chain hits the connecting device, and by moving the vessel slightly passed but without the second chain jumping over the operating device should rotate such that it orients correctly relative to the connecting device;
[0047] h. lowering the operating device such that the connecting device is between the first and the second chain;
[0048] i. continuing to lower the operating device until it sits on top of the connecting device;
[0049] j. after the lower end of the operating device has docked onto the connecting device sliding it down along the connecting device until it stops against a first docking element, a second docking element on the operating device connecting around the first docking element;
[0050] k. operating the operating device via the umbilical for pushing the mooring line in a tensioning direction; repeating this step until a requested tension is achieved;
[0051] 1 . lifting the operating device off the connecting device, unhooking from the first docking element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] Below the invention will be described in detail with reference to the attached figures. Contents of the figures as follows:
[0053] FIG. 0.1 Typical mooring line composition including both rope and chain parts. The inventive tensioning system may replace OS, UCS2 and SP
[0054] FIG. 0.2 Location of the tensioning system/connector in the mooring system
[0055] FIG. 0.3 Assembly of the connecting device and the operating device of the tensioning system
[0056] FIG. 0.4 Fixed tensioner part with illustration of force direction from chain onto locking elements
[0057] FIG. 0.5 Connecting device of tensioning system
[0058] FIG. 0.6 General arrangement of the connecting device of the tensioning system
[0059] FIG. 0.7 Operating device of the tensioning system
[0060] FIG. 0.8 General arrangement of operating device of tensioning system
[0061] FIG. 0.9 Docking of operating device onto connecting device
[0062] FIG. 0.10 Illustration of fixed and operating device including tensioned chain and free end
[0063] FIG. 0.11 Illustration of docking of operating device onto connecting device
[0064] FIG. 0.12 Tensioning operation
[0065] FIG. 0.13 Slackening operation
[0066] FIG. 4.1 Mid Line Tensioning system
[0067] FIG. 4.2 Mid Line Tensioner Connecting device
[0068] FIG. 4.3 Mid Line Removable Tool
[0069] FIG. 4.4 Locking Element in Connecting device
[0070] FIG. 4.5 Pushing Element in Operating device
DETAILED DESCRIPTION
[0071] Main goal of this inventive concept is to manage regular tensioning adjustments of mooring lines—both tensioning and relaxing, in order to stay within the design envelope of the mooring system. The tensioning system shall not require a huge offshore campaign, and the operation shall be done with a relatively small vessel in combination with an ROV, without opening the mooring line. The re-tensioning operation is planned conducted with a vessel with minimum crane or A-frame capacity, but equipped with an ROV/WROV that can observe the operation as well as operate the power (normally hydraulics) of the tensioning system. Alternatively, the power can be operated via an umbilical between the tensioner and the vessel.
[0072] The inventive tensioning system comprises two main parts; confer FIG. 2.1 for a general illustration and FIGS. 4.1, 4.2, 4.3, 4.4, 4.5 for details:
Connecting device; this component becomes a permanent/fixed part in the mooring line Operating device; this is a tool, used (only temporary) for the tensioning/slacking process, also called ‘removable part’
[0075] The operating device of the tensioner can be mounted/docked on top of the connecting device through a hook or similar arrangement at the lower end. During the tensioning process the pushing element of the operating device pushes the upper chain towards the lower end of the connector. The movement of the chain unlocks the locking element of the connecting device, which remains unlocked until the chain has moved far enough for the locking element to drop down by gravity and thereby lock the chain again. The pushing element can then be retreated such that it can take a new grip and repeat the sequence until the mooring line has been shortened to the desired length. Each cycle will typically move two chain links.
[0076] A corresponding operation can also be used to lengthen the mooring line thus reducing the tension, but this requires that the locking elements of the connecting device are lifted by the ROV when the pushing element has off-loaded the contact between the chain and the locking elements. Otherwise it will lock the chain from being moved backwards.
[0077] The tensioner will most likely be located above or below the Mooring Line Buoyancy Element (MLBE), as shown in FIG. 1.1 and FIG. 1.2 .
[0078] The reason for dividing the tensioner into a fixed and a removable part is to minimize the permanent weight in the mooring system and thereby minimize the required buoyancy of the MLBE and the STL/STP Buoy. It will also reduce the overall cost since the same removable part can be used for all mooring lines, and maintenance of the hydraulic parts and the mechanical components will be easier.
[0079] A fixed weight for instance a hinged rod is attached to the connecting device in order to lower the overall centre of gravity and thus ensure that the connecting device is always upright. This weight may not be required.
[0080] The locking elements for the chain can be kept in place by plates on each side as well as a one-sided bolt with threads on one side and threadless and headless on the other side. This bolt is entered through the outer tensioner wall into the locking element and locked inside the element preferably with a ZipNut; see FIG. 2.6 .
[0081] When the bolt is fully fixed it is flush with the outer tensioner wall and free to rotate inside the hole in the wall. There is clearance between the wall opening and the bolt such that the load from the chain into the locking element and further into the support structure does not stress the bolt. Main reason for using the ZipNut technology is to be able to relatively easily replace the locking element with a WROV.
[0082] Hydraulically operated cylinders f. inst can be mounted on the operating device, preferably one on each side of the tool, in order to provide the required force to push the chain. Total available force from two hydraulic cylinders could be 150 tonnes, which means that each unit would have to provide minimum 75 tonnes. The cylinder units will be connected together such that they provide the same push at the same time. Hydraulic pressure could be provided via a WROV or directly via an umbilical from the surface.
[0083] The tension adjusting system can be protected against corrosion in order to avoid any degradation of the functionality due to the marine environment. However, since the operating device typical is only used temporarily, this protection needs only be considered to be applied to the connecting device.
[0084] Operation Procedure
[0085] The following provides a possible high level description of the tensioning operation. The main steps in the tensioning operation would be:
[0086] 1) Position a surface vessel above the mooring line, slightly to the side of the connecting device.
[0087] 2) Attach a chain or similar to one of the padeyes on the V-shaped guide at the end of the operating device. Attach a weight bar to the end of the chain.
[0088] 3) Attach a longer chain or similar to the other padeye on the V-shaped guide at the end of the operating device. Attach a weight bar to the end of the chain.
[0089] 4) Attach a lifting/handling wire to the padeye at the upper end of the operating device.
[0090] 5) Connect the (typically hydraulic) umbilical to the power system of the operating device, and to power providing unit on board the surface vessel.
[0091] 6) Overboard the operating device with the umbilical and the chain accessories and weight bars and lower it to almost the same depth as the connecting device mounted on the mooring line. Pay out the umbilical accordingly. The operating device should now be positioned slightly to the side (the side depends on which side of the operating device the longer chain is connected) of the connecting device, with the lower end of the weight bar connected to the short end above the connecting device and the other bar below the fixed bar.
[0092] 7) Move the vessel such that the longer chain hits the connecting device. By moving the vessel slightly passed but without the long chain jumping over the operating device should rotate such that it orients correctly relative the connecting device.
[0093] 8) Lower the operating device such that the connecting device is between the two chain segments; confer FIG. 3.1 and FIG. 3.3 . Continue to lower it until the operating device sits on top of the connecting device. After the lower end of the operating device has docked onto the connecting device it will slide down the connecting device until it stops against the pin, which the hook shall connect to. Continue to pay out until the operating device has fully docked, and the hook is fully engaged around the pin. The hook will connect to the pin at a relative angle of 30 to 45 degrees between the fixed and operating device; 0 degrees is when they are fully latched together.
[0094] 9) With the supervision of an ROV, operate the hydraulic units via the umbilical to the surface vessel for the pushing the chain. Number of cycles of 2-link pushes depends on how much total length adjustment that is required, confer the pushing sequence shown in FIG. 3.4
[0095] 10) When the tensioning has been completed the operating device is lifted off the connecting device, and either lifted onboard the surface vessel or moved to the next mooring line.
[0096] For slackening the system the same procedure can be used, but the cylinder pistons are operated in the opposite direction, confer FIG. 3.5 . Another difference is that when the pushing segment release the stresses on the locking elements by pushing at the far end of the 2-link grip the locking elements on the connecting device must be lifted/opened by the ROV; otherwise the locking elements will prevent the chain from being moved backwards. The ROV will let the locking elements engage with the mooring chain as soon as the first link has passed underneath the element.
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A mooring line tension adjusting system comprises a connecting device, connecting and locking two adjacent chain sections of a mooring line, and an operating device, moving one of the chain sections inside the connecting device to change the tension of the mooring line. The system has the inventive feature that the operating device is remotely attachable to the connecting device before a tensioning operation and detachable from the connecting device after the tensioning operation. The invention discloses also a method how to use the tensioning system.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of mobile transactions and more specifically to a system and a method of providing a simple and secure way for facilitating mobile transactions such as payment, ticketing and access.
[0002] Several telecommunications providers and similar competitors in the computer marketplace offer “mobile payment” solutions. In 2001 with the eCommerce boom—many start-up companies and telecommunications providers attempted to provide fancy mobile payment solutions. These solutions were often ephemeral. That is, they appeared and then disappeared from the marketplace, many times within the same year, and only to be replaced.
[0003] Current solutions that are still in existence rely on the mobile phone as the device to execute transactions. The problem with these solutions is that they are still error-prone and cumbersome. In addition, all of the deployed solutions impose limitations in process sequence, usability and security. A summary of the limitations imposed by all of the current solution offerings thus include the following:
1). The process sequence and usability in all solutions on the marketplace are too complex and tricky. The solutions require multiple communication steps and user interactions between the involved parties. This makes the hand; 2). In cases where an initiated transaction can't be terminated for any reason, there is currently no simple rollback process available; and, 3). As unique transactions are performed and executed—security is a major important issue and must be considered. The solutions must be secure as to prevent Trojan programs and the like from gaining access to the mobile device and/or the transaction data. Current implementations in the marketplace do not employ or recommend any security methods for preventing such attacks, which may be acceptable considering the above limitations, but is not acceptable in terms of a fully secure mobile transaction system.
SUMMARY OF THE INVENTION
[0007] In view of the above it is an object of the present invention to provide a system and method which enables mobile devices (mobile phones, smart phones, PDA's and the like) to perform transactions in an easy, simple and secure way.
[0008] Another object of the present invention is to provide for a system and a method to perform transactions in an easy and secure way by avoiding the use of credit cards or electronic cash cards (EC cards) while preserving at the same time the simplicity of such known card payment systems. In particular, the system and method according to the invention is aimed towards providing an alternative to payments via electronic cash without impairing safety, simplicity (for the end user) and wide acceptance of electronic cash systems.
[0009] The above and further objects to become apparent hereinafter are achieved
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Further characteristics and advantages of the invention will become better apparent from the following description of a preferred but not exclusive embodiment of the implant system according to the invention, illustrated by way of non-limitative example in the accompanying drawings wherein:
[0011] FIG. 1 shows a first embodiment of the equipment for use in carrying out mobile payments at a retail store or the like,
[0012] FIG. 2 shows a second embodiment of the equipment for use in carrying out mobile payments at a retail store or the like, and
[0013] FIG. 3 shows an enhancement of the second embodiment of the equipment for use in carrying out mobile payments at a retail store or the like with an extension IMTP coupon module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] In general terms the solution of the present invention accomplishes the above stated objects by means of a visual interface (visual symbol) on the mobile device, of optical technology, and of an Innovative Mobile Transaction Platform (IMTP)—also mobile transaction platform—solution architecture which preferably maps a received registration number of the user of the mobile device (or the mobile device number) into a card number. The card number can be used by a payment provider in the same manner as in a conventional system with an electronic fund transfer at a point of sale (EFT/POS) transaction. Alternatively, the mapping or conversion of the registration number into a card number may take place at the end of the payment provider.
[0015] At the outset, some terms should be defined.
[0016] The term “mobile transactions” or “transaction” may include:
Mobile payment transactions (payment, voucher, coupon, or the like) Ticketing transactions Access (physically and electronically)
[0020] The term “visual interface” or “visual symbol” may be understood to include:
1D, 2D barcode etc. Hologram OCR Or all machine readable visual symbols and formats
[0025] Finally, the term “communication” is meant to include:
SMS (Nokia Picture SMS, EMS, and the like) combined with visual symbols like a 2D barcode (see generic term “visual interfaces”) MMS combined with visual symbols like a 2D barcode (see generic term “visual interfaces”) Email with attached visual symbols like a 2D barcode (see generic term “visual interfaces”)
[0029] In prior mobile transactions solutions a multiple user (customer)/recipient (merchant) interaction was needed. In the solution of the present invention, the mobile device user (who is the customer) confirms a payment or other transactions in one single step (presenting the message with a symbol or format to the recipient or merchant scanner). In addition, prior art mobile transaction solutions re-used security codes. Each component within the process chain was vulnerable to unauthorized access. Further, since a hacker or other unauthorized user can “sniff” and record even message data, the reuse of these codes did not provide adequate security. The use of unique one time security code in the present invention code is unique and securely stored in the Innovative Mobile Transaction Platform (IMTP) database (see FIG. 1 ), which is a closed loop, unauthorized access is frustrated.
[0030] With specific reference to FIG. 1 a preferred embodiment of the present invention is shown including a recipient (merchant) cash desk designated by reference numeral 1 which is operatively connected to a scanner 4 and a PIN input device 8 . The cash desk 1 is adapted to communicate via an appropriate link like for instance LAN, WLAN, GPRS etc. designated with reference numeral 5 with an Innovative Mobile Transaction Platform (IMTP) indicated generally with numeral 9 . The IMTP 9 includes an application server 91 , MMI (man machine interface) 92 , a database 93 , a messaging unit 94 , and external interfaces 95 all to be described hereinafter. The IMTP 9 interfaces with a payment provider 7 , such as SwissPost or the like to authorize and effect a transaction and a mobile operator 6 , such as Swisscom, Orange, Sunrise, Vodafone or the like to provide the data of an authorized transaction via a wireless communication channel 3 to a mobile phone or smart phone 10 or a similar device like a PDA (not shown) of a customer which data can be scanned into the recipient (merchant) cash desk 1 .
[0031] In FIG. 1 only one single scanner 4 is shown which is used both to scan transaction data (price of a product to be purchased, product code etc.), customer data (number of the mobile device or an assigned registration number) and visual symbols (barcode). Therefore, the recipient (merchant) cash desk 1 integrates point of sale (POS) functionality. However, the person skilled in the art will appreciate that separate scanners can be used one for merchandise data/transaction data, one for customer data and visual symbols, and in the latter case the POS functionality may be separate from cash desk register 1 .
[0032] According to one aspect of the present invention the parties involved in
Recipient (Merchant, Shop) Innovative Mobile Transaction Platform—IMTP operator Payment provider (Bank, Financial Institute) Mobile Network Operator Customer
[0038] According to a preferred method of the invention which is described with respect to an embodiment integrating the POS functionality of FIG. 1 and to one embodiment with a dedicated barcode scanner as shown in FIG. 2 , at a first step, a recipient (merchant) initiates a payment transaction by typing in or scanning the requested price of the merchandise to be purchased (transaction data) and the mobile device number or registration number (customer data) of a customer who wants to purchase the merchandise. The input device could be the recipient (merchant) cash desk register 1 including the scanner 4 (hereinafter only cash desk register for the sake of simplicity) or a dedicated barcode scanner 14 as shown in FIG. 2 .
[0039] Furthermore, the safety of the method/system may be also increased if a PIN, which may be a service specific PIN assigned to the user/customer prior to the activation of the inventive payment system, is input by the customer via the input device 8 as shown for instance in FIG. 1 . In a similar manner the PIN may be input via a keyboard provided on the dedicated barcode scanner 14 of FIG. 2 .
[0040] It should be further noted that the PIN may also be altered by the customer, such that the customer ultimately may use the same PIN for turning on the mobile device (or any other PIN of his/her choice) and for confirming the transaction with the IMTP. It should be also noted that the original PIN and the registration number are preferably assigned to the customer upon the registration process with the present payment system. In this case, the customer may be provided by mail with form of a tag bearing a 2D barcode that can be adhered to the mobile device. Nevertheless, as an alternative, it is contemplated that the number of the mobile device and/or the PIN thereof are used instead of the specially assigned registration number and/or PIN.
[0041] Accordingly, information including the price of the merchandise to be purchased (transaction data), the registration number (customer data) and possibly the PIN, if the latter is required, are available at the cash desk register 1 of FIG. 1 or the dedicated barcode scanner 14 of FIG. 2 .
[0042] In a second step this information is combined with a unique ID from the cash desk register 1 of FIG. 1 or the dedicated barcode reader 14 of FIG. 2 , which ID may be embodied as the serial number of the cash desk register or of the dedicated barcode reader, and is transmitted over the wire or wireless network 5 (LAN, WLAN, GPRS etc.) for receipt by the Innovative Mobile Transaction Platform (IMTP) 9 .
[0043] The application server 91 of the IMTP 9 provides for appropriate interfacing capabilities with the cash desk register 1 or the dedicated barcode scanner 14 and routs, in a third step, the information combined with the unique ID to database 93 where a check occurs whether the customer was previously registered with the IMTP 9 .
[0044] In the case of the customer who has not previously registered with the IMTP 9 , a registration process starts to collect necessary customer data via a man machine interface (MMI) 92 .
[0045] If the customer is registered within the IMTP 9 , the IMTP 9 converts or maps, in a fourth step, the received registration number into a card number which system with an electronic fund transfer at point of sale (EFT/POS) transaction. In this manner the IMTP 9 according to the present invention appears to the payment provider 7 as a conventional credit card or electronic cash card transaction requester, and advantageously no further modifications at the end of the payment provider 7 are necessary to complete a transaction. Alternatively, the conversion of the customer's registration number into a card number may occur at the end of the payment provider 7 .
[0046] The IMTP 9 communicates, in a fifth step, the combined information including the registration number or the card number via the external interface 95 to an acquiring system and an issuer authorization system of the payment provider 7 where the authorization is handled in a conventional manner as in EFT/POS transaction when a card number is available. Otherwise, an additional conversion step would be required at the payment provider 7 . The authorization request may include plausibility checks, including a plausibility check against a daily limit which is preferably only applicable for present IMTP type transaction. If the acquiring system does not send a response to the IMTP 9 within a preset time (i.e. a given time out), the IMTP 9 generates a reversal request that is confirmed by the acquiring system by a reversal acknowledgment.
[0047] In a subsequent sixth step, the authorization information of the transaction is sent by the issuer authorization system via external interface 95 to the IMTP 9 and the IMTP 9 saves the received authorization information in a database record of the database 93 with additional generated attributes like Transaction ID, security code etc. and then uses this authorization information along with the additional attributes to generate a message, namely the visual symbol embedded in an SMS, MMS, Email, or the like containing a machine readable visual symbol or format such as a 2D barcode. In addition further text information like merchant name, date, amount and the like may be associated with the visual symbol, such
[0048] It should be noted that according to a preferred aspect of the invention the security code stored in the data base 93 is a unique one time security code that never leaves the IMTP 9 .
[0049] This visual symbol, possibly with associated text information, is then sent to a mobile device of the customer via the external interface 95 and a mobile network operator 6 .
[0050] Upon receipt in the mobile device of the customer, the customer may provide the received visual symbol, possibly with associated text information, to the scanner 4 of the cash desk register 1 , when the invention is implemented with an integrated POS functionality, or to the dedicated barcode scanner 14 . The scanned and decoded visual symbol is sent back to the IMTP, and thus the transaction may be completed.
[0051] In the first embodiment shown in FIG. 1 the inputting of all data including transaction data (price of a product to be purchased, product code etc.), customer data (number of the mobile device or registration number) and visual symbols (barcode) is provided via a single scanner, although it will be appreciated that one or more similar electronic or optical means may be used.
[0052] In the second embodiment as shown schematically in FIG. 2 , where the separate dedicated barcode scanner 14 is used for reading the visual symbols of the mobile device, a barcode scanner with GSM/GPRS communication capability may be used that is commercially available from the firm Gavitec AG, Jens-Otto-Krag-Str. 11, 52146 Würselen, Germany. All other relevant data necessary to perform a transaction like price of a product to be purchased, number of the mobile device or registration number, PIN etc. may be inputted by means of the embodiment provides for the advantage of rendering possible the upgrading of already existing equipment at the end of the merchant, like a conventional cash desk register.
[0053] It should also be noted that any other dedicated barcode scanner that is capable of reading visual symbols from a mobile phone display (e.g., a barcode scanner commercially available from Denso AG, a subsidiary of Toyota Tsusho Europe S. A., Denso ID Systems Department, Carl-Schurz-Str. 2, 41460 Neuss, Germany) or the like may be used.
[0054] In a seventh step the merchant, namely the scanner of the cash register or the dedicated barcode scanner, receives the visual symbol (possibly including the text information) from the customer's mobile device 10 , and will then send the received and decoded visual symbol via wire or wireless network to the IMTP 9 as a confirmation/receipt.
[0055] The IMTP 9 will then validate, in an eighth step, the decoded visual symbol sent in the seventh step against the authorization information saved in a database record of the database 93 at the sixth step. If there is no match, an error message will be sent to the merchant device and no transaction will be performed.
[0056] If there is a positive validation, the transaction may proceed. At this point, at a ninth step, the payment provider 7 receives from the IMTP 9 the data needed for the financial transaction (debit/credit). Simultaneously the recipient (merchant) receives a confirmation message. If desired, the recipient can optionally print out receipt for the customer.
[0057] With reference to FIG. 3 an enhancement of the second embodiment of the invention including a coupon module 15 is shown. Nevertheless, the person embodiment of FIG. 1 . The coupon module 15 is operatively connected to a mobile operator 6 and is adapted to selectively provide, inter alia, vouchers or loyalty points to selected customers which can be used upon a purchase via IMTP 9 .
[0058] Advantageously, the enhanced second embodiment includes means (not shown) to recognize the mobile device of a customer when entering a specific store for which vouchers or loyalty points are available according to the profile of the customer. The recognition system may be based on blue tooth or any known triangulation systems which are familiar to those skilled in the art of mobile phone/GSM systems. Therefore, the description thereof will be omitted.
[0059] Upon effecting a transaction in the manner described in connection with the embodiments of FIGS. 1 and 2 , the coupon module 15 provides to the IMTP, upon request of the IMTP, information according to the profile of the recognized customer, as indicated by arrow 96 in FIG. 3 , and such information including vouchers or coupons is then taken into account while effecting the transaction.
[0060] Alternatively, the voucher/couponing information can be sent in a similar manner as indicated by the arrow 96 ′ directly from the coupon module 15 via the mobile operator 6 in form of a machine readable visual symbol or format such as a 2D barcode and possibly text information in clear writing. In the latter alternative, the transaction is performed by scanning two machine readable visual symbols sent via SMS or the like, namely one representative of the transaction and one representative of the voucher/coupon information. In fact, it will be appreciated by the skilled reader that the voucher/coupon information may be sent to the customer immediately upon the recognition step, prior to effecting a transaction, such that the customer is informed prior to the purchasing of vouchers or coupons available to him. tion is used to carry out mobile payments such as Ad hoc or instant payment, mobile bill presentment and payment (EBPP), vouchers (discounts, gift coupons and bonus), and the like, it will be understood that the solution of the present invention can be applied to carry out the following services:
[0061] Mobile Ticketing
Indoor Arena (events, concerts, stadium, sport, etc.) Outdoor Arena (events, concerts, stadium, sport, etc.) Public transportation (Rail, Coaches, Metro, etc.)
[0065] Mobile Access
Physically Access (temporary) Doors, Barriers, and Gates (e.g. visitor parking) Vehicles (e.g. rental cars)
[0069] Electronic Access
[0070] Used for one-time access to sensitive information. In such a case the user should get access to information which is usually not available to him. He would then get a message with a symbol or format which could be read by a scanner attached to the terminal. The access point could be located anywhere (e.g. Internet Coffee, Event Lobby Halls, etc.).
[0071] The described solution enables the customer to confirm the payment, requested by the recipient/merchant in one step without any additional typing, namely by merely presenting the visual symbol. This fact delivers an outstanding and unique usability for the customer. The solution offers a one step confirmation without any additional typing or voice interaction. The process does not need a rollback procedure from the financial transaction because the trigger for the financial transaction will only be generated after a positive validation occurred. As recipient a financial transaction will not proceed. In addition, a hacker or a “man in the middle” cannot manipulate the process chain or even the message itself at any point. This is because the unique security code generated by the solution remains within the Innovative Mobile Transaction Platform (IMTP) solution architecture. Since the process chain is a closed loop, the correct security code will always be requested before a financial transaction will be executed.
[0072] Clearly, several modifications will be apparent to and can be readily made by the person skilled in the art without departing from the scope of the present invention.
[0073] For instance, the transaction performed by the customer is not limited to one per visual symbol but it may include sub-transactions for which a single visual symbol is sent to the customer. By way of example one may envisage a situation where a customer effects, upon purchasing goods in a store (first sub-transaction), also a second sub-transaction which is the payment of his parking ticket. In such case the same visual symbol is used in both sub-transactions. In a similar manner a person may, upon purchasing a ticket for a sporting or cultural event, also effect several sub-transactions like advance payment of beverages/food, of a parking ticket, a program etc. yet again by using the same visual symbol. Clearly, the IMTP and/or the payment provider 7 must be adapted, in a manner familiar to the person skilled in the art, to handle the multiple use of the same visual symbol.
[0074] Therefore, the scope of the claims shall not be limited by the illustrations or the preferred embodiments given in the description in the form of examples, but rather the claims shall encompass all of the features of patentable novelty that reside in the present invention, including all the features that would be treated as equivalents by the person skilled in the art. signs, those reference signs have been included just for the sole purpose of increasing intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.
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The invention relates to a system and a method for providing a mobile transaction, such as a payment, the system including: a first means at a point of sale for entering transaction data and customer data and having a unique ID associated therewith; and a mobile transaction platform connected via a first link to the first means, the mobile transaction platform being adapted to receive the transaction data, the customer data and the unique ID, and to route the transaction data, the customer data and the unique ID to a payment provider for obtaining authorization for an electronic fund transfer at the point of sale, the mobile transaction platform being further adapted to provide the authorization information of the payment provider via a second link, which is distinct from the first link, to a mobile device of the customer, wherein the authorization information is in form of a machine readable visual symbol, the first means being adapted to read and decode the visual symbol from the mobile device and to send the decoded visual symbol via the first link to the mobile transaction platform for finalizing the transaction.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to the field of processing of buffalo hair, and more particularly, to the creation and production of a yarn useful for the creation of garments made of buffalo hair and buffalo down.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with the formation of fibers and yarn, as an example.
Heretofore, in this field, animal fibers have been used for the creation, formation and manipulation of yarns that are useful for the manufacture of clothing. In order to produce sufficient yarn of sufficient strength a number of yarn types have been created that take advantage of different weaves and weave patterns to produce yarns. More recently, the introduction of synthetic fibers for the production of yarn have yielded to great increases in production and the strength of fibers.
For production of wool yarn, for example, the wool fibers must be spun on worsted system or on woolen system. On a worsted system, the wool staple length is long and distribution of the length usually is extremely uneven compared to those of cotton. Wool top is virtually impossible to draft with roller drafting, mechanism. Good uniformity of product requires faller bar incorporation into the process.
If a distance between drafting rollers could be set in accordance with the longest fiber length, shorter fibers would be floated, when being drafted, while longer fibers that exceed the distance between the rollers, would be broken or cut. In the former case, fallers must be applied on gill frame to control these floating fibers.
Cotton-wool blended yarns have been spun with squared wool fiber, but all-wool yarns like worsted yarns cannot be spun by means of the conventional cotton system until now. With worsted yarns produced by the conventional worsted yarn system, long fibers of more than 120 mm length of wool top occupies only about 10% of the total. Therefore, for the purpose of uniform drafting, gilling should be used. In general, however, worsted spinning system is considered as of higher cost and lower in productivity, which results in much higher spinning costs in worsted system than in cotton system. Likewise, the creation of a yarn based on buffalo has always required that, at a minimum, a significant amount of wool be interspersed with the buffalo hair and/or fibers. At least one problem with the buffalo-wool blend is that it is more characteristic in feel, comfort and durability to wool than to buffalo.
To date, no one has been able to produce a yarn based solely on buffalo or bison hair (termed collectively herein “buffalo”) at a lower cost, as well as higher productivity and good quality. Whole buffalo hair and buffalo down blended with a minimum of 40% wool fibers have long been used for providing durable, warm and comfortable protection in cold and warm weathers. A yarn based solely on buffalo hair and fibers would be expected to have similar or improved characteristics, however, the inability to produce such yarn in an efficient, cost-effective manner has not been achieved.
SUMMARY OF THE INVENTION
It has been found, however, that the present invention may be used to produce yarn from buffalo hair and fibers in an efficient and cost-effective manner. In the industry it has long been felt that buffalo hair could not be formed into yarn due to characteristics of the fibers that were incompatible with the yarn manufacturing systems, viz., the wollen, worsted and cotton systems.
A significant problem of the wollen, worsted and cotton systems is that they were not designed for the formation of yarn from complex fleece, such as buffalo fleece. One problem with buffalo fleece is that it may contain up to 5 different types of hair fibers, that is, it is a multi-layered fleece.
What is needed is a method of preparing buffalo hair and fibers for the creation of buffalo based yarn, and in particular, yarn that is made solely with buffalo hair. In the present invention, a pure buffalo yarn is produced that does not include wool or other fiber fillers.
More particularly, the present invention is a method of producing yarn solely from buffalo hair including the steps of, scouring a buffalo fleece with detergent and water at a temperature of at least 80 degrees centigrade to clean the fleece and separating the coarse from the down hair of the buffalo fleece. Next, the buffalo fleece is dehaired to remove unwanted course hair from the fleece to produce dehaired fleece, followed by blending the dehaired fleece with an oil and water emulsion in a mixing picker to produce a mixed fiber. A carding step follows the blending step in which the mixed fiber to produce a roving of straight and parallel fibers. Spinning the roving produces a yarn, which is twisted into the pure buffalo yarn to increase the bulk and softness of the yarn. The method of the present invention may also include the collection of the fleece from a buffalo hide using sheep shears prior to the step of scouring the fleece. dr
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a flow diagram of a process for the creation of buffalo yarn and the processing of buffalo hair of the present invention; and
FIG. 2 is a flow diagram of the separation step of the present invention that allows for the production of pure buffalo yarn using the steps of the woolen system.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
It is well known by the skilled in the art that in a spinning process of woollen type yarns, after the carding operation through two or more sets, a number of bands are split from the sheet or web of fibers by a “condensor”, which pass the bonds on leather tapes to a series of double leather endless belts or “rubbers”, and the reciprocating movement of these, rubs and compresses the fibers of each band into narrow, round untwisted slivers or slubbings (i.e., having a false or “mock” torsion) that are wound on to elongated spools to be generally mounted as coaxial spool pairs on a spinning frame, being ready to feed a section of same for the final spinning.
One such method of using and improving upon the Woolen system for use with the creation of wool-based yarn is disclosed in U.S. Pat. No. 3,979,893, issued to Gelli, et al. These inventors disclose a mechanical system and method for continuous working woolen type yarn from cards to spinning frame in which a working web of woolen type yarns leaving a finisher card is produced with reduced steps. More particularly, they take advantage of a condenser head that Splits the web into parallel bands. The bands are delivered to pairs of rubbing rolls which reciprocate relative to one another to convert the bands to slubbings having false torsion. The slubbings are conveyed to spinning frames. In most cases such slubbings are arranged as four coaxial and side-by-side elongated spools, and the “mock” torsion thereof is provided by the rubbing and compressing action of said double leather endless belts during the reciprocating movement of same. The relevant portions of U.S. Pat. No. 3,979,893 are incorporated herein as reference to teach the basic woolen system as would be known to those of skill in the art of wool-based yarns spun according to the woolen system and modifications thereof.
As an example of the Woolen system when the winding phase of slubbings on to elongated spools through the condenser is completed, these elongated spools are collected and carried to the spinning frames to continue the spinning process as final spinning of the woollen yarn as desired. Some of the problems often encountered with using the woolen system is that following a period of spinning forced interruptions occur in the process that include: (a) forming elongated spool of woollen stubbing through the condensers of prior art, which are provided with mechanical means for said purposes; (b) unloading said elongated spools and collecting same waiting for the next use on a spinning frame; and (c) carrying said elongated spools both for collection and loading of same on the spinning frames. The interruption results in a loss of time which is by-itself not indifferent, but also a consequently higher manufacturing cost.
More particularly, the present invention is used to produce a pure buffalo hair yarn. The method and yarn produced using the present invention begins with obtaining shaved buffalo or bison hair. Two types of yarn may be produced: a down yarn or a whole-hair yarn. The down yarn has had at least about 90 percent of the coarse hair taken out prior to processing and spinning, and preferably at least 95 percent. The whole-hair yarn, on the other hand, is yarn that has had the coarse hair taken out at the separation stage and then re-blended with 50 percent buffalo down and 50 percent coarse hair. In some cases, about 10 percent wool may be added to strengthen the whole-hair yarn. The down hair grows underneath the coarse hair of the bison to keep it warm. The whole-hair yarn has been processed the same way that the down hair has except that it has not been dehaired.
In operation, the general steps of the present invention are described in conjunction with FIG. 1 in a flow chart generally designated as 10 . The first step involves the collection of the buffalo or bison hair at step 12 . Next, in step 14 , the collected hair or fleece is scoured to remove dirt and unwanted hair contaminants. To form a more homogeneous mixture of fine soft fibers the whole hair may be dehaired in step 16 by opening the fibers. Next, in step 18 the separated hair, now generally a down hair, is emulsified with oil, water and even if necessary an anti-static compound. At step 20 , the hair fibers are carded to produce a mat of straightened fibers to produce a roving of buffalo hair. At step 22 , the roving is spun into a primary buffalo yarn. Finally, at step 24 , the primary buffalo yarn may also be twisted to produce a yarn that is less dense and generally softer to the touch. Each of the steps in FIG. 1 is described in greater detail hereinbelow.
Collecting the Bison Hair. The bison hair is shaved from the torso of the bison the day it is slaughtered for meat. The hair is shaved before the hides are salted down. The bison hair may be shaved using, e.g., sheep shears. Generally, the buffalo hair is only shaved during the winter months. The raw bison fleece may be stored in 300 pound burlap bags in unheated barns that stay at about 15 degrees Fahrenheit until it is transported to the scouring plant where it is cleaned.
Scouring. Dirt and grease are removed from the raw Buffalo fleece. After the dirt and grease are removed the fleece is passed through a series of washing tanks filled with hot water and soap or detergent. It may then be rinsed and dried prior to further processing or stored.
Dehairing. The cleaned fleece is fed into a dehairing machine. The dehairing process removes the unwanted coarse hair leaving at least about 90 percent fine soft fibers, and preferably, about 95 percent fine soft fibers. The cleaned fleece is fed to the dehairing machine which moves it once slowly through eight large heads in the machine taking out about 95 percent of the unwanted coarse hair. The coarse hair cannot be completely removed because it breaks the fibers down to run them through the machine again. The dehairing process creates a very fine soft fiber.
Blending. First, the dehaired Buffalo fiber is fed into to a mixing picker, which opens the fiber. Secondly, the opened fiber now receives a fine spray of emulation consisting of water oil and an anti static compound. The anti-static compound may be added before, during of after the oil and water emulsion and will generally be non-foaming. An anti-foam may also be added with the emulsion. Finally, the emulsified fiber is now blown into a large mixing chamber to thoroughly mix the fiber and the emulation. This process may be repeated several times to achieve a homogeneous mixture of both fiber and emulation.
Carding. The mixed fiber is now placed in a feeding machine that delivers an even amount of blended Buffalo fiber to a feed apron. The feed apron delivers the fiber to the carding machine. The carding machine is made up of a large number of rolls covered with the fine pointed wire, similar to a hair brush. These rolls are of different sizes and run at different speeds. The fiber passes from one roll to another moving through the machine. As the fiber makes its way through the machine the fibers are being straightened and paralleled.
This mat of straightened fiber leaves machine in a web form and is delivered to a set of dividing rolls. These rolls divide the web into ½″ sections and deliver them to a condensing unit which rubs them into a cylindrical form looking like a long spaghetti. This is now called buffalo roving and many ends are wound onto a large spool.
Spinning. The buffalo roving, now in the form of a spool or spooled fibers, is placed on the spinning machine that unwinds the roving from the spool. The roving passes through two sets of rolls running at different speeds. These are called drafting rolls. As the roving passes through these rolls it is reduced in size. The drafted roving is now wound onto a bobbin turning at very high speeds. This applies twist to the drafted roving locking the fiber together and giving it strength. It is now called buffalo yarn.
Twisting. Two ends of yarn are fed through a set of feed rolls onto a bobbin spinning at a high rate of speed. As the yarn is wound to the bobbin twist is applied to the two ends of yarn. This twist is applied in opposite direction of the single spun yarn. By removing twist from the single spun end and applying it to the two ply ends the yarn becomes softer and bulkier.
The present invention is based on the realization that prior attempts to spin buffalo yarn had failed to produce a yarn of sufficient strength and with consistency. To avoid the problems associated with the production of pure buffalo yarn, prior users of buffalo based fleece have had to resort to the addition of wool fibers to provide a scaffolding for the formation of a yarn that included buffalo. A key step to overcoming the problem of spinning pure buffalo yarn was the realization that the components of the buffalo hair had to be separated prior to the spinning operation. The un-separated hair could not be consistently matted in the carding process to form a consistent yarn. Therefore, the present inventor separated the coarse buffalo hair from the down buffalo hair prior to entering the basic woolen yarn procedure.
The details of the separation procedure are described in the flowchart of FIG. 2 . In step 32 , the buffalo or bison hair is removed from the hide with shears, preferably sheep shears or other like shears as will be known to those of skill in the art of shearing to produce a dual fiber fleece. After scouring and/or washing the fleece the coarse hair is removed or separated from the down by dehairing. The present inventor realized that the coarse and the down hair had to be separated prior to the yarn making procedures in order to make yarn from buffalo hair. Once the down and coarse hair are separated, as indicated in step 34 , about 95% of the down fiber is coarse hair free, with the remaining coarse hair being too small to further separate.
In step 36 , the fibers are once again mixed in a mixing picker and sprayed with an emulsion or water and oil, as is generally done is the standard Woolen procedure. The oil and water mixture may also include other additives such as antistatic and other additives. Finally, in step 38 , the fibers are once again joined by mixing in a large mixing chamber, which is then followed by the remaining steps of the woolen yarn making procedure.
While this invention has been described in reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments.
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A method for making a pure buffalo yarn is disclosed and includes the steps of, scouring a buffalo fleece with detergent and water at a temperature of at least 80 degrees centigrade to clean the fleece, dehairing the buffalo fleece to remove unwanted course hair from the fleece to produce dehaired fine soft fibers, blending the dehaired fine soft fibers with an oil and water emulsion in a mixing picker to produce a mixed fiber, carding the mixed fiber to produce a roving of straight and parallel fibers, spinning the roving to produce a yarn and twisting the yarn to increase the bulk and softness of the yarn.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application relates to and claims the benefit of priority of U.S. Provisional Patent Application No. 60/614,066, filed Sep. 29, 2004. The full disclosure of U.S. Provisional Patent Application No. 60/614,066, filed Sep. 29, 2004, is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to power system protection techniques, and more particularly, power system protection techniques that are relatively easy and relatively inexpensive to implement.
A power system (or electrical network) is said to be operating under steady-state conditions when there exists a balance between generated and consumed active power for the system. Power systems operating under steady-state conditions typically operate at or very near their nominal frequency. In the case of power systems within the United States of America, the nominal frequency is equal to sixty cycles per second (or sixty hertz).
Under certain circumstances, a power system can be disturbed such that it no longer operates under steady-state conditions. In that regard, power systems are subjected to a wide range of small or larger disturbances during operating conditions. Small changes in loading conditions occur continually. The power system must adjust to these changing conditions and continue to operate satisfactorily and within the desired bounds of voltage and frequency. A power swing condition can be the result of a disturbance that causes the power system to be removed from its steady state operating condition. Such power swings are characterized by variations in the power flow for a power system. These variations occur when the internal voltages of system generators slip relative to each other. Power system faults, line switching, generator disconnection, and the loss or the application of large amounts of load are examples of system disturbances that can cause a power swing condition to occur in a power system. Upon the occurrence of a power swing condition, there exists an imbalance between generated and consumed active power for the system. In particular, upon the occurrence of a power swing condition, there is a sudden change of the electrical power demand for the system. On the other hand, the mechanical power input to the system generators remains relatively constant. As a result of the power swing condition, the system generator rotors may accelerate and oscillations in the rotor angles for the sytem generators may occur, which can translate into severe system disturbances.
Depending on the severity of the system disturbance(s) and the actions of the power system controls during a power swing, the system may remain stable and return to a new equilibrium state, having experienced what is referred to as a stable power swing. However, severe system disturbances can produce a large separation of system generator rotor angles, large swings of power flows, large fluctuations of voltages and currents, and eventually lead to a loss of synchronism between groups of system generators or between neighboring utility systems. This occurence is referred to as an unstable power swing.
Large power swings, whether stable or unstable, can cause undesirable results. In particular, large power swings can cause the impedance presented to a distance relay to fall within the operating characteristics of the relay, away from the pre-existing steady-state load condition, and cause the relay to actuate an undesired tripping of a system transmission line. The undesired operation of system relays during a power swing can aggravate further the power system disturbance and cause system instability, major power outages and/or power blackouts. This can cause an otherwise stable power swing to become an unstable power swing. It will therefore be understood that distance relays preferably should not operate during stable power swings to allow the power system to establish a new equilibrium state and return to a stable condition.
During an unstable power swing, two or more areas of a power system, or two or more interconnected networks, lose synchronism. Uncontrolled tripping of circuit breakers during an unstable power swing condition could cause equipment damage and pose a safety concern for utility personnel. Therefore, it is imperative that the asynchronous system areas be separated from each other quickly and automatically in order to avoid extensive equipment damage and shutdown of major portions of the power system. During an unstable power swing condition, a controlled tripping of certain power system elements is necessary in order to prevent equipment damage, widespread power outages, and to minimize the effects of the disturbance.
Ideally, the asynchronous areas should be separated in such locations as to maintain a load-generation balance in each of them. System separation does not always achieve the desired load-generation balance. In cases where the separated local area load is in excess of local area generation, some form of non-essential load shedding is necessary to avoid a complete blackout of the system area.
To protect the power system, distance relays have integrated numerous protection functions including power swing detection and responsive relay blocking functions and unstable power swing detection and responsive selective tripping or pole slipping functions. The main purpose of power swing detection and responsive relay blocking functions is to differentiate faults from power swings and block operation of distance or other relay elements during all power swing conditions (stable and unstable power swings). In other words, during a power swing, it is ordinarily desirable to prevent tripping of the power system elements.
Faults occurring during a power swing must however be detected and cleared with a high degree of selectivity and dependability. Therefore, in such situations, the utilized power swing detection and responsive relay blocking function should allow the distance relay elements to operate and clear any faults that occur in their zone of protection during a power swing condition.
Power swing blocking functions are designed to detect power swings, differentiate power swings from faults, and prevent distance relay elements from operating during power swing conditions. Power swing blocking functions prevent system elements from tripping at random and at undesired source voltage phase angle difference between system areas that are in the process of losing synchronism with each other.
Unstable power swing detection and responsive selective tripping functions are also available in distance relays. The main purpose of these functions is to detect an unstable power swing condition by differentiating between stable and unstable power swing conditions. Power system utilities designate certain points on their network as separation points allowing for separation of asynchronous system areas during unstable power swing conditions. During an unstable power swing condition and at the appropriate source voltage phase angle difference between asynchronous system areas, the unstable power swing detection and responsive selective tripping function initiates controlled tripping of appropriate breakers (or other system elements) at predetermined network locations, to uncouple asynchronous system areas quickly and in a controlled manner in order to maintain power system stability and service continuity. Distance relay elements prone to operate during unstable power swings should be inhibited from operating to prevent system separation from occurring at random and in locations other than preselected ones.
Power swing detection and responsive relay blocking elements conventionally monitor the rate of change of the positive sequence impedance to detect power swing conditions. The required settings for these elements can be difficult to calculate in many applications, particularly those where fast power swings can be expected. For these cases, extensive stability studies are required in order to determine the fastest rate of possible power swings.
Unstable power swing detection and responsive selective tripping functions also typically monitor the rate of change of the positive sequence impedance. The required settings for this function are also difficult to calculate and in most applications it is required to perform an extensive number of power system stability studies with different operating conditions. This is a costly exercise and one can never be certain that all possible scenarios and operating conditions were taken under consideration.
The difference in the rate of change of the impedance vector has been conventionally used to detect a stable or unstable power swing and block the operation of the appropriate distance protection elements before the impedance enters the protective relay operating characteristics because it is known that it takes a finite period of time for the torque angle of system generators to advance due to system inertias. In other words, the time rate of change of the impedance vector is slow during stable or unstable power swings, because it takes a finite period of time for the generator rotors to change position with respect to each other due to their large inertias. On the other hand, the time rate of change of the impedance vector is very fast during a system fault.
Actual implementation of measuring the impedance rate of change is normally performed though the use of two impedance measurement elements together with a timing device. If the measured impedance stays between the two impedance measurement elements for a predetermined time, then a power swing is detected and a relay blocking signal is generated to prevent operation of the appropriate distance relay elements.
These conventional protection functions are mostly based on measuring the positive-sequence impedance at a relay location. During normal system operating conditions, the measured impedance is the load impedance and its locus is away from the distance relay protection characteristics on the impedance plane well known by those skilled in the art. When a fault occurs, the measured impedance moves immediately from the load impedance location on the impedance plane to the location representative of that fault condition on the impedance plane. During a system fault, the rate of impedance change is primarily determined by the amount of signal filtering in the relay.
During a power swing, the measured impedance moves relatively slowly on the impedance plane. For a power swing, the rate of impedance change is determined by the slip frequency of an equivalent two-source system.
This difference of impedance rate of change during a fault and during a power swing is utilized in conventional power swing detection schemes to differentiate between a fault and a swing. Placing two concentric impedance characteristics, separated by impedance ΔZ, on the impedance plane and using a timer to time the duration of the impedance locus as it travels between the characteristics is one manner used to make the differentiation. In that regard, if the impedance measured crosses the concentric characteristics within a predetermined period of time, then the event is deemed to be a system fault event. Conversely, if the impedance does not cross the concentric characteristics within the predetermined period of time, then the event is deemed to be a power swing.
Different impedance characteristics have been designed for power swing detection. These characteristics (identified as inner Z element and outer Z element) include the double blinders illustrated in FIG. 1 , polygons illustrated in FIG. 2 , concentric circles illustrated in FIG. 3 , and lens characteristics illustrated in FIG. 4 .
There are a number of issues that must be addressed to apply and set the power swing detection functions. To guarantee that there is enough time to carry out blocking of the appropriate distance relay elements following detection of a power swing, the power swing detection and responsive relay blocking function inner impedance (z) element must be positioned on the impedance plane outside the position of the largest distance relay protection characteristic on the impedance plane. Also, the power swing detection and responsive relay blocking function outer impedance (z) element must be positioned on the impedance plane at a position away from the position of the load region on the impedance plane to prevent power swing detection and responsive relay blocking logic operation caused by heavy loads, which would incorrectly cause blocking of the line mho tripping elements. These relationships among the impedance (z) measurement elements are illustrated in FIG. 2 , using concentric polygons as power swing detection elements.
Those skilled in the art appreciate that these requirements are difficult to achieve in some applications depending on the relative line and source impedance magnitudes. It can be difficult to set the inner and outer power swing detection impedance (z) elements, and in certain circumstances incorrect relay blocking could occur.
Another shortcoming of conventional power swing detection schemes that measure the rate of change of the impedance is the determination and setting of the separation between the inner and outer impedance (z) elements and the determination and setting of the time period to be used to differentiate a fault from a power swing. These settings are difficult to calculate and depending on the power system under consideration, it may be necessary to run extensive system stability studies in order to calculate these settings.
Compounding matters further, the rate of slip between two system generators is a function of the accelerating torque and system inertias. In general, the slip cannot be determined without performing system stability studies and analyzing the angular relationships of system generators as a function of time to estimate an average slip in degrees/sec or cycles/sec. While this approach may be appropriate for systems having a slip frequency that does not change as a function of time, in many power systems, the slip frequency increases considerably after the first slip cycle and on subsequent slip cycles. In those instances, a fixed impedance separation between the inner and outer impedance (z) elements and a fixed time period for detection of a power swing might not be suitable to provide a continuous blocking signal to the mho distance elements.
Still another shortcoming of conventional power swing detection techniques is that they are very difficult to implement in complex power systems because of the difficulty in obtaining the proper source impedance values required to establish the inner and outer impedance (z) elements and the time period settings. In such power systems, the source impedances vary constantly due to network changes, for example due to additions of new system generators and other system elements. The source impedances could also change drastically during a major disturbance and during system conditions when the blocking functions are desired. Very detailed and extensive power system stability studies must be carried out, taking into consideration all contingency conditions in order to find the most suitable settings for the detection of the power swing.
Yet another shortcoming of conventional power swing detection and responsive relay blocking and unstable power swing detection and responsive selective tripping functions is that those functions are often combined together in a single logic structure within relays. This approach of combining the functions can present conflicting setting requirements if it is desired to apply both functions at the same transmission line location.
In view of the foregoing, it is desirable to provide a power system protection technique designed to protect against power swings occurring within the system.
It is also desirable to provide such a protection technique that separates the power swing detection and responsive relay blocking function from the unstable power swing detection and responsive selective tripping function. This will eliminate user confusion in the application of these relay functions and at the same time remove the conflicting setting requirements if it is desired to apply both functions in the same relay at the same transmission line location.
It is further desirable to eliminate user settings and the need for stability studies for the power swing detection and responsive relay blocking function.
It is still further desirable to provide for a power swing detection and responsive relay blocking technique that is independent of network parameters.
It is also desirable to provide for a power swing detection and responsive relay blocking technique that can be used effectively with long heavily loaded transmission lines of the type that present problems when using conventional techniques.
It is also desirable to provide for a power swing detection and responsive relay blocking technique that can detect three-phase faults that may occur during power swings and allow the protective relays to issue a tripping command and isolate the faulted power system element.
It is also desirable to provide for a power swing detection and responsive relay blocking technique that can track a power swing irrespective of the location of the apparent impedance in the complex plane.
It is still further desirable to remove the need for stability studies and simplify the settings for the unstable power swing detection and responsive selective tripping function when it is desired to trip on-the-way-out (TOWO).
It is yet further desirable to provide an option for the user to perform the unstable power swing detection and responsive selective tripping function on-the-way-in (TOWI).
These and other benefits of the preferred form of the inventive subject matter will become apparent from the following description. It will be understood, however, that a system and method could still appropriate the inventive subject matter claimed herein without having each and every one of these benefits, including those gleaned from the following description. The appended claims, not the benefits, define the exclusive subject matter and should be construed to the fullest extent permitted by law, including the applicable range of equivalency. Any and all benefits are derived from the preferred forms of the inventive subject matter, not necessarily from it in general.
BRIEF SUMMARY OF THE INVENTION
With regard to its most preferred aspects, a novel power swing detection and responsive relay blocking function has been designed. The power swing detection and responsive relay blocking function requires no user settings, is independent of network parameters and there is no need to perform any stability studies. The power swing detection and responsive relay blocking function is based on the positive-sequence swing-center voltage (SCV 1 ) for the monitored power system. For this function, a starter zone is used that is based on the location of the calculated positive-sequence impedance (Z 1 ) in the complex plane and the magnitude of the positive-sequence swing-center voltage (SCV 1 ), thereby not requiring user settings to set the starter zones. A swing signature detector (SSD) using information stored in three-cycles distinguishes between a fault and a power swing at the moment just before the outermost zone desired to be blocked is about to pickup. A dependable power swing detection logic (DPSB) allows the detection of incipient power swings occurring immediately after a fault has been cleared from the power swings. A slope detector logic (SD) uses the first and second time derivatives of the positive-sequence swing-center voltage (SCV 1 ) and the magnitude of the SCV 1 to detect power swings anywhere in the complex impedance (Z) plane. The second time derivative of the positive-sequence swing-center voltage (SCV 1 ) is used to increase the reliability of power swing detection and the detection of three-phase faults occurring during a power swing condition. The power swing detection and responsive relay blocking function detects three-phase faults during a power swing condition in a manner that is fast and independent of the power swing frequency.
A novel unstable power swing detection and responsive selective tripping function has also been designed. With regard to the most preferred aspects of this function, there is no need to perform any stability studies if it is desired to trip on-the-way-out (TOWO). The unstable power swing detection and responsive selective tripping function is independent from the power swing detection and responsive relay blocking function, thereby permitting application of both functions at the same location without any conflicting setting requirements and user confusion.
The unstable power swing detection and responsive selective tripping function offers the option of trip on-the-way-out (TOWO) during the first slip cycle, TOWO after a set number of slip cycles have occurred, and trip on-the-way-in (TOWI) before completion of the first slip cycle. No timers are required for the unstable power swing detection and responsive selective tripping function. The unstable power swing detection and responsive selective tripping function monitors and tracks the positive-sequence impedance (Z 1 ) trajectory as it moves in the complex impedance (z) plane. The settings for the resistive and reactive blinders (preferably four resistive and four reactive blinders) are easy to calculate and the resistive blinder settings for the trip on-the-way-out (TOWO) option can be self-calculated by the relay based on the line positive-sequence impedance (Z 1 ). Provided a power swing has been detected, an unstable power swing will be detected if the tracked impedance trajectory moves from right-to-left or left-to-right across the entire selected complex plane.
BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS
In the foregoing background and following detailed description, reference has been and will be made to the following figures, in which like reference numerals refer to like components, and in which:
FIG. 1 is a diagrammatic view of an impedance plane with a first set of impedance elements for power swing detection;
FIG. 2 is a diagrammatic view of an impedance plane with a second set of impedance elements for power swing detection;
FIG. 3 is diagrammatic view of an impedance plane with a third set of impedance elements for power swing detection;
FIG. 4 is diagrammatic view of an impedance plane with a fourth set of impedance elements for power swing detection;
FIG. 5 is a circuit diagram representing a two-source equivalent circuit of a power system;
FIG. 6 is a voltage phasor diagram for the two-source equivalent circuit of a power system shown in FIG. 5 ;
FIG. 7 is a graphical representation of a positive-sequence swing center voltage;
FIG. 8 is a phasor diagram directed to an approximation of the positive-sequence swing center voltage;
FIG. 9 is a block diagram representing a no-setting power swing detection system designed in accordance with the principles of the present invention;
FIG. 10 is a mixed block and circuit diagram of the system illustrated in FIG. 9 , showing a circuit diagram representation of the reset circuit illustrated in FIG. 9 ;
FIG. 11 is a diagram representing the measurement of the first and second time derivatives for the positive sequence swing-center voltage signal SCV 1 ;
FIG. 12 is a circuit diagram representation of the swing-center voltage slope detector logic illustrated in FIG. 9 ;
FIG. 13 is a diagram representing the calculation of values used in the circuit diagrams of FIGS. 14 and 15 ;
FIG. 14 a circuit diagram representation of the swing signature detector logic illustrated in FIG. 9 ;
FIG. 15 is a circuit diagram representation of the dependable power swing detector illustrated in FIG. 9 ;
FIG. 16 is a circuit diagram representation of the three-phase fault detector illustrated in FIG. 9 ;
FIG. 17 is a circuit diagram representation of system unbalanced protection logic designed to detect an unbalanced system condition in the relay forward direction;
FIG. 18 is a circuit diagram representation of a circuit designed to enable blocking of the ground distance elements during a single pole open condition;
FIG. 19 is a graphical representation used to define a starter zone for the positive sequence impedance;
FIG. 20 is a graphical representation used to define the inner zone for the positive sequence impedance;
FIG. 21 is a graphical representation of the resistive and reactive blinders used for the unstable power swing detection and responsive selective tripping or pole slipping function;
FIG. 22 is a circuit diagram representation of the logic used to define specific zones within FIG. 21 ; and,
FIG. 23 is a circuit diagram for a circuit used to carry out the unstable power swing detection and selective relay tripping function.
DETAILED DESCRIPTION OF THE INVENTION
For the present invention, the power swing detection and responsive relay blocking function is based upon a power system quantity, the positive-sequence swing-center voltage (SCV 1 ), which provides the benefits associated with requiring no user settings. Preferably, a suitable approximation for this quantity is used. The approximation is referred to as the Vcosφ and it is believed it was first introduced and used for power swing detection by Illar et al. in their U.S. Pat. No. 4,426,670. Vcosφ is an estimate of the swing-center voltage (SCV), and in a purely inductive two-machine system, it is identical to the swing-center voltage.
The swing-center voltage is uniquely suited for effectively carrying out power swing detection because it is independent of the system source and line impedances, unlike other power system quantities such as the resistance and its rate of change or the real power and its rate of change, which depend on the line and system source impedances and other system parameters. Consequently, the swing-center voltage can provide for a no-setting power swing detection and responsive relay blocking function.
The swing-center voltage is also bounded with a lower limit of zero and an upper limit of one per unit, regardless of system impedance parameters. This contrasts to other electrical system quantities, such as impedance, currents, and active or reactive powers, whose limits depend on a variety of system parameters. Furthermore, the magnitude of the swing-center voltage directly relates to δ, the angle difference of two system sources.
Swing center voltage (SCV) is defined as the voltage at the location of a two-source equivalent system where the voltage value is zero when the angles between the two sources are one hundred eighty degrees apart. The swing center voltage will now be derived from a two-source equivalent system.
FIG. 5 illustrates a two-source equivalent circuit 100 for a power system. As shown, circuit 100 includes a local source 102 having a local source impedance 104 , a remote source 106 having a remote source impedance 108 , and a line 110 having a line impedance 112 . The machine angle differential between local source 102 and remote source 106 is represented as δ, or in the case where the differential varies as a function of time, δ(t). When the machine angle differential between the two sources 102 , 106 swings apart to one hundred eighty degrees, there is a location on the line 110 where the voltage will be zero. The voltage at this location, as a function of the machine angle differential (δ(t)) and as a function of time (t), is defined as the swing-center voltage (SCV(t)).
Allowing the source voltage for local source 102 to be,
e s ( t )=√{square root over (2)} E S sin(ω t+ δ( t ))
and allowing the source voltage for the remote source 106 to be,
e R ( t )=√{square root over (2)} E R sin(ω t )
and assuming the swing-center voltage location is a distance referenced by m in FIG. 5 from the local measurement terminal S, the swing-center voltage takes the following value when the local source 102 acts alone,
u C ❘ S ( t ) = Z 1 R + ( 1 - m ) Z 1 L Z 1 S + Z 1 L + Z 1 R 2 E S sin ( ω t + δ ( t ) )
When the remote source 106 acts alone, the swing-center voltage equals,
u C ❘ R ( t ) = Z 1 S + m Z 1 L Z 1 S + Z 1 L + Z 1 R 2 E R sin ( ω t )
Taking into consideration the definition of the swing-center voltage, the following equation can be derived,
Z 1 S + m Z 1 L Z 1 S + Z 1 L + Z 1 R E R = Z 1 R + ( 1 - m ) Z 1 L Z 1 S + Z 1 L + Z 1 R E S
through voltage division. The location of the swing-center, m, can be calculated from the preceding equation. Using the superposition principle, the swing-center voltage can be expressed as a linear combination of voltage drops acting by the two sources 102 , 106 individually. The swing-center voltage (SCV(t)) therefore equals,
SCV ( t )= u C|S +U C|R =√{square root over (2)} U C0 [sin(ω t+δ ( t ))+sin(ω t )]
In this equation, U C0 represents the quantity given in prior equation. Using the trigonometric equality.
sin A + sin B = 2 sin A 2 cos A 2 + 2 sin B 2 cos B 2 = 2 ( sin 2 B 2 + cos 2 B 2 ) sin A 2 cos A 2 + 2 ( sin 2 A 2 + cos 2 A 2 ) sin B 2 cos B 2 = 2 [ sin A 2 cos B 2 + sin B 2 cos A 2 ] · [ cos A 2 cos B 2 + sin A 2 sin B 2 ] = 2 sin ( A + B 2 ) · cos ( A - B 2 )
the swing center voltage can be re-written as follows:
SCV ( t ) = 2 2 U C 0 sin ( ω t + δ ( t ) 2 ) · cos ( δ ( t ) 2 )
with the assumption that both sources 102 , 106 have an equal magnitude, E, it can be verified the U C0 =E/2. Under this equal magnitude assumption, the swing-center voltage can be represented as follows:
SCV
(
t
)
=
2
E
sin
(
ω
t
+
δ
(
t
)
2
)
·
cos
(
δ
(
t
)
2
)
FIG. 6 illustrates the voltage phasor diagram of the general two-source system illustrated in FIG. 5 . As shown, the swing center voltage (SCV) is represented as the phasor extending from origin o to the point o′. When a two-source system illustrated by FIG. 5 loses stability and a power swing condition occurs after some disturbance, the angle difference of two sources, δ(t), will increase as a function of time. In the equation set forth above, SCV(t) is the instantaneous swing center voltage. SCV(t) is a typical magnitude-modulated sinusoidal waveform. The first sine term is the base sinusoidal wave, or the carrier, with an average frequency of
ω + δ ( t ) 2 .
The second term is the cosine magnitude modulation.
FIG. 7 illustrates a representation of a positive-sequence swing center voltage having a given average frequency and a constant slip frequency. When the frequency of a sinusoidal input is different from that assumed in its phasor calculation as is in the case of a power swing condition, oscillations in the phasor magnitude result. However, the magnitude calculation in FIG. 7 is smooth because the positive-sequence quantity effectively averages out the magnitude oscillations of individual phases, as will be appreciated by those skilled in the art.
As shown in FIG. 7 , the magnitude of the swing center voltage changes between zero and one per unit of system nominal voltage. The voltage magnitude is forced to zero every given time period based upon the given slip frequency. The carrier in adjacent modulation cycles is similar, but its instantaneous values have opposite signs because the modulation frequency is half of the slip frequency.
Preferably, the present invention utilizes the following approximation of the swing center voltage using locally available quantities:
SCV≈|V S |·cos φ, where |V S | is the magnitude of the local measured voltage, and φ is the angle difference between the phasor representation of the local source voltage V S and the phasor representation of the local current I, as shown in the phasor diagram of FIG. 8 . As further illustrated by FIG. 8 , the approximation of the swing center voltage is a projection of the local source voltage phasor representation onto the axis of the current phasor representation. For a homogeneous system with the system impedance angle θ close to 90°, the above approximation of the swing center voltage is sufficiently accurate. Moreover, for the purpose of power swing detection, it is the rate of change of the swing center voltage that provides the primary means of detection. Therefore, some differences in magnitude between the true system swing center voltage and its approximation made using locally measured values has little impact in detecting power swings.
For purposes of this invention, it will be appreciated that either the true swing center voltage or the approximation set forth above can be used, although it will be understood that use of the approximation is more practical. The two are used herein interchangeably and reference to swing center voltage in the claims shall be construed to cover both the true swing center voltage and the approximation thereof.
From the preceding equations, the relation between the SCV and the phase angle difference δ of two source voltage phasors can be simplified to:
SCV 1 = E 1 · cos ( δ 2 )
In this equation, E 1 represents the positive-sequence source magnitude equal to E S1 that is assumed to be also equal to E R1 . SCV 1 in the equation represents the positive-sequence swing-center voltage, used for power swing detection due to its desired smooth magnitude during the occurrence of a power swing condition. The absolute value of the swing center voltage is at its maximum when the angle between the two sources 102 , 106 ( FIG. 5 ) is zero and is at its minimum or zero when the angle is one hundred eighty degrees. A power swing can be detected then by evaluating the rate of change of the swing-center voltage. The time derivative of the positive-sequence swing center voltage (SCV 1 ) then becomes:
ⅆ ( SCV 1 ) ⅆ t = - E 1 2 sin ( δ 2 ) ⅆ δ ⅆ t
This equation provides the relation between the rate of change of the swing center voltage and the slip frequency of the two source system (dδ/dt). As will be appreciated, the derivative of the swing center voltage is independent from the network impedances and is at its maximum value when the angle between the sources is one hundred eighty degrees. On the other hand, when the angle between the two sources is zero, the rate of change of the swing center voltage is at its minimum, specifically equal to zero.
Two differences exist between the true system swing-center voltage and its approximation arrived at by measuring local values. First, when there is no load flowing on a transmission line, the current from a line terminal is essentially the line charging current that leads the local source voltage by approximately ninety degrees. In this case, the approximation of the swing center voltage is close to zero and does not represent the true system swing-center voltage. Second, the approximated swing center voltage has a sign change in its value when the phase difference angle δ of two equivalent sources goes through zero degrees. The true system swing-center voltage does not have this discontinuity. These differences, however, do not impact the ability of the approximated swing center voltage to be used for power swing detection, because such detection is primarily based on the rate of change of the swing center voltage.
FIG. 9 illustrates a block diagram representing a no-setting power swing detection technique that, in turn, can be used to cause relay blocking. While this invention is described and illustrated in terms of being implemented using logic “gates” and other electronic components, it will be understood that a preferred implementation of the present invention is carried out by software or firmware. The logic “gates” illustrated in this application are therefore functions and operations that may be performed by various implementations known in the art, such as solid state electronic circuits, software code and/or firmware, for example. Accordingly, the description herein shall constitute and shall be understood to be a description of these various means of implementing the noted logic for carrying out the subject invention.
Referring back to FIG. 9 , as shown, a dependable power swing detector 114 , a swing-center voltage slope detector 116 , and a swing signature detector 118 are used to detect the occurrence of a power swing condition. Also included are reset logic 120 and three-phase fault detector 122 . Upon detection of a power swing condition, the power swing detection signal (PSB) is generated and may be used to enable a relay blocking function.
In operation, the swing-center voltage slope detector 116 monitors the absolute value of the positive-sequence swing-center voltage time rate-of-change (|d(SCV 1 )/dt|), the magnitude of the positive-sequence swing-center voltage (|SCV 1 |), and the output of a discontinuity detector. Upon the detection of a power swing condition by measurement of a sufficiently large value of |d(SCV 1 )/dt|, the swing-center voltage slope detector 116 generates a slope detector output SLD, which in turn causes the generation of the power swing detection signal (PSB) through OR logic or gate 124 .
Slope detector 116 will produce an output signal SLD only when the absolute value of the time rate-of-change of the positive-sequence swing center voltage is within a predetermined range defined by maximum and minimum thresholds, the magnitude of the positive-sequence swing center voltage is correspondingly within a predetermined range defined by maximum and a minimum threshold values, and the positive-sequence impedance measured by the distance relay is within a predetermined starter zone. The output SLD of slope detector 116 is blocked any time the absolute value of the time rate-of-change of the positive-sequence swing center voltage exceeds its predetermined maximum threshold or the absolute value of the discontinuity detector exceeds a predetermined maximum threshold.
The minimum and maximum thresholds for the rate-of-change of the positive-sequence swing center voltage determine the measurement interval of the slip frequency for a classical two-source equivalent system model, such as that illustrated in FIG. 5 . Preferably, these maximum and minimum thresholds are set with a security factor that guarantees that a slip frequency between 0.1 to 7 Hz will be covered.
Slope detector 116 is used to detect the majority of the occurrences of power swing conditions. However, in certain circumstances, slope detector 116 may not operate. For this reason, slope detector 116 is supplemented with the dependable power swing detector 114 and the swing signature detector 118 .
The swing signature detector 118 is used to distinguish between a power swing and a real fault at the moment the outermost distance element to be blocked by the power swing detection picks up. Ordinarily, the slope detector 116 will detect a power swing first and will cause the power swing detection signal (PSB) to be generated. The PSB signal in turn will block the mho fault detectors and the swing signature detector 118 logic will not be processed.
In operation, the swing signature detector 118 preferably continuously stores the absolute value of the first-order derivative of the positive-sequence swing center voltage in a three-cycle buffer memory for a predetermined period of time constituting a few cycles. The maximum value of this buffer memory is then established. If the detected fault is a real fault, this slope maximum value will be very high because a discontinuity has occurred in the positive-sequence swing center voltage waveform. Preferably, eight of the older, stored samples are then compared to this maximum value. If the fault is real, the eight samples used for comparison will be below a variable threshold that is proportional to the slope maximum value. If, on the other hand, the fault is due to a power swing, no discontinuity will appear in the buffer and all of the compared old samples will be above the same variable threshold, causing the swing signature detector 118 to assert a signal at its output SSD and, in turn generate the power swing detection signal PSB through OR logic or gate 126 .
The dependable power swing detector 114 will cause the power swing detection signal PSB to be generated in situations where neither the slope detector 116 nor the swing signature detector 118 can detect a power swing fast enough. An example of such circumstances is when a power swing condition occurs immediately following the clearance of a lasting external fault. Under circumstances such as this, the dependable power swing detector 114 will assert a temporary signal at its output DPSB, causing the power swing detection signal PSB to be generated through OR logic or gate 124 . The dependable power swing detector 114 will assert a signal at its output DPSB for a predetermined period of time that will permit the slope detector 116 to detect the occurrence of a power swing condition. Thus, the dependable power swing detector 114 compensates for the pickup delay of the slope detector 116 .
Reset logic 120 is used to reset the power swing detection signal PSB and thereby disenable the responsive relay blocking function upon recession of the power swing condition. Recession of the power swing condition is primarily detected because the rate-of-change of the positive-sequence swing center voltage signal falls to a very small value. In response, the reset logic 120 asserts a signal at its output RST, which is sent to the reset terminal of a set/reset flip-flop 128 , as shown in FIG. 9 . The set terminal of flip flop 128 is fed by the output of OR logic or gate 126 , which is enabled when either of the slope or swing signature detectors 116 , 118 are activated. The output terminal of flip flop 128 is coupled to one of the inputs for OR logic or gate 124 .
The three-phase detector 122 generates a signal at its output DTF upon detection of a three-phase fault on a transmission line during a power swing. Consequently, the power swing detection signal PSB is blocked from being generated at AND logic or gate 130 . In turn, the relay blocking function is disenabled. The use of the three-phase detector 122 is possible because if a three-phase fault occurs on a transmission line during a power-swing, a discontinuity will be present on the corresponding positive-sequence swing center voltage waveform. This discontinuity can be detected by monitoring and detecting when the positive-sequence swing center voltage and its time rate-of-change are relatively very low, and when its second derivative is relatively high. This permits the three-phase fault detector 122 to be very fast and independent from the swing speed.
A starter zone is preferably used with the power swing detection and responsive relay blocking function, allowing the power swing detection signal PSB to be generated only when the positive sequence impedance Z 1 has a trajectory on the impedance plane with a chance to cross any of the relay operating characteristics during a power swing. Advantageously, with the present invention, the area covered by this preferred starter zone is not critical and can be defined to be a rectangle, the dimensions of which are automatically set so that the zone will encompass all of the relay operating characteristics that must be blocked during a stable power swing condition. The starter zone will preferably also encompass the largest relay operating characteristic used in the unstable power swing detection and tripping logic, if a user enables that function.
During the occurrence of a power swing condition and upon the generation of the power swing detection signal PSB, only phase-faults are blocked by the PSB signal and prevent relay activation. Ground-faults are not blocked by the power swing detection signal PSB because a power swing is a three-phase balanced phenomenon. Therefore, preferably, three-phase and phase-to-phase faults are detected so that the relay blocking function can be disabled, allowing such faults to be cleared during the occurrence of the power swing. In order to detect phase-to-phase faults, a directional overcurrent element based on a negative-sequence directional element can be used.
If a power swing is detected during an open-pole situation, the ground-faults detector is preferably blocked because, under these circumstances, the power swing is not balanced. Detection of any subsequent fault is important and can be carried out by monitoring the phasor angle ratio of the zero-sequence current over the negative-sequence current. For example, if phase-A is open, the angle ratio normally lies between −60° and 60°. If a fault occurs on phase-B or phase-C, or both, the relation no longer holds and the relays would be allowed to clear such faults.
FIG. 10 also illustrates the no-setting power swing detection technique illustrated in FIG. 9 but shows details of a preferred circuit that may be used to implement the reset logic 120 . The logic shown in FIG. 10 is used to set and reset the power swing detection signal PSB, which is used to provide relay blocking. As will be appreciated, the power swing detection signal PSB is controlled by the output of SR flip-flop 128 . As shown, swing-center voltage (SCV) slope detector 116 and swing signature detector 118 are used to set the flip-flop 128 . Preferred circuit implementations of these two system elements are illustrated in FIGS. 12 and 14 , respectively. A preferred circuit implementation of the dependable power swing detector 114 is illustrated in FIG. 15 . As shown in FIG. 10 , dependable power swing detector 114 supplements the swing-center voltage slope detector 116 and the swing signature detector 118 .
Still referring to FIG. 10 , the power swing detection signal PSB is set when the output signal SD of slope detector 116 goes HIGH. Slope detector 116 measures the time-derivative of the swing-center voltage and will detect most power swing conditions.
The power swing detection signal PSB will also be set when the output signal SSD of swing signature detector 118 goes HIGH. Swing signature detector 118 detects a power swing only if the power swing causes one of the outermost zone mho-phase elements, desired to be blocked, to pick-up. If there is a power swing with no pick-up by such a mho-phase element, SSD will not be asserted.
The power swing detection signal PSB will also be set when the output signal DPSB of the dependable power swing detector 114 goes HIGH. The dependable power swing detector 114 does not control flip-flop 128 and is used in those relatively infrequent occasions when slope detector 116 and swing signature detector 118 fail to detect a power swing. As further shown in FIG. 10 , the power swing detection signal PSB is inhibited during the occurrence of a three-phase fault, permitting the relays to operate and clear any such faults.
The reset logic 120 is preferably implemented with a plurality of logic gates including comparators 131 - 133 , OR gates 134 - 137 , AND gates 138 - 140 , and counters 141 - 143 . The circuit elements are preferably coupled as shown in FIG. 10 .
The power swing detection signal PSB will be reset as a result of the reset logic 120 causing flip-flop 128 to be reset. In the illustrated example, a reset signal will be sent to flip-flop 128 when the unstable power swing detection and responsive selective tripping or pole slipping function is not enabled, EOOST is set to O in FIG. 10 , and when the positive sequence swing-center voltage SCV 1 magnitude goes below 0.85 Volts per unit per cycle (V(pu)/cycle) or the positive sequence impedance Z 1 goes outside the starter zone for a time interval greater than 0.5 seconds. A reset signal will also be sent to flip-flop 128 when the unstable power swing detection and responsive selective tripping or pole slipping function is enabled, EOOST is set to I in FIG. 10 , and the positive sequence impedance Z 1 stays outside a predetermined zone defined by the unstable power swing detection logic (referred to as zone 7 in FIG. 10 ) for an interval of time greater than 0.5 seconds. Still further, a reset signal will be sent to flip-flop 128 when the magnitude of the slow derivative of the positive-sequence swing center voltage |dSCV 1 _S| falls below 0.0026 V(pu)/cycle for more than ten cycles and a fault is not detected in the same time. It has been observed that, for the illustrated case, the threshold of 0.0026 V(pu)/cyc is the value of the minimum detectable swing center voltage rate of change. A reset signal will also be sent to flip-flop 128 when the ultra-fast derivative of the positive-sequence swing center voltage |dSCV 1 _UF| exceeds 0.55 V(pu)/cycle for more than four cycles. It has been observed that, for the illustrated case, the threshold of 0.55 V(pu)/cyc is the maximum boundary for the measurement of the swing center voltage rate of change.
The preceding circumstances refer to instances where the power swing detection signal PSB will be reset by flip-flop 128 and the relay blocking function will be inhibited. The examples used refer to time derivatives for the positive sequence swing-center voltage signal SCV 1 . FIG. 11 illustrates the measurement of the first and second time derivatives for the positive sequence swing-center voltage signal SCV 1 , including slow, fast, ultra-fast and unfiltered derivatives, as shown. These derivatives are used in the preceding examples and in other examples set forth in this disclosure. In particular, the preferred circuits used to implement swing center voltage slope detector 116 and swing signature detector 118 require these measurements to operate.
Preferably, function processing is carried out every eighth of one cycle. As such, there are four types of first-order time derivatives and a single second-order time derivative applicable. Referring to FIG. 11 , the positive sequence voltage V 1 and positive sequence current I 1 are received from a full-cycle cosine filter (not shown). When a pole-open condition exists, it is important that the corresponding voltage and current are set to zero when the computation of the positive sequence voltage and current are performed. Doing otherwise can lead to a very noisy positive sequence swing center voltage SCV 1 and positive sequence impedance Z 1 . Noise becomes particularly noxious when the derivatives of SCV 1 are measured.
The positive sequence impedance Z 1 is calculated as shown in the formula within box 150 . Similarly, the positive sequence swing-center voltage is established using the positive sequence voltage V 1 and current I 1 as shown in the formula within box 152 . SCV 1 _Unflt represents the unfiltered normalized (per unit) positive sequence swing center voltage. The unfiltered first order derivative of the positive sequence swing center voltage (dSCV 1 _Unflt) is computed by taking the difference over two samples of the unfiltered swing center voltage (SCV 1 _Unflt), as represented by box 154 . The positive sequence swing center voltage SCV 1 is the product of passing the unfiltered per unit positive sequence swing center voltage SCV 1 _Unflt through a low-pass fourth-order Butterworth filter 156 with a cut-off frequency at fifty hertz. The ultra-fast first order time derivative of the positive sequence swing center voltage (dSCV 1 _UF) is computed by taking the difference between two successive samples of the positive sequence swing center voltage (SCV 1 ), as represented by block 158 . The ultra-fast second order time derivative of the positive sequence swing center voltage (d 2 SCV 1 _UF), also referred to as the discontinuity detector, is computed by taking the difference over one sample interval of the ultra-fast first order time derivative of the positive sequence swing center voltage (dSCV 1 _UF), as represented by block 160 . The fast first-order time derivative of the positive sequence swing center voltage (dSCV 1 _F) is computed by taking a three-point average of the ultra-fast first-order time derivative of the positive sequence swing center voltage (dSCV 1 _UF), as represented by block 162 . Finally, the slow first-order time derivative of the positive sequence swing center voltage (dSCV 1 _S) is computed by taking an eight-point average of the ultra-fast first order time derivative of the positive sequence swing center voltage (dSCV 1 _UF), as represented by block 164 .
FIG. 12 illustrates a preferred circuit used to implement the swing-center voltage slope detector logic 116 , which performs the primary functions related to power swing detection and responsive relay blocking. Swing center voltage slope detector 116 detects a power swing by monitoring the time rate of change of the swing center voltage signal. The minimum and maximum values for the useful rate-of-change interval that will be measured are defined establishing parameters for detection of power swing conditions. As derived above, assuming the output voltage E for a two-machine system with a transmission line between the two machines, the swing center voltage SCV and the angle difference δ between the two sources is given by:
SCV = E cos ( δ 2 )
Furthermore, the first order time derivative of the swing center voltage, given as a function of the rate of change of the angle between the two machines, is given by:
ⅆ ( SCV ) ⅆ t = - E 2 sin ( δ 2 ) ⅆ δ ⅆ t
The rate of change of the angle between the two machines dδ/dt is also called the slip frequency. When setting the desired interval of the slip frequency for detection of a power swing, it is important to determine the corresponding safe interval for the rate of change of the swing center voltage (d(SCV)/dt). The interval chosen for this preferred example is a slip frequency between 0.1 and 7 hertz. For the purpose of computing the upper boundary, the maximum value of the derivative of the swing center voltage will occur when δ is close to one hundred eighty degrees. Expressing the rate of change of the swing center voltage in per unit value of the rated voltage per cycle and introducing a security factor of 1.5 yields:
max ( ⅆ ( SCV ) ⅆ t ) = - 1.5 2 π 7 2 60 = 0.55 V ( pu ) / cyc
Computing the lower boundary corresponding to a slip frequency of 0.1 Hz and introducing a security factor of two yields:
min
(
ⅆ
(
SCV
)
ⅆ
t
)
=
-
2
π
0.1
2
2
60
=
0.0026
V
(
pu
)
/
cyc
Referring to FIG. 12 , the swing center voltage slope detector logic preferably includes, as shown, a plurality of logic gates including comparators 170 - 178 , OR gates 179 - 185 , AND gates 186 - 195 , and counters 196 - 200 . These circuit elements are preferably coupled in the manner shown in FIG. 12 .
In operation, if the absolute value of the ultra-fast first-order time derivative of the positive sequence swing center voltage (|dSCV 1 _UF|) is greater than the maximum value established above (0.55 V(pu)/cyc), as determined by comparator 170 , measurement of the variation of the swing center voltage is inhibited. Counter 196 functions as a dropout timer and extends the inhibition for a half cycle when the condition is removed.
The same inhibition is applicable when the ultra-fast second order time derivative of the positive sequence swing center voltage (|d 2 SCV 1 _UF|), also known as the discontinuity detector, is greater than 0.23, as determined by comparator 171 , and |dSCV 1 _UF| is greater than 0.2, as determined by comparator 172 . These two conditions ensure that no measurement is made of the time rate of change of the swing center voltage when the maximum rate-of-change is exceeded and/or when the discontinuity detector reflects that one or more select changes have occurred on the network (fault or other). If a fault is detected on the network (at least one of M 2 P to M 5 P go HIGH at OR gate 179 ), measurement of the rate of change of swing center voltage is also inhibited during the duration of the fault detection. This ensures that a power swing condition is not detected during a fault, which would block select relay operation. Consequently, the fault will be cleared.
Comparators 173 and 174 monitor a negative time-change of the positive sequence swing center voltage. The minimum rate of change threshold for this example established above (−0.0026 V(pu)/cyc) is compared with the slow first order derivative of the positive sequence swing center voltage (dSCV 1 _S), at comparator 174 . If this slow derivative is below the minimum threshold for at least five cycles, as determined by counter 198 , the condition is recognized. Similarly, time-rates below −0.0172 V(pu)/cyc are detected by the fast first order time derivative of the positive sequence swing center voltage (dSCV 1 _F) and must last 1.75 cycles before they are detected, as determined by comparator 173 and timer 197 .
Comparators 175 and 176 monitor a positive time change of the positive sequence swing center voltage. For this example, the minimum detectable change is 0.0026 V(pu)/cyc, as established above. This minimum change is compared with the slow first order time derivative of the positive sequence swing center voltage (dSCV 1 _S) at comparator 176 and as before, the change has to be present for at least five cycles to be detected, as determined by counter 200 . Similarly, changes above 0.0172 V(pu)/cyc are detected by the fast first order time derivative of the positive sequence swing center voltage (dSCV 1 _F), at comparator 175 , and must last 1.75 cycles before they are detected, as determined by counter 199 .
Upon detection of the occurrence of any significant rate of change of the swing center voltage, the output of OR gate 183 goes HIGH. As a result, the swing center voltage slope detector signal SLD will be asserted when the absolute value of the positive sequence swing center voltage is less than 0.85 pu, as determined by comparator 177 , and the location of the positive sequence impedance (Z 1 ) is inside the starter zone, as determined by AND gate 193 , and the absolute value of the positive sequence swing center voltage exceeds 0.05, as determined by comparator 178 and AND gate 194 . Alternatively, when there is a significant rate of change of the swing center voltage causing the output of OR gate 183 to go HIGH, the swing center voltage slope detector signal SLD will assert if an unstable power swing is detected (i.e., EOOST=I, O, C) and if the positive sequence impedance (Z 1 ) is inside a predetermined zone (referred to as zone 7 ).
FIG. 13 illustrates the calculation of the maximum unfiltered first order time derivative of the positive swing center voltage used in the preferred circuit implementation of the swing signature detector logic illustrated in FIG. 14 . FIG. 13 also illustrates the calculation of the average ultra-fast second order time derivative of the positive sequence swing center voltage used in the preferred circuit implementation of the dependable power swing detector logic illustrated in FIG. 15 .
The upper portion of FIG. 13 illustrates a twenty-four sample memory buffer used to store the unfiltered first order time derivatives of the positive sequence swing center voltage over three cycles at a processing rate of eight samples per cycle. The input to the memory buffer comes from a differentiator-smoother output, specifically block 154 of FIG. 11 . The maximum unfiltered first order time derivative of the positive sequence swing center voltage is determined from the absolute values of the past three-cycle derivatives saved. In this example, an index with a higher value represents a more recent swing center voltage derivative result. Index (k) represents the present swing center voltage derivative, while index (k−23) represents a swing center voltage derivative at the time instant of −23 samples.
The lower portion of FIG. 13 illustrates a nineteen sample memory buffer used to store the ultra-fast second order time derivative of the positive sequence swing center voltage (discontinuity detector) for the past 2.375 cycles, as output from block 160 of FIG. 11 . A control bit, referred to as Freeze Averages in FIG. 11 , is used with this calculation. When the control bit is not asserted, the average ultra-fast second order time derivative of the positive sequence swing center voltage is calculated as the average of absolute values of saved second derivatives from samples k−1 to k−18, skipping the present sample k. When the control bit is asserted, the average ultra-fast second order time derivative of the positive sequence swing center voltage takes the previous calculated value.
FIG. 14 illustrates a preferred circuit implementation of the swing signature detector logic 118 . The swing signature detector logic 118 is designed to block or inhibit the operation of the distance elements prone to operate improperly during power swing conditions. The swing signature detector logic 118 uses the most overreaching distance element subject to power swing blocking as the detection boundary. Therefore, no additional power swing detection zones are required. At the time that the most overreaching distance element picks up, the swing signature detector logic 118 evaluates the unfiltered first order time derivatives of the positive sequence swing center voltage saved in the three cycle memory buffer as illustrated in FIG. 13 and finds the signature differentiating power swings from faults. If the swing signature detector logic 118 determines that the distance element pickup is due to a power swing, then the logic asserts its output signal SSD, which, in turn, causes the distance element output stage to block the distance element from operation. If there is a power swing condition on the system, but the swing does not cause any distance elements subject to power swing blocking to pick up, then the swing signature detector logic 118 is inactive.
Preferably, the swing signature detector logic 118 and, for that matter, the rest of the power swing detection logic, is processed after the distance element logic and before the final distance element output (trip) logic.
The preferred circuit implementation of the swing signature detector logic 118 includes a plurality of logic gates including comparators 210 - 219 (with comparators 212 - 216 not shown in FIG. 14 ), OR gates 220 - 223 , AND gates 224 - 237 , counters 238 - 239 , and summation element/adder 240 . These circuit elements are preferably coupled as shown in FIG. 14 .
In operation, if the transmission line section protected is not in a single-pole-open condition (SPO is LOW), the AND gates 228 - 231 and OR gate 239 monitor the most overreaching phase distance element subject to power swing detection and responsive relay blocking. When the most overreaching phase distance element picks up, the AND gate 239 allows the element to output if the output of AND gate 235 is LOW. The output of AND gate 235 is conditioned upon system unbalanced protection logic picking up and its pickup duration being less than eight cycles without the single-pole-open (SPO) condition, as determined by AND gates 232 , 235 and counter 239 . The system unbalanced protection logic monitors the forward unbalanced condition on the system and is further explained with reference to FIG. 17 . If that logic picks up at the time that the most overreaching phase distance element picks up, then the distance element indicates a fault condition because power swings are a balanced phenomenon without a single-pole-open condition. If the logic picks up for more than eight cycles without the single-pole-open condition on the line section under protection, then the condition indicates a possible single-pole-open condition of adjacent lines and will reset the system unbalanced protection logic on the phase distance element outputs through AND gate 239 .
During a single-pole-open condition on the protected line, the AND gates 224 - 227 and OR gate 221 monitor the most overreaching ground distance element subject to power swing detection and responsive relay blocking. When the most overreaching ground distance element picks up, AND gate 233 allows the element to output if the output of OR gate 220 is asserted. OR gate 220 has inputs of PSBA, PSBB and PSBC elements that indicate a single-pole-open condition for each phase without any additional faults on the line. PSBA, PSBB and PSBC elements are further explained with reference to FIG. 18 .
The most overreaching phase and ground distance elements subject to power swing detection and responsive relay blocking are inputs to OR gate 223 , with its output connected to the input of the counter/timer 238 . Counter 238 has an instantaneous pickup time and a half cycle dropout time, as shown. Its purpose is to de-bounce the distance elements that may drop out and then pick up again for a brief duration during a clearance of a fault.
At the rising edge of the output of counter 238 , provided the output of AND gate 236 is asserted, the output of AND gate 237 asserts to indicate a power swing condition. When a system operates at equilibrium/steady state, the swing center voltage time derivative is relatively close to zero. If a fault occurs on the system, the swing center voltage time derivative will jump to a relatively high value. Considering the total filtering delay of a typical microprocessor relay, the maximum swing center voltage time derivative caused by a fault will appear in the first cycle of the three cycle memory buffer. Comparators 210 - 217 compare the absolute values of the unfiltered first order time derivatives of the positive sequence swing center voltage from the oldest one cycle of the buffer with the maximum unfiltered first order time derivative of the positive sequence voltage, as derived from FIG. 13 . The output of comparator 219 is asserted if the number of these derivatives that are greater than five percent of the maximum value is greater than or equal to two, as shown. The purpose of comparator 218 is to ensure that the maximum unfiltered first order time derivative of the positive sequence swing center voltage is a valid value instead of noise. The output of AND gate 236 goes HIGH upon the occurrence of a disturbance on the system prior to distance element pickup.
FIG. 15 illustrates the preferred circuit implementation for the dependable power swing detector 114 . For a system with a small stability margin, the system may start to swing during an external multi-phase fault. Depending on the system stability reserve margin, the fault clearance time and the fault type, the angle difference between two equivalent machines may already swing to a large value at the time of the fault clearance. Therefore, by the time the fault is cleared, the impedance measured by a distance relay may already reside in a protection zone subject to power swing blocking and the power swing detection logic will fail to operate to block the distance element operation.
Due to the manner in which it operates, the swing signature detector logic 118 will correctly pick up and block the distance element in such situation if the initial fault is in the reverse direction. However, the swing center voltage slope detector 116 and the swing signature detector 118 will fail to block the distance element if the initial fault is in a forward distance zone subject to power swing detection and responsive relay blocking and the system starts to swing inside this distance zone after the fault is cleared.
The dependable power swing detector logic 114 is designed to deal with these difficulties. As shown in FIG. 15 , the preferred circuit implementation of dependable power swing detector logic 114 includes a plurality of logic gates, including comparators 250 - 251 , OR gates 252 - 256 , AND gates 257 - 268 , and counters 269 - 276 . The circuit elements are preferably coupled as shown in FIG. 15 .
The dependable power swing detector logic 114 is responsive to the detection of an external multi-phase fault. If the detected external multi-phase fault is on the system for two and one-half cycles without the power swing detection and responsive relay blocking operation and the local trip, then the dependable power swing detection logic will be initiated. If the zone-2 phase distance element picks up within one and one-half cycles of a reverse fault clearance, or if the zone-1 phase element picks up or the second time derivative of the swing center voltage has a sudden change after the dependable power swing detector logic is initiated, then a power swing condition is declared.
Following the declaration of a power swing condition by the dependable power swing detector logic 114 , if the zone-2 distance element stays in a pickup state for more than one second, or the rate change of the positive-sequence impedance Z 1 is less than a predetermined minimum threshold for one and one half power cycles, then the power swing detection signal resets. These reset conditions are safety measurements in case an internal multi-phase fault does occur following the clearance of the external multi-phase fault. The rate of change of the impedance is a good indication if the disturbance evolves into an internal multi-phase fault. However, as a last line of defense, if the time that the zone-2 element picks up is determined to exceed a predetermined relatively very long period of time (one second in this example), the logic resets the power swing detection signal even if the positive sequence impedance rate change condition is not satisfied.
The dependable power swing detection logic 114 considers external multi-phase faults only because the transient stability margin of a power system is sized under severe transient disturbances, such as three-phase or multi-phase faults.
Referring to FIG. 15 , in operation, DIR 3 is a relay setting that sets the direction of zone-3 distance elements. If DIR 3 =F, then the zone-3 distance elements detect faults that are in the forward direction. If DIR 3 =R, then the zone-3 distance elements detect faults that are in the reverse direction. M 3 P is a zone-3 phase distance element. The state of M 3 P is HIGH if any multi-phase faults are detected inside the zone-3 protection region. DIR 4 and M 4 P are the direction setting and phase distance element for zone-4 protection. DIR 5 and M 5 P are the direction setting and phase distance element for zone-5 protection. M 2 P is the zone-2 phase distance element that is fixed to the forward direction. MAB 12 , MBC 12 and MCA 12 are zone-1 phase distance elements with a fixed security pickup count.
FF 1 is the output of the circuit illustrated in FIG. 10 . When a power swing condition has been detected by the no-setting power swing detection circuit illustrated in FIG. 10 , FF 1 is in a HIGH state. TRIP is the output of the relay trip logic. When TRIP is in a HIGH state, this is an indication that the relay has closed its contact output and energized a circuit breaker trip coil. MAB 2 _I, MBC 2 _I and MCA 2 _I are zone-2 phase elements taken before the security counters in the phase zone-2 mho logic.
A two-input AND gate 257 outputs the zone-3 phase distance element, M 3 P, to a three-input OR gate 252 , if the zone-3 direction is set to reverse. Similarly, AND gates 258 , 259 output zone-4 and zone-5 phase distance elements, M 4 P and M 5 P respectively, to OR gate 252 , if their directions are set to reverse-looking. The output of OR gate 252 therefore represents any multi-phase faults behind the relay that are inside zone-3, zone-4 or zone-5 protection regions when they are set as reverse-looking protection elements.
The output of OR gate 252 is coupled to a three-input AND gate 263 , which also receives inputs from existing relay elements, TRIP and FF 1 . The output of AND gate 263 indicates a condition that there is a reverse multi-phase fault without the power swing condition detected and the relay is not issuing a trip output. The output of AND gate 263 is then fed to a counter or delay pickup timer 269 , which has a 2.5-cycle delay pickup time and an instantaneous dropout time. The falling edge of the output of delay pickup timer 269 feeds to a counter or timer 270 , which has an instantaneous pickup timer and a one and one-half cycle delay dropout time, as shown. The output of timer 270 serves as one of the inputs for a two-input AND gate 264 . The other input of AND gate 264 is fed by the output of counter or timer 273 . The input to timer 273 is the output of OR gate 256 , which is a function of MAB 2 _I, MBC 2 _I and MCA 2 _I, identified above. The output of timer 273 is therefore any internal zone-2 phase element pickups that are de-bounced by a 0.25-cycle delay dropout time, as shown.
The two-input AND gates 260 - 262 route zone-3, zone-4 or zone-5 phase distance elements to a four-input OR gate 253 , if their directions are set as forward. Zone-2 phase distance element M 2 P is the fourth input of OR gate 253 . The directionality of zone-2 phase element is fixed as forward-looking only. The output of OR gate 253 therefore represents any multi-phase faults in the front of the relay that are inside zone-2, zone-3, zone-4 or zone-5 protection regions when zone-3, zone-4 or zone-5 are set as forward-looking protection elements.
The output of OR gate 253 is an input to the three-input AND gate 265 . The other two inputs of AND gate 265 come from existing relay elements, TRIP and PSB. The output of AND gate 265 indicates a condition that there is a forward multi-phase fault without the power swing condition detected and the relay is not issuing a trip output. The output of AND gate 265 is then fed to a counter or delay pickup timer 271 , which has a two and one-half cycle delay pickup time and an instantaneous dropout time.
The output of delay pickup timer 271 is fed to one of the inputs of a two-input AND gate 266 . The other input of AND gate 266 is fed by the output of the four-input OR gate 254 . Three of the four inputs of OR gate 254 are three zone-1 phase distance elements, MAB 12 , MBC 12 and MCA 12 . These zone-1 phase elements differ from the normal zone-1 phase distance elements, MAB 1 , MBC 1 and MCA 1 in that MA 12 , MBC 12 and MCA 12 are faster than MAB 1 , MBC 1 , and MCA 1 , respectively. The other input of OR gate 254 is fed by the output of counter or timer 272 , which has a two-processing-count delay pickup time and an instantaneous dropout time. The input of timer 272 is fed by the output of comparator 250 , which is in a HIGH state when the ultra-fast second order time derivative of the positive sequence swing center voltage exceeds two times its average (as calculated in FIG. 13 ), plus 0.06. The output of AND gate 266 represents a condition that either a zone-1 multi-phase fault has been detected, or the second order time derivative of the swing center voltage has a sudden change after a forward overreach zone detects a multi-phase fault for two and one-half power cycles.
The rising edge of the output of AND gate 266 feeds one input of three-input OR gate 255 . When the output of AND 266 transitions HIGH, the input of OR gate 255 goes HIGH for one processing cycle. Otherwise, that input is LOW. Another input of OR gate 255 is fed by the output of AND gate 264 , causing the output of OR gate 255 to go HIGH for one processing cycle upon the output of AND gate 264 transitioning HIGH.
The output of OR gate 255 feeds counter or qualifying timer 276 . Timer 276 has a 0.125-cycle delay pickup time and an instantaneous dropout time. The delay pickup time of timer 273 must be less than the time difference between MAB 12 , MBC 12 and MCA 12 element pickup time and MAB 1 , MBC 1 and MCA 1 element pickup time when their adaptive pickup time is at the upper value.
Comparator 251 , AND gates 267 - 268 , and two counters/timers 274 - 275 form a seal-in and unlatch logic for the output of OR gate 255 . Once the output of OR gate 255 is initially asserted by either a rising edge of the output of AND gate 264 or a rising edge of the output of AND gate 266 , the output of OR gate 255 is sealed in as long as the output of AND gate 268 is in a HIGH state.
The positive input of comparator 251 is fixed as the Z 1 MAG setting, which corresponds to the secondary ohm value of the transmission line under protection. |Z 1 k −Z 1 k-1 |*8*fnom is the absolute value of the rate change of the positive-sequence impedance, Z 1 , scaled to ohms per second. With the assumptions of a maximum power swing detection period of two seconds and the total system impedance equaling one and one-half times the line impedance, the minimum value of this quantity is (3π/8) times Z 1 MAG, which occurs when the phase difference (δ) is equal to one hundred eighty degrees. For convenience, a value of 1.0 may be used to approximate (3π/8). The output of comparator 251 indicates a condition that the time rate change of the positive-sequence impedance is smaller than the minimum value of the rate of change that results from a legitimate power swing condition.
The output of comparator 251 feeds a two-input AND gate 267 . The other input of AND gate 267 is fed by the output of OR gate 255 . Timer 274 has a one and one-half cycle delay pickup time and an instantaneous dropout time, as shown. Timer 274 qualifies the output of AND gate 267 accordingly. This output is asserted when the output of OR gate 255 is HIGH and the impedance rate of change has fallen below a minimum value for at least 1.5 cycles.
The output of timer 267 feeds an active LOW input of a four-input AND gate 268 . AND gate 268 has another active LOW input fed by the output of timer 275 . The input of timer 275 is fed by the output of AND gate 268 , creating a feedback-type relationship, as shown. Timer 275 has a delay pickup time of one second and an instantaneous dropout time, as shown. AND gate has two more inputs, one is fed by the output of timer 273 and the other is fed by the output of OR gate 255 .
When the output of OR gate 255 is asserted and the internal zone-2 elements stay picking up, the output of AND gate 268 will be asserted, provided that the outputs from timers 274 - 275 remain LOW. The output of AND gate 268 feeds OR gate 255 and latches its output. The output of AND 268 can be reset when its output asserts for more than one second or when the impedance rate of change is below a predetermined minimum threshold for more than one and one-half power cycles.
The dependable power swing detection signal DPSB is the final output of the dependable power swing detector 114 . This signal DPSB complements the remainder of the no-setting power swing detection and responsive relay blocking scheme to increase the dependability of stable power swing detection after an external multi-phase fault is cleared.
FIG. 16 illustrates a preferred circuit implementation of three-phase fault detector 122 , which is included in order to detect the occurrence of three-phase faults during power swing conditions and inhibit the relay blocking function until such time as the detected three-phase fault is cleared. Three-phase fault detector 122 preferably includes a plurality of logic gates, including comparators 280 - 293 , AND gates 284 - 287 , counters or timers 288 - 291 , and OR gate 292 arranged and coupled as shown in FIG. 16 .
The magnitude of the discontinuity detector (|d 2 SCV 1 _UF|) will exceed 0.23 when a change has taken place on the network that could be a fault. The output of timer 228 will agree when this condition exists. Timer 228 has a dropout time of six cycles.
The output of timer 289 will assert only when the following conditions occur for more than two power cycles: the magnitude of the slow first order time derivative of the positive sequence swing center voltage (|dSCV 1 _S|) must fall below 0.01; the magnitude of the positive sequence swing center voltage (SCV 1 ) must fall below 0.1; the flip-flop 128 illustrated in FIG. 10 must be asserted; and the positive sequence impedance (Z 1 ) location must be within a predetermined inner zone.
A three-phase fault is detected if timer 288 and timer 289 are asserted. In response, three-phase fault detection signal DTF will be asserted.
If timer 288 is not asserted and the conditions referenced above causing timer 289 to be asserted last for more than five cycles, the output of timer 290 is asserted, as shown. In response, a three-phase fault is detected and the three-phase fault detection signal DTF is asserted.
If flip-flop 128 (see FIG. 10 ) is asserted, the positive sequence impedance (Z 1 ) is within the predetermined inner zone, the magnitude of the positive sequence swing center voltage is less than 0.1 and all three conditions exist for more than ten cycles, a three phase fault is detected, as determined by AND gate 285 , comparator 283 and timer 291 . Consequently, three-phase fault detection signal DTF is asserted through OR gate 292 .
Referring back to FIG. 10 , when the three-phase fault detection signal DTF is asserted upon the detection of a three-phase fault, the power swing detection signal PSB is inhibited to permit the three-phase fault to be cleared.
During a three-phase fault, the positive sequence swing-center voltage SCV 1 is expected to take a low value. It has been observed that for lines with a lower angle, the positive sequence swing center voltage could exceed 0.1 during a three-phase fault. For this reason, the maximum value of 0.1 or the cosine of the line angle serves as the threshold value for comparators 281 , 283 in FIG. 16 .
FIG. 17 illustrates system unbalanced protection logic 300 designed to detect an unbalanced system condition in the relay forward direction. This logic 300 is preferably incorporated within the swing signature detector logic 118 and is preferably also incorporated in the phase mho logic to reset the power swing detection condition. As illustrated, logic 300 preferably includes comparators 301 , 302 , counters or timers 303 , 304 and AND gate 305 .
The system unbalanced condition represented by the negative-sequence current I 2 is qualified by requiring its magnitude be greater than a 2 (defined herein) times the magnitude of the positive-sequence current I 1 . Setting a 2 is an existing relay setting that is normally set to above normal unbalance of the system coming from different line conductor arrangements and/or untranposed lines. The negative-sequence quantity always has a transient output when there is a line-switching event. The total system filtering and the negative-sequence filtering determine the duration of the transient. With filters used in typical distance relays, the transient duration is less than one and one-half cycles. The timer 303 is therefore set to qualify the unbalanced condition by requiring the output of comparator 301 to last for more than one and one-half cycles.
Comparator 302 qualifies the quantity of the positive-sequence current by requiring it be greater than 0.1 times the nominal current setting In. During a power swing condition, the phase current magnitude oscillates. To prevent the system unbalanced protection logic from dropping out during a current minimum, timer 304 is set with a half-cycle delay dropout time to support the qualification of the I 1 during a power swing condition.
As shown in FIG. 17 , system unbalanced protection logic 300 asserts if the outputs of timers 303 and 304 and the negative-sequence forward directional element, represented as 32 Q, assert.
FIG. 18 illustrates a representative circuit 320 used to enable blocking of the ground distance elements during a single pole open condition. The outputs of circuit 320 , namely signals PSBA, PSBB and PSBC indicate a single-pole-open condition for each phase without any additional faults on the line. PSBA, PSBB and PSBC are fed to OR gate 220 of the swing signature detector logic illustrated in FIG. 14 . During a single-pole-open condition for a phase without any additional faults on the line, the system may lose its synchronism. Therefore, it is desired to block the ground distance elements during these circumstances using the power swing detection logic output. Should an additional emerging fault occur on the system, it is important to inhibit the power swing blocking function. This single-pole-open power swing blocking logic represented by circuit 320 is designed to fulfill this purpose. Circuit 320 includes AND gates 322 - 329 and OR gates 330 - 334 . The logic uses the angle difference between the zero-sequence current and the negative-sequence current. This angle difference stays in certain sections on the angle plane for different poles opened. In particular, the angle difference is between positive and negative sixty degrees when A-phase is open, the angle difference is between sixty degrees and one hundred eighty degrees when B-phase is open, and the angle difference is between negative sixty degrees and negative one hundred eighty degrees when C-phase is open. If the measured angle difference does not match the pole that is opened, then the mismatch indicates an additional fault during the single-pole-open condition. Should a phase-phase-ground fault occur on the remaining two phases during a single-pole-open condition, the angle difference between the zero-sequence current (I 0 ) and negative-sequence current (I 2 ) will not deviate from the angle sector that matches the pole opened. In this situation, the same three-phase fault detector is used to inhibit the power swing blocking function from blocking operation of the distance elements.
During a single-pole-open condition, if there is a sufficient amount of load current, the induced zero-sequence current and negative-sequence current will cause elements 50 GF, 50 GR, 50 QF and 50 QR to be picked up. Based on the logic between OR gates 330 , 331 and AND gate 323 , if 50 GF or 50 GR and 50 QF or 50 QR pick up, the AND gate 323 will assert its output, which in turn, will assert the output of AND gate 322 under this condition. A HIGH output from AND gate 322 will enable the calculation of the angle difference between the zero-sequence current and negative-sequence current to be made, as illustrated in FIG. 18 . This HIGH output from AND gate 322 will also open the select one of AND gates 324 - 326 to output the angle sector decision.
If the calculated angle difference is within the range reserved for A-phase (±60°) and the pole opened is A-phase (i.e., SPOA is asserted), then the output of AND gate 327 will assert. If the calculated angle difference is within the range reserved for B-phase (between 60° and 180°) and the pole opened is B-phase (i.e., SPOB is asserted), then the output of AND gate 328 will assert. If the calculated angle difference is within the range reserved for C-phase (between −60° and −180°) and the pole opened is C-phase (i.e., SPOC is asserted), then the output of AND gate 329 will assert.
Based on OR gates 332 - 334 , PSBB and PSBC will assert when the output of AND gate 327 , which indicates that there is no additional fault on the system during the A-phase open period, and therefore the B-phase and C-phase ground distance elements can be blocked using the power swing blocking function. Similarly, PSBC and PSBA will assert when the output of AND gate 328 asserts to allow C-phase and A-phase ground distance elements to be blocked using the power swing blocking function. Also, PSBA and PSBB will assert when the output of AND gate 329 asserts to allow A-phase and B-phase ground distance elements to be blocked using the power swing blocking function.
FIG. 19 illustrates a representation for defining the starter zone, namely that zone where the positive sequence impedance (Z 1 ) must lie prior to the declaration of a power swing condition. It will be appreciated that with the subject invention, the area covered by the starter zone is not critical. It is only necessary to define the starter zone such that all mho detectors that are to be blocked during a power swing condition have their characteristic within the starter zone. Accordingly, the starter zone area may simply be defined as the rectangle illustrated by FIG. 19 . In addition, if it is desired to enable the unstable power swing tripping function (i.e., EOOST is not set to N), then the starter zone preferably includes the outermost zone-7 of the unstable power swing tripping function with a margin of twenty percent. Upon occurrence of a power swing, if for the line of interest, the positive sequence impedance does not cross the starter zone, the power swing detection and responsive relay blocking signal (PSB) will not assert and thus the power swing will not be detected.
FIG. 20 illustrates a preferred inner zone corresponding to the zone within five percent around the transmission line extended positive sequence impedance characteristic in the complex plane. A three-phase fault is detected (see FIG. 16 ) only if the positive sequence impedance (Z 1 ) lies within the inner zone. The purpose of the inner zone is therefore to add to the reliability of the three-phase fault detector.
FIG. 21 illustrates the resistive and reactive blinders that are used for the unstable power swing detection and responsive selective tripping or pole slipping function. The logic used to carry out this function takes advantage of already available calculations for the left, right, top, and bottom blinders of the sixth and seventh zones. The settings to be used are R 1 R 6 , R 1 R 7 , X 1 T 6 , and X 1 T 7 . Settings X 1 B 6 and X 1 B 7 can be specified by a user under the advanced settings option. The above settings are not difficult to calculate and do not require any stability studies as long as it is desired to perform an out-of-step trip on-the-way-out (TOWO). The out-of-step tripping on-the-way-in (TOWI) option requires a fast and robust detection of an unstable power swing, and a very accurate relative phase angle difference between equivalent sources to allow tripping before unsafe and dangerous conditions are reached. Therefore, the settings for this option are generally more difficult to calculate. Nonetheless, the application of this TOWI option is infrequent (may be not even applied at all). If a user desires to apply the TOWI option, stability studies to determine the proper settings for right and left hand blinders RR 6 and RR 7 must be performed.
FIG. 22 illustrates a representative logic circuit 350 used to derive logic bits X 6 , X 7 , R 6 , R 7 , RR 6 , RR 7 , RL 6 , and RL 7 , which are defined as zones in the illustration of FIG. 21 . As shown, FIG. 22 includes comparators 351 - 359 , OR gate 360 , and AND gates 361 - 372 . Several calculations related to the zone-6 and zone-7 right, left, top, and bottom blinders serve as inputs for comparators 352 - 359 in FIG. 22 . The formulas for each of these calculations are set forth below:
Zone 6:
Left Hand Blinder : R 1 L 6 _C = R 1 L 6 sin ( Z 1 ANG ) + Im ( Z 1 ) tan ( Z 1 ANG ) Right Hand Blinder : R 1 R 6 _C = R 1 R6 sin ( Z 1 ANG ) + Im ( Z 1 ) tan ( Z 1 ANG ) Top Blinder : X 1 T 6 _C = X 1 T 6 sin ( Z 1 ANG ) - Re ( Z 1 ) tan ( Z 1 ANG ) Bottom Blinder : X 1 B 6 _C = X 1 B 6 sin ( Z 1 ANG ) - Re ( Z 1 ) tan ( Z 1 ANG )
Zone 7:
Left
Hand
Blinder
:
R
1
L
7
_C
=
R
1
L
7
sin
(
Z
1
ANG
)
+
Im
(
Z
1
)
tan
(
Z
1
ANG
)
Right
Hand
Blinder
:
R
1
R
7
_C
=
R
1
R
7
sin
(
Z
1
ANG
)
+
Im
(
Z
1
)
tan
(
Z
1
ANG
)
Top
Blinder
:
X
1
T
7
_C
=
X
1
T
7
sin
(
Z
1
ANG
)
-
Re
(
Z
1
)
tan
(
Z
1
ANG
)
Bottom
Blinder
:
X
1
B
7
_C
=
X
1
B
7
sin
(
Z
1
ANG
)
-
Re
(
Z
1
)
tan
(
Z
1
ANG
)
Still referring to FIG. 22 , each of the top inputs for AND gates 365 - 372 is an inverted output of OR gate 360 . If a three-pole open condition exists (i.e., 3PO is HIGH) or a loss of potential is detected by the relay (i.e., ILOP is HIGH), the output of OR gate 360 is asserted and the logic bits X 6 , X 7 , R 6 , R 7 , RR 6 , RR 7 , RL 6 , and RL 7 are inhibited from asserting.
Each middle input for AND gates 365 - 372 is fed by the output of comparator 351 . Output C 1 must be asserted (logic HIGH) to allow any of the logic bits X 6 , X 7 , R 6 , R 7 , RR 6 , RR 7 , RL 6 , and RL 7 to assert, depending upon the status of the respective bottom input of AND gates 365 - 372 .
X 6 is the zone defined between the top blinder XT 6 and bottom blinder XB 6 illustrated by FIG. 21 . The X 6 bit is the output of three input AND gate 369 . For X 6 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of AND gate 363 must be asserted. The outputs of comparators 356 and 357 must be asserted in order for the output of AND gate 363 to assert. The output of comparator 356 is asserted if the calculated value of X 1 T 6 _C is greater than the imaginary part of the calculated positive-sequence impedance (Z 1 ). The output of comparator 357 is asserted if the calculated value of X 1 B 6 _C is less than the imaginary part of the calculated positive-sequence impedance (Z 1 ).
X 7 is the zone defined between the top blinder XT 7 and bottom blinder XB 7 illustrated by FIG. 21 . The X 7 bit is the output of a three input AND gate 365 . For X 7 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of AND gate 361 must be asserted. The outputs of comparators 352 and 353 must be asserted in order for the output of AND gate 361 to assert. The output of comparator 352 is asserted if the calculated value of X 1 T 7 _C is greater than the imaginary part of the calculated positive-sequence impedance (Z 1 ). The output of comparator 353 is asserted if the calculated value of X 1 B 7 _C is less than the imaginary part of the calculated positive-sequence impedance (Z 1 ).
R 6 is the zone defined between the right blinder RR 6 and left blinder RL 6 illustrated by FIG. 21 . The R 6 bit is the output of a three input AND gate 371 . For R 6 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of AND gate 364 must be asserted. The outputs of comparators 358 and 359 must be asserted in order for the output of AND gate 364 to assert. The output of comparator 358 is asserted if the calculated value of R 1 R 6 _C is greater than the real part of the calculated positive-sequence impedance (Z 1 ). The output of comparator 359 is asserted if the calculated value of R 1 L 6 _C is less than the real part of the calculated positive-sequence impedance (Z 1 ).
R 7 is the zone defined between the right blinder RR 7 and left blinder RL 7 illustrated by FIG. 21 . The R 7 bit is the output of a three input AND gate 367 . For R 7 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of AND gate 362 must be asserted. The outputs of comparators 354 and 355 must be asserted in order for the output of AND gate 362 to assert. The output of comparator 354 is asserted if the calculated value of R 1 R 7 _C is greater than the real part of the calculated positive-sequence impedance (Z 1 ). The output of comparator 355 is asserted if the calculated value of R 1 L 7 _C is less than the real part of the calculated positive-sequence impedance (Z 1 ).
RR 6 is the zone defined to the left of blinder RR 6 illustrated by FIG. 21 . The RR 6 bit is the output of a three input AND gate 370 . For RR 6 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of comparator 358 must be asserted. The output of comparator 358 is asserted if the calculated value of R 1 R 6 _C is greater than the real part of the calculated positive-sequence impedance (Z 1 ).
RR 7 is the zone defined to the left of blinder RR 7 illustrated by FIG. 21 . The RR 7 bit is the output of a three input AND gate 366 . For bit RR 7 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of comparator 354 must be asserted. The output of comparator 354 is asserted if the calculated value of R 1 R 7 _C is greater than the real part of the calculated positive-sequence impedance (Z 1 ).
RL 6 is the zone defined to the right of blinder RR 6 illustrated by FIG. 21 . The RL 6 bit is the output of a three input AND gate 372 . For RL 6 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of comparator 359 must be asserted. The output of comparator 359 is asserted if the calculated value of R 1 L 6 _C is less than the real part of the calculated positive-sequence impedance (Z 1 ).
RL 7 is the zone defined to the right of blinder RR 6 illustrated by FIG. 21 . The RL 7 bit is the output of a three input AND gate 368 . For RL 7 to assert, the output of comparator 351 must be asserted, the output of OR gate 360 must not be asserted, and the output of comparator 355 must be asserted. The output of comparator 355 is asserted if the calculated value of R 1 L 7 _C is less than the real part of the calculated positive-sequence impedance (Z 1 ).
FIG. 23 illustrates the logic diagram of a circuit 400 designed to carry out the unstable power swing detection and selective relay tripping function. As shown, circuit 400 includes AND gates 401 - 413 , OR gates 421 - 425 , flip flops 431 - 436 , and counter 440 .
For the unstable power swing detection logic to function, the output of AND gate 401 must be asserted. Two conditions must be satisfied for the output of AND gate 401 to assert. First, the PSB_I bit, shown in FIG. 10 , must be asserted. Second, the EOOST bit must be enabled and not set to N. The possible EOOST settings are N, I, O, and C. When EOOST is I, trip-on-the-way-in (TOWI) is permitted. When EOOST is O or C trip-on-the-way-out (TOWO) is permitted during the first slip cycle as long as the positive sequence impedance trajectory lies within zone X 6 . When EOOST is C trip-on-the-way-out (TOWO) is permitted after a set number of slip cycles as long as the positive sequence impedance trajectory lies within zone X 7 and outside zone X 6 .
The unstable power detection logic monitors the movement of the calculated positive-sequence impedance (Z 11 ) trajectory during a power swing and tracks it as it moves from the right to the left hand plane of the X-axis in the R-X diagram, or as it moves from the left to the right hand plane of the X-axis of the R-X diagram. In FIG. 23 , the logic comprised of AND gates 401 , 404 , 405 and 406 , OR gate 421 and flip-flops 432 and 433 is responsible for tracking the calculated positive-sequence impedance as it moves from the right to the left hand plane of the X-axis in the R-X diagram. The logic comprised of AND gates 401 , 407 , 408 and 409 , OR gate 421 and flip-flops 434 and 435 is responsible for tracking the calculated positive-sequence impedance as it moves from the left to the right hand plane of the X-axis in the R-X diagram.
AND gates 410 and 411 allow trip-on-the-way-out (TOWO) as long as the calculated positive-sequence impedance lies in zone X 6 . AND gates 410 , 412 and 413 , flip-flop 436 , and pole-slip counter 440 allow trip-on-the-way-out (TOWO) after a set number of slip cycles as long as the positive-sequence impedance lies in zone X 7 and outside zone X 6 .
The logic comprised of AND gates 402 and 403 and flip-flop 431 allow trip-on-the-way-in (TOWI) as long as the calculated positive-sequence impedance lies between zones R 6 and X 6 and EOOST is set to I.
To facilitate an understanding of how this logic works and how it tracks the calculated positive-sequence impedance during a power swing, reference is made to FIG. 21 and an example is provided wherein the areas are defined as follows. Area 1 is defined as that area to the right of blinder RR 7 ; area 2 is defined as that area between blinders RR 6 and RR 7 ; area 3 is defined as that area between blinders RL 6 and RR 6 ; area 4 is defined as that area between blinders RL 6 and RL 7 ; area 5 is defined as that area to the left of blinder RL 7 ; area 6 is defined as that area between blinders XT 6 and XT 7 ; area 7 is defined as that area between blinders XB 6 and XB 7 ; and, area 8 is defined as that area between blinders XT 6 and XB 6 .
The unstable power swing detection circuit 400 asserts its output (OST bit) provided that a power swing has been detected (i.e., PSB_I is asserted), the setting EOOST is not set to N (i.e., EOOST is enabled), and the positive-sequence impedance trajectory travels from the right to the left hand plane of the X-axis in the R-X diagram. Under these circumstances, the output of AND gate 401 is asserted because PSB_I is asserted (HIGH) and EOOST is not set to N. If the positive-sequence impedance trajectory is in areas 1 or 2 , then the RL 6 bit is asserted and the RR 6 bit is not asserted (see FIG. 22 ), which causes the output of AND gate 404 to be asserted and sets the output of flip-flop 432 . If the positive-sequence impedance trajectory moves in zone R 6 , i.e. between blinders RL 6 and RR 6 (in area 3 ), then the output of AND gate 405 is asserted and sets the output of flip-flop 433 .
If the positive-sequence impedance trajectory moves to area 4 (between blinders RL 6 and RL 7 ) and then into area 5 , as soon as RL 6 drops-out, the output of AND gate 406 is asserted and through OR gate 421 , the upper input of AND gate 410 is satisfied. If it is desired to trip-on-the-way-out (TOWO), i.e., EOOST is set to O or C, the only remaining condition necessary for the output of AND gate 410 to be asserted is for the positive-sequence impedance trajectory to move to the left of blinder RL 7 (area 5 ), which will prevent the output of zone R 7 from being asserted. AND gate 411 verifies if the positive-sequence trajectory lies in zone X 6 , i.e. between blinders XT 6 and XB 6 . If that is true, then the output of AND gate 411 is asserted, causing a trip on-the-way-out on the first slip cycle.
Movement of the positive-sequence impedance trajectory from the left to the right hand plane of X-axis in the R-X plane is tracked in a similar manner, but uses the logic of AND gates 407 - 409 and flip-flops 434 and 435 as described herein. The output of AND gate 401 is asserted since PSB_I is asserted and the EOOST setting is enabled (not set to N). If the positive-sequence impedance trajectory is in areas 5 or 4 , then the RR 6 bit is asserted and the RL 6 bit is not asserted, causing the output of AND gate 407 to assert and set the output of flip-flop 434 . If the positive-sequence impedance trajectory moves in zone R 6 , i.e. between blinders RL 6 and RR 6 (in area 3 ), then the output of AND gate 408 is asserted and sets the output of flip-flop 435 .
If the positive-sequence impedance trajectory moves to area 2 (between blinders RR 6 and RR 7 ) and then into area 1 , as soon as RR 6 drops-out, the output of AND gate 409 is asserted and through OR gate 421 , the upper input of AND gate 410 is satisfied. If it is desired to trip-on-the-way-out (TOWO), i.e., the EOOST setting is set to O or C, the only remaining condition necessary for the output of AND gate 410 to be asserted is for the positive-sequence impedance trajectory to move to the right of blinder RR 7 (area 1 ), which will prevent the output of zone R 7 from being asserted. AND gate 411 verifies if the positive-sequence trajectory lies in zone X 6 , i.e. between blinders XT 6 and XB 6 . If so, the output of AND gate 411 is asserted, causing a trip on-the-way-out on the first slip cycle.
Assuming now that the positive-sequence trajectory is moving between blinders XT 6 and XT 7 or between blinders XB 6 and XB 7 , i.e., in zone X 7 and outside of zone X 6 . Under such circumstances, if it is desired to trip after a set number of slip cycles, i.e., setting EOOST is set to C, AND gate 412 is asserted after the positive-sequence impedance trajectory moves across the R-X plane (either from right to left, or left to right) and the pole slip counter 440 is incremented by one count. When the positive-sequence impedance trajectory returns to the right hand plane after the first slip cycle, as soon as it crosses the RR 7 blinder from right to left and RR 7 asserts, flip-flops 432 and 434 are reset and the logic is ready to process the second slip cycle. Following satisfaction of the setting for the pole-slip counter 440 , the output of flip-flop 436 is set. Thereafter, as soon as the positive-sequence impedance trajectory moves outside of zone R 7 , the output of AND gate 413 is asserted, causing a trip-on-the-way-out (TOWO) to occur after a preset number of slip cycles.
Referring now to application of a trip-on-the-way-in (TOWI), this function is accomplished if the following described conditions are satisfied. First, the output of AND gate 401 is asserted if PSB_I is asserted and setting EOOST is not set to N (i.e., EOOST is enabled). If the positive-sequence impedance trajectory moves from left to right, or right to left and enters area 3 , i.e., zone R 6 , the output of AND gate 402 is asserted and the output of flip-flop 431 is set, which causes the bottom input of AND gate 403 to be satisfied. The trip-on-the-way-in (TOWI) will then take place (signified by assertion of the output of AND gate 403 ) if EOOST has been set to I and the positive-sequence impedance trajectory is in zone X 6 , i.e. between blinders XT 6 and XB 6 .
Still referring to FIG. 23 , reset of the PSB_I bit will in turn reset flip-flops 431 - 436 and will also reset pole-slip counter 440 . Flip-flops 432 and 433 will also reset on dropout of RR 7 . Similarly, and flip-flops 434 and 435 will reset on dropout of RL 7 . This is done to allow the tracking of the impedance trajectory on subsequent slip cycles in order to be able to increment the pole-slip counter 440 .
While the several aspects of the inventive subject matter described herein have been described with reference to certain illustrative embodiments, it will be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the illustrative embodiments without departing from the true spirit and scope of the invention, as defined by the following claims. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law.
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A system and method for accomplishing power swing blocking and unstable power swing tripping schemes during disturbances of electrical networks is disclosed. The disclosed system and method eliminates the requirement of stability studies. The no-setting scheme utilizes the swing center voltage of the electrical network to carry out its functions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/626,178, filed Jul. 24, 2008, which is a divisional of application Ser. No. 09/988,860, filed Nov. 21, 2001.
FIELD OF THE INVENTION
[0002] The invention relates to rhinologically active substances which give rise to a refreshing and clearing feeling in the area of the mouth, the throat and the airways, and to preparations which comprise these compounds.
BACKGROUND OF THE INVENTION
[0003] 1,8-Cineole (eucalyptol) is a substance which is used in large amounts as a rhinologically active substance in pharmaceutical preparations, oral care preparations, such as toothpastes and mouthwashes, and confectionery products, such as cough sweets and chewing-gum, especially because of its property of producing a cooling-refreshing and thus clearing feeling in the region of the mouth, the throat and the airways. In addition to this effect, 1,8-cineole (eucalyptol), however, has a strong typical flavor which, because of its pronounced medicinal note, is perceived as unpleasant by many consumers.
[0004] There is, therefore a requirement for substances which, in a similar manner to 1,8-cineole (eucalyptol), produce a cooling-refreshing and thus clearing feeling as a rhinologically active compound in the region of the mouth, the throat and the airways, especially in the nasal cavity, and in the pharyngeal cavity, but which do not have such a strong and unpleasant typical taste.
[0005] The advantage of such rhinologically active substances is that they are universally usable, that is to say can be used in preparations having a multiplicity of aromas of the most varying flavor notes.
[0006] Lower alkyl ethers of isobornane, here particularly of methyl isobornyl ether (Food Chem. Toxicol. 30 (Suppl.), 53S (1992), and of bornane, for example bornyl methyl ether and bornyl ethyl ether, (U.S. Pat. No. 4,131,687) have already been known for a relatively long time as fragrance and aroma substances having fresh, herb-like, rosemary-like or eucalyptus-like sensory properties. However, because of their strong typical flavor, they cannot be used as replacement products for 1,8-cineole (eucalyptol) in the sense described above.
SUMMARY OF THE INVENTION
[0007] New rhinologically active substances have been found, which are part of the formula
[0000]
[0000] wherein
x is 0 or 1,
R 1 denotes an alkyl group having 1 to 4 carbon atoms,
R 2 denotes a methyl or ethyl group and
R 3 denotes a monocyclic carbon system having 5, 6, 7 or 8 carbon atoms that can be unsubstituted or substituted with further alkyl groups having 1 to 4 carbon atoms or alkenyl groups having 2 to 4 carbon atoms,
DETAILED DESCRIPTION OF THE INVENTION
[0008] The inventive new rhinologically active substances are acyclic ethers.
[0009] The alkyl group having 1 to 4 carbon atoms can be methyl, ethyl, propyl, isopropyl, butyl or isobutyl.
[0010] The alkenyl group having 2 to 4 carbon atoms can be vinyl, 2-propenyl, allyl or 2-buten-1-yl.
[0011] The radical R 3 can be unsubstituted or can be substituted, for example, with 1 to 3 methyl groups or with 1 isopropyl group or with 1 methyl group and 1 isopropyl group or with 1 methyl group and 1 isopropyl group or with 1 methyl group and 1,2-propenyl group.
[0012] The inventive rhinologically active substances exhibit an activity comparable to 1,8-cineole (eucalyptol) with respect to a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways, without producing an unpleasant taste sensation.
[0013] These rhinologically active substances, in addition to their activity of producing a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways, exhibit fresh, ethereal, minty, cooling, sweet and fruity flavor notes and are therefore also outstandingly suitable as flavor compounds.
[0014] The fact that the inventive rhinologically active compounds exhibit an activity comparable to 1,8-cineole (eucalyptol), with respect to a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways, was surprising and not predictable to the extent that the inventive ethers do not have the ether linkage within the ring of a cyclic structure like 1,8-cineole (eucalyptol), but have an alicyclic structure wherein the ether linkage is not within the ring.
[0015] Preferred rhinologically active compounds in the context of the present invention are compounds of the formula
[0000]
[0000] wherein
x can have the value 0 or 1,
R 1 denotes a methyl or ethyl group,
R 2 denotes a methyl or ethyl group and
R 3 denotes a monocyclic carbon system having 6 or 7 carbon atoms that can be unsubstituted or substituted with further alkyl groups having 1 to 3 carbon atoms and/or alkenyl groups having 3 carbon atoms.
[0016] The present flavor compounds, render pleasantly tasting flavor compounds which have the activity of causing a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways. The inventive rhinologically active compounds are selected from the group of 1-menthyl methyl ether, d-menthyl methyl ether, dl-menthyl methyl ether, menthyl ethyl ether, menthyl propyl ether, menthyl isobutyl ether, isopulegyl methyl ether, 2-isopropylcyclohexyl methyl ether, 2-isopropylcyclohexyl ethyl ether, 3,3,5-trimethylcyclohexyl methyl ether, 1-(3,3-dimethylcyclohexyl)-ethyl ethyl ether, 1-(3,3-dimethylcyclohexyl)e-thyl propyl ether, and 1-(3,3-dimethylcyclohexyl)ethyl methyl ether.
[0017] The activity of causing a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways, in the case of the inventive rhinologically active compounds, applies to all isomeric forms, that is to say to diastereomers and enantiomers.
[0018] The following acyclic ethers for the inventive rhinologically active compounds are novel:
[0019] Isopulegyl methyl ether, 1-(3,3-dimethylcyclohexyl)ethyl ethyl ether, 1-(3,3-dimethylcyclohexyl)ethyl propyl ether and 1-(3,3-dimethylcyclohexyl)ethyl methyl ether.
[0020] Preparation of the Ethers for the Inventive Rhinologically Active Compounds is Known per se. It can be performed, for example, by etherification of the corresponding alcohols with alkylating agents, such as alkyl halides, alkyl tosylates, alkyl mesylates or alkyl halides in the presence of an equivalent amount of a basic compound. Particularly advantageous here is etherification by the phase-transfer process, which is described, for example, in Angew. Chem. 85, 868-869 (1973), and is carried out as follows: the alcohol to be etherified is vigorously stirred in a nonpolar solvent in the presence of a phase-transfer catalyst, for example tetrabutylammonium iodide, with a 2.5-fold excess of 50% strength sodium hydroxide solution and 1.2-fold excess of an alkylating agent is added. After a customary cleanup, the corresponding ether is obtained, which is separated off from unreacted alcohol by distillation or liquid chromatography.
[0021] To achieve fresh ethereal, minty, cooling, sweet and fruity flavor notes in combination with a refreshing clearing feeling in the mouth, pharyngeal cavity and the airways, the inventive rhinologically active compounds can be combined with one another in pure form, or, in a particularly preferred form, can be combined with aroma substances or flavor substances.
[0022] Suitable aroma substances are both complex natural raw materials, such as extracts and essential oils produced from plants, and fractions and homogeneous substances produced therefrom, and also homogeneous synthetically or biotechnologically produced aroma substances.
[0023] Examples of natural raw materials are, for example:
[0024] peppermint oils, spearmint oils, Mentha arvensis oils, aniseed oils, clove oils, citrus oils, cinnamon bark oils, winter green oils, cassia oils, davana oils, spruce needle oils, eucalyptus oils, fennel oils, galbanum oils, ginger oils, camomile oils, cumin oils, rose oils, geranium oils, sage oils, yarrow oils, star anise oils, thyme oils, juniper berry oils, rosemary oils, angelica root oils, and fractions of these oils.
[0025] Examples of homogeneous aroma substances are, for example:
[0026] anethole, menthol, menthone, isomenthone, menthyl acetate, menthofuran, mint lactone, eucalyptol, limonene, eugenol, pinene, sabinene hydrate, 3-octanol, carvone, gamma-octalactone, gamma-nonalactone, germacrene-D, viridiflorol, 1,3E,5Z-undecatriene, isopulegol, piperitone, 2-butanone, ethyl formate, 3-octyl acetate, isoamyl isovalerate, hexanol, hexanal, cis3-hexenol, linalool, alpha-terpineol, cis and trans carvyl acetate, p-cymol, damascenon, damascone, rose oxide, dimethyl sulfide, fenchol, acetaldehyde diethyl acetal, cis-4-heptenal, isobutyraldehyde, isovaleraldehyde, cis-jasmone, anisaldehyde, methyl salicylate, myrtenyl acetate, 2-phenylethyl alcohol, 2-phenylethyl isobutyrate, 2-phenylethyl isovalerate, cinnamaldehyde, geraniol, nerol. In the case of chiral compounds, the aroma substances can be present as racemate or an individual enantiomer or as enantiomer-enriched mixture.
[0027] Examples of other flavor substances which can be advantageously combined with the inventive rhinologically active substances are, for example, substances having a physiologically cooling action, that is to say substances which cause an impression of cold in the mucous membranes. Such substances having a cooling action are, for example, l-menthol, 1-isopulegol, menthone glycerol acetal, menthyl lactate, substituted menthane-3-carboxamides (for example N-ethylmenthane-3-carbox amide), 2-isopropyl-N,2,3-trimethylbutanamide, substituted cyclohexanecarboxamides, 3-menthoxy-1,2-propanediol, 2-hydroxyethylmenthyl carbonate, 2-hydroxypropylmenthyl carbonate, N-acetylglycine menthyl ester, menthylhydroxycarboxylic esters (for example menthyl 3-hydroxybutyrate), menthyl monosuccinate, 2-mercaptocyclodecanone, menthyl 2-pyrrolidin-5-one carboxylate.
[0028] The inventive rhinologically active substances can be present in the aroma or flavor substance compositions at a content of 0.1 to 100% by weight. Preference is given to a content of 0.1 to 70% by weight; particular preference is given to a content of 0.5 to 40% by weight.
[0029] The aroma or flavor substance compositions comprising the inventive rhinologically active substances can be used in pure form, as solutions, or else in specially prepared form, and incorporated into ready-to-use products.
[0030] Suitable solvents are, for example, ethyl alcohol, 1,2-propylene glycol, triacetin, benzyl alcohol and fatty oils, for example coconut oil or sunflower seed oil.
[0031] The aroma or flavor substance compositions comprising the inventive rhinologically active substances can also comprise additives and aids, for example preservatives, pigments, antioxidants, anticaking agents, thickeners etc.
[0032] In particular prepared forms, the aroma or flavor substance compositions comprising the inventive rhinologically active substances can be bound to a carrier, spray-dried or else encapsulated.
[0033] In the bound form, the aroma or flavor substance compositions can be bound on or in a carrier, for example sodium chloride, sugar, starches or sugar melts.
[0034] The spray-dried form is produced from the liquid compositions by producing an emulsion with addition of defined amounts of a carrier, preferably biopolymers such as starch, modified starches, maltodextrin and gum arabic. This emulsion is dried in spray-dryers by very fine distribution with uniform temperature application. A powder results having the desired loading of liquid composition.
[0035] The encapsulated form is also produced from the liquid compositions by adding a carrier. Various technologies exist by which capsules can be produced. The most familiar are extrusion, spray-granulation and coazervation. The particle sizes customarily extend from 10 to 5 mm. The most familiar capsule materials are various starches, maltodextrin and gelatin. In these capsules, the liquid or solid aroma or flavor substance compositions are enclosed and can be released by various mechanisms such as use of heat, pH shift or chewing pressure.
[0036] The inventive rhinologically active substances are suitable for producing preparations of the most varied flavors, particularly for use in aroma compositions having a cooling-refreshing mint-like flavor. The mint compositions are essentially characterized by a content of peppermint oils, Mentha arvensis oils, spearmint oils, eucalyptus oils, 1,8-cineole (eucalyptol), menthol and substances having a physiologically cooling activity.
[0037] The contents of the individual composition constituents of the mint compositions can vary here generally between 0.1 and 99.9%.
[0038] Mint compositions which are preferably used are those having 1 to 90% by weight of menthol, 1 to 60% by weight of menthone, 1 to 90% by weight of peppermint or Mentha arvensis oils, 1 to 90% by weight of spearmint oils, 1 to 90% by weight of eucalyptol or eucalyptolcontaining eucalyptus oils, 0.5 to 70% by weight of the inventive rhinologically active substances, for example menthyl methyl ether, isopulegyl methyl ether or the like and 0.5 to 70% by weight of substances having a physiologically cooling action.
[0039] Mint compositions which are particularly preferably used are those having 20 to 60% by weight of menthol, 5 to 30% of menthone, 5 to 60% by weight of peppermint or Mentha arvensis oils, 5 to 60% by weight of spearmint oils, 2 to 50% by weight of eucalyptol or eucalyptol-containing eucalyptus oils, 0.5 to 40% by weight of the inventive rhinologically active substances, for example menthyl methyl ether, isopulegyl methyl ether or the like and 1 to 30% by weight of substances having a physiological cooling action.
[0040] Substances having a physiological cooling action can be the above-described, in which case they are used individually or as mixtures. If mixtures are used, these are generally mixtures, for example, of menthone glycerol acetal, menthyl lactate, substituted menthyl-3-carboxamides (for example N-ethylmenthyl-3-carboxamide), 2-hydroxyethylmenthyl carbonate and 2′-hydroxypropylmenthyl carbonate.
[0041] Generally, mixtures are used which have 1 to 99% by weight of menthone glycerol acetal, 1 to 99% by weight of menthyl lactate, 1 to 99% by weight of N-ethylmenthyl-3-carboxamide, 1 to 99% by weight of 2-hydroxyethylmenthyl carbonate and 1 to 99% by weight of hydroxypropylmenthyl carbonate.
[0042] Preference is given to mixtures having 1 to 70% by weight of menthone glycerol acetal, 1 to 70% by weight of menthyl lactate, 1 to 70% by weight of N-ethylmenthyl-3-carboxamide, 1 to 70% by weight of 2-hydroxyethylmenthyl carbonate and 1 to 70% by weight of 2-hydroxypropylmenthyl carbonate.
[0043] By adding other aroma substances, for example of the sweet, sweet-aromatic, fresh, fruity types, or if appropriate, of other flavors also, these mint compositions can be modified in flavor, with the content by weight of the added aroma substances generally being 0.001 to 50% by weight, based on the weight fraction of minty compounds and cooling compounds. Preference is given to an addition of 0.01 to 30% by weight, particularly preferably an addition of 0.1 to 10% by weight, based on the weight fraction of the minty and cooling substances.
[0044] By using the inventive rhinologically active substances in such compositions, the content of the eucalyptus oils and of 1,8-cineole (eucalyptol) and thus the strong medicinal flavor note can be reduced, without reducing the refreshing clearing feeling in the mouth, pharyngeal cavity and the airways. The perception of freshness which is produced by the inventive rhinologically active substances in the airways, in the mouth and in the pharyngeal cavity is of longer duration than that caused by 1,8-cineole (eucalyptol).
[0045] It is noteworthy, here, that the flavor intensity and roundness of flavor of the mint compositions are increased by using the inventive rhinologically active substances, and the cooling action of the substances having a physiological cooling action is intensified.
[0046] The preparations comprising the inventive rhinologically active substances can advantageously be used, especially in oral care compositions, such as toothpastes and mouthwashes, chewing-gum, foods, such as confectionery and sweets for sucking, luxury consumption merchandise, such as tobacco, pharmaceutical preparations, nasal sprays.
[0047] The content of the preparations comprising the inventive rhinologically active substances typically comprises 0.0001 to 10% by weight of rhinologically active substances. The content of the preparations comprising the inventive rhinologically active substances is, in ready-to-use mouthwashes 0.01 to 1% by weight, particularly preferably 0.1 to 0.3% by weight. In mouthwash concentrates, the content of the compositions comprising the inventive rhinologically active substances is between 0.01 and 20% by weight, preferably 0.1 to 10% by weight, particularly preferably 3 to 5% by weight. In toothpastes and chewing-gum the compositions comprising the inventive rhinologically active substances are used at a concentration between 0.1 and 5% by weight, preferably 0.5 to 2% by weight, particularly preferably between 0.8 and 1.5% by weight. In sweets for sucking, the content of the compositions comprising the inventive rhinologically active substances is between 0.01 and 2% by weight, preferably 0.05 to 1% by weight; particularly preferably between 0.1 and 0.5%.
[0048] Toothpastes that are flavored with the compositions comprising the inventive rhinologically active substances generally consist of an abrasive system (abrasives or polishes), for example silicic acids, calcium carbonates, calcium phosphates, aluminium oxides and/or hydroxyl apatites; surface-active substances, for example sodium lauryl sulphate, sodium lauryl sarcosinate and/or cocamidopropylbetaine; humectants, for example glycerol and/or sorbitol; thickeners, for example carboxymethyl cellulose, polyethylene glycols, carrageenans and/or Laponites®, sweeteners, for example saccharin; stabilizers; and active compounds, for example sodium fluoride, sodium monofluorophosphate, tin difluoride, quaternary ammonium fluorides, zinc citrate, zinc sulphate, tin pyrophosphate, tin dichloride, mixtures of various pyrophosphates, triclosan, cetylpyridinium chloride, aluminium lactate, potassium citrate, potassium nitrate, potassium chloride, strontium chloride, hydrogen peroxide and/or sodium bicarbonate.
[0049] Chewing-gum that is flavored with the compositions comprising the inventive rhinologically active substances generally consists of a chewing-gum base, that is to say a chewing mass which becomes plastic on chewing; sugars of various types; sugar substitutes; sweeteners; sugar alcohols; humectants; thickeners; emulsifiers; and stabilizers.
[0050] When finished products that comprise the compositions having the inventive rhinologically active substances are used, it is found that the inventive rhinologically active substances or the compositions comprising the inventive rhinologically active substances are particularly suitable for freshening the breath and neutralizing or reducing bad breath.
[0051] The use of the inventive rhinologically active substances or the compositions comprising the rhinologically active substances in oral care products, for example mouthwashes and toothpastes, and chewing-gum, leads to unpleasant, especially bitter, taste impressions being masked or neutralized, as are caused, for example, by substances such as triclosan, zinc citrate, zinc sulphate, polyphosphates and pyrophosphates, bicarbonates, strontium salts and potassium salts, tin pyrophosphate, tin chloride, aluminium lactate, hydrogen peroxide, fluorides, vitamins, cetylpyridinium chloride, and emulsifiers, for example particularly sodium lauryl sulphate, sodium lauryl sarcosinate and cocamidopropylbetaine, and sweeteners, for example aspartame, saccharin, acesulfame-K, sorbitol; xylitol, cyclamates (for example sodium cyclamate), sucralose, alitame, neotame, thaumatin, neohesperidin DC, maltitol, lactitol or chewing-gum bases.
[0052] A further positive property of the inventive rhinologically active substances which must be emphasized is their stability in toothpastes based on chalk or bicarbonate which, because of their alkaline pH, are difficult to flavor.
[0053] The inventive rhinologically active substances and the compositions comprising the inventive rhinologically active substances are also suitable, however, for use in pharmaceutical preparations, for example nasal drops and nasal sprays or embrocations. The compositions comprising the inventive rhinologically active substances are suitable, in particular, for masking the bitter taste of medicaments.
EXAMPLES
[0054] The examples below are intended to illustrate the use of the inventive rhinologically active substances. However, the use of the inventive rhinologically active substances is not restricted to the examples cited.
Example 1
Preparation of the Alkyl Ethers
[0055] General Instructions:
[0056] 1 mol of the alcohol to be etherified is dissolved in 400 ml of toluene and stirred vigorously after addition of 2.6 mol, of 50% strength sodium hydroxide solution and 2 g of tetrabutylammonium iodide. At a bottom temperature of a maximum of 45° C., 1.2 mol of alkylating agent is added in the course of 1 h. The mixture is then stirred for a further 3 h at this temperature. If dialkyl sulphates were used as alkylating agent, ammonia is added to destroy them and the mixture is stirred for a further 30 min at room temperature. After addition of water, the phases are separated. The solvent is taken off from the organic phase and the residue is fractionated by distillation. The pure ethers are obtained by redistillation via a split-tube column. In this manner the following ethers were prepared:
[0000]
Compound:
Mass spectrum:
Menthyl methyl ether
m/z =
170
155
138
123
95
85
81
67
55
45
41
%
1
2
45
19
36
100
49
18
27
15
28
Menthyl ethyl ether
m/z =
184
138
123
113
99
95
81
71
55
41
%
2
36
12
8
100
20
26
28
18
20
Menthyl propyl ether
m/z
198
138
123
113
95
81
71
55
41
%
2
46
16
100
26
33
63
22
29
Menthyl isobutyl ether
m/z
212
138
127
123
95
83
81
71
57
55
41
%
2
43
76
21
34
38
53
100
43
28
34
2-Isopropylcyclohexyl methyl ether
m/z
156
141
124
113
109
99
95
81
71
67
55
41
%
5
12
100
16
58
21
23
60
90
36
25
56
2-Isopropylcyclohexyl ethyl ether
m/z
170
155
127
124
109
99
95
85
81
67
57
41
%
8
16
24
100
55
18
20
96
50
26
75
38
1-(3,3-Dimethylcyclohexyl)ethyl ethyl ether
m/z
184
123
81
73
69
55
45
41
28
%
2
16
8
100
7
10
59
14
10
1-(3,3-Dimethylcyclohexyl)ethyl propyl ether
m/z
198
183
123
87
81
69
55
45
41
%
1
2
16
93
9
14
13
100
23
1-(3,3-Dimethylcyclohexyl)ethyl methyl ether
m/z
170
155
123
110
95
81
69
59
55
41
%
1
3
13
5
6
9
7
100
10
12
3,3,5-Trimethylcyc lohexyl methyl ether
m/z
156
141
124
109
99
85
67
58
55
41
%
4
3
29
61
87
100
23
18
28
30
Isopulegyl methyl ether
m/z
168
153
136
121
111
98
93
85
81
67
55
41
%
18
13
9
41
30
34
28
100
24
21
23
25
Example 2
Production of a Toothpaste Flavoring of the Eucalyptus Menthol Type, Using Menthyl Methyl Ether
[0057] The following were mixed:
[0000]
0.5
parts by weight
camphor
3
parts by weight
anethole
6
parts by weight
peppermint oil of the Mentha arvensis type
2
parts by weight
menthyl lactate
2
parts by weight
2-hydroxyethylmenthyl carbonate
2
parts by weight
2-hydroxypropylmenthyl carbonate
20
parts by weight
1,8-cineole (eucalyptol)
64.5
parts by weight
1-menthol
[0058] In a second mixture batch, the 1,8-cineole (eucalyptol) content was replaced by 1-menthyl methyl ether. Both flavorings are incorporated at a concentration of 1.3% by weight into a standard toothpaste mix based on silicic acid. Both types of toothpaste were tested under conditions of practice by an expert panel trained in sensory testing. The result showed that the flavoring containing 1-menthyl methyl ether and without 1,8-cineole (eucalyptol) markedly decreased the strongly medicinal taste, without the taste impression of freshness in the airways, mouth and pharyngeal cavity being reduced. Overall, the second flavoring led to a clearer longer-lasting taste impression with more roundness and volume.
[0059] Comparable effects are obtained if isopulegyl methyl ether, 3,3,5-trimethylcyclohexyl methyl ether or 1-(3,3-dimethylcyclohexyl)ethyl methyl ether were used instead of 1-menthyl methyl ether.
Example 3
Production of Toothpaste Flavoring of the Wintergreen Type Using Menthyl Methyl Ether
[0060] The following were mixed:
[0000]
10
parts by weight
anehtol
5
parts by weight
peppermint oil of Mentha arvensis type
5
parts by weight
peppermint oil of Mentha piperita type
25
parts by weight
methyl salicylate
40
parts by weight
1-menthol
15
parts by weight
1-menthyl methyl ether
[0061] The flavoring was incorporated at a concentration of 1.3% by weight into a standard toothpaste mix based on silicic acid. The toothpaste was tested under conditions of practice by an expert panel trained in sensory testing. The results showed that the flavoring gave a taste impression of high intensity and long-lasting duration, a pronounced markedly refreshing, clearing feeling being perceived in the airways, in the mouth and in the pharyngeal cavity.
Example 4
Production of a Chewing-Gum Flavoring Using 1-Menthyl Methyl Ether
[0062] The following were mixed:
[0000]
40 parts by weight
peppermint oil of the Mentha arvensis type
20 parts by weight
1-menthone
20 parts by weight
1-menthol
20 parts by weight
1-menthyl methyl ether
[0063] The flavoring was incorporated at a concentration of 1.5% by weight into a sugar-free standard chewing-gum base. The chewing-gum was tested for a sensory quality by a trained expert panel. It was found that addition of 1-menthyl methyl ether gave a markedly refreshing clearing feeling in the airways, in the mouth and in the pharyngeal cavity, and the taste roundness and intensity of the peppermint flavoring was markedly increased.
[0064] Although the invention has been described in detail in the foregoing 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 limited by the claims.
|
Acyclic compounds containing an ethers functionality external to the ring can be used as rhinologically active substances. In the regions of the mouth, the throat and the airways they produce a refreshing and clearing feeling.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to novel polyaniline derivatives soluble in organic solvents and also to their production process.
2. Description of the Related Art
Investigation has been conducted in recent years with a view toward applying polyanilines as new electronic materials or electroconductive materials in a wide variety of fields such as cell electrode materials, antistatic materials, electromagnetic shielding materials, functional devices--e.g., photoelectric transducers, optical memories and various sensors, display devices, various hybrid materials, transparent electroconductors, and various terminal equipment.
Polyanilines however have a highly developed π-conjugated system. They are hence accompanied by the serious drawbacks that they are insoluble in most organic solvents and do not melt even when heated due to having a rigid main chain and the existence of strong interaction and many strong hydrogen bonds between polymer chains and also have poor moldability and permit neither cast molding nor coating.
They are therefore formed, for example, into electroconductive composite materials by impregnating base materials of a desired shape--such as fibers, porous bodies or the like of high-molecular materials--with their corresponding aniline monomers and then bringing the monomers into contact with a suitable polymerization catalyst or subjecting the monomers to electropolymerization to polymerize the monomers. As an alternative, such aniline monomers are polymerized in the presence of powder of a thermoplastic polymer to obtain similar composite materials.
In the meantime, polyanilines soluble in N-methyl-2-pyrrolidone alone has also been synthesized by suitably choosing the polymerization catalyst and reaction temperature [M. Abe et al.: J. Chem. Soc.., Chem. Commun., 1989, 1736). These polyanilines are however practically insoluble in other general organic solvents so that their application field is limited.
Further, processes for introducing substituents into N-positions which comprise by reacting reduced polyaniline with alkyl halides or acylhalides are described in U.S. Ser. No. 07/693,268 now U.S. Pat. No. 5,100,977, Japanese Patent Applications 115162/1990 and U.S. Ser. No. 07/693,867. These processes however have drawbacks that dedoping treatment is required after conclusion of the reaction because of forming hydrogen chloride during the reaction, and consequently, they cause deterioration of yield and require troublesome steps. Moreover, the polyaniline derivatives produced are impossible to reform themselves because the substituents introduced into nitrogen atoms contained in the polyaniline have no reactivity.
SUMMARY OF THE INVENTION
The present invention has been completed with a view toward overcoming the problems described above.
An object of the present invention is therefore to provide a novel polyaniline derivative having reactive groups as side chains, which is soluble in general organic solvent or water and has excellent processability in casting, coating or impregnation, etc. Another object of the present invention is to provide a process for producing the novel polyaniline derivative without formation of impurities such as hydrogen halide, etc. during production steps.
As a result of earnest investigation with a view toward overcoming the above problems, the present inventor has found that the polyaniline derivative having reactive groups as side chains, which is soluble in general organic solvents or water and has excellent processability in casting, coating or impregnation, etc. can be easily produced by reacting a reduced polyaniline with an oxirane compound, an aziridine compound, a thiirane compound, an isocyanate compound, an isothiocyanate compound or a cyclic carboxylic acid anhydride compound, leading to the completion of the present invention. The present inventor has simultaneously found that such an polyaniline derivative can be obtained without formation of impurities such as hydrogen halides during the production steps, leading to the completion of the present invention.
Each polyaniline derivative according to the present invention is a novel polymer, which is a polymer composed of a structural unit represented by the following formula (I) ##STR3## wherein m and n are each an integer of 0 or more but m and n are not zero simultaneously, and a structural unit represented by the following formula (II) ##STR4## wherein Z means a group represented by the formula --CHR 1 --CHR 2 --X, --C(═W)--NH--R 1 or --C(═0)--Y--COOM, wherein R 1 and R 2 denote each a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted aryl group or a substituted or unsubstituted benzyl group, X denotes an oxygen atom, a sulfur atom or NH, W denotes an oxygen or a sulfur atom, M represents a hydrogen atom or an alkali metal, and Y denotes a substituted or unsubstituted o-phenylene group, --CR 1 ═CR 2 --or --CHR 1 --CHR 2 --, R 1 and R 2 being the same meaning as defined above, said high polymer having a degree of substitution of the N-hydrogen atoms of k/(n+2m+k)=0.001-0.5 wherein k is a number of the structural unit represented by the formula (II), and a polymerization degree of n+2m+k=7--2000.
The above polyaniline derivative of the present invention can be produced by reacting a reduced polyaniline with at least one compound represented by the following formula (III), (IV) or (V) ##STR5## wherein X, W, Y, R 1 and R 2 have the same meanings as defined in the formula (I).
Described in more detail, a polyaniline is treated with ammonia to convert the polyaniline to a soluble polyaniline, which is then treated with excess hydrazine to convert it to a reduced polyaniline. After the reduced polyaniline is dissolved in an amide solvent or dispersed in an aromatic solvent or an ether solvent, at least one compound represented by the above formula (III) (IV) or (V) is added to introduce the substituent group Z to one or more of the nitrogen atoms of the reduced polyaniline.
The polyaniline derivative of the present invention is soluble in organic solvents and has excellent processability, for example, film formability, coating applicability, impregnation ability. Furthermore the polyaniline derivative of the present invention can be used in various fields, because it easily reacts with other materials because of having a functional reactive group in the substutuent introduced into the nitrogen atoms thereof. The production process of the present invention has advantages that it produces the polyaniline in a high purity without requiring a step of removing impurities because of not forming impurities during the production steps.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will hereinafter be described in detail.
Usable for the production of the polyaniline derivative according to the present invention a polyaniline which has been obtained by oxidative polymerization of aniline using ammonium persulfate or the like as an oxidizing agents at a low temperature, for example, in the range of from -20° C. to 50° C. and which has a number average molecular weight of 2,000-500,000 (as measured by GPC in N-methyl-2-pyrrolidone as a solvent and converted relative to polystyrene). First of all, the polyaniline is treated with ammonia to convert it to a soluble polyaniline. The soluble polyaniline is then treated with excess hydrazine to prepare a reduced polyaniline. The term "reduced polyaniline" means a reduced product of the above polyaniline as obtained by the oxidative polymerization, said reduced product containing a hydrogen atom bonded to each of all nitrogen atoms contained in the polyaniline. The hydrazine treatment can be effected by dispersing the soluble polyaniline in water, adding hydrazine in an amount at least equivalent to, preferably three times the nitrogen atoms in the polyaniline under a nitrogen atmosphere and then stirring the resultant mixture at 0°-30° C. for 24 hours.
The reduced polyaniline thus obtained is soluble in N-methyl-2-pyrrolidone or N,N-dimethylacetamide but is practically insoluble in other general organic solvents, for example, chloroform and tetrahydrofuran.
Next, the reduced polyaniline was dissolved in an amide solvent or dispersed in an ether solvent or concentrated hydrochloric acid. The substitution reaction can be conducted by adding at least one of the compound represented by the formula (III)-(V) to the resultant solution or dispersion and then stirring the thus-obtained mixture in a temperature range of from -10° C. to 100° C., preferably 40°-80° C. under a nitrogen atmosphere for few hours -2 days.
Usable, exemplary amide solvents include N-methyl-2-pyrrolidone, N,N-dimethylacetamide, N,N-dimethylformamide, hexamethylphosphoric triamide, 1,3-dimethyl-2-imidazolidinone. Usable, illustrative aromatic solvents include benzene, toluene, xylene, ethylbenzene and tetralin. Further, usable ether solvents include ether, tetrahydrofuran and dioxane.
In the formulas (III)-(V), R 1 and R 2 may be identical or different each other, which denote each a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted aryl group or a substituted or unsubstituted benzyl group.
Exemplary, substituted or unsubstituted alkyl groups include linear alkyl groups such as ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl hexadecyl, docosyl; branched alkyl groups such as isobutyl, isopentyl, neopentyl, isohexyl; cyclic alkyl groups such as cyclohexyl; and those obtained by substituting one or more of their hydrogen atoms with a like number of halogen atoms and/or cyano, nitro, alkoxyl, ester and/or hydroxyl groups.
Example of substituted or unsubstituted alkeyl groups include butenyl, pentenyl and hexenyl groups and those obtained by substituting one or more of their hydrogen atoms by a like number of halogen atoms and/or cyano, nitro, alkoxyl, ester and/or hydroxyl groups.
Illustrative, substituted or unsubstituted aryl groups include a phenyl group and those obtained by substituting one or more of the hydrogen atoms of a phenyl group with a like number of halogen atoms and/or alkyl, phenyl, cyano, nitro, alkoxyl, ester, and/or hydroxyl groups.
Examples of one or more substituent groups in the substituted benzyl group include halogen atoms and/or cyano, nitro, alkoxyl, ester, and/or hydroxyl groups.
Preferred, specific examples of the compounds represented by the above formulas (III)-(V) include the following compounds. Preferred examples of oxirane compounds include propylene oxide, 1,2-dodecylene oxide, styrene oxide, epichlorohydrin, epibromohydrin, glycidyl metacrylate, and the like.
Preferred examples of aziridine compounds include aziridine, 2-ethyl aziridine, and the like.
Preferred examples of thiirane compounds include thiirane, 2-ethyl thiirane, and the like.
Preferred examples of isocyanate compounds and isothiocyanate compounds include n-propyl isocyanate, n-butyl isocyanate, octyl isocyanate, dodecyl isocyanate, p-chlorophenyl isocyanate, anisyl isocyanate, n-propyl isothiocyanate, n-butyl isothiocyanate, octyl isothiocyanate, dodecyl isothiocyanate, p-chlorophenyl isothiocyanate, anisyl isothiocyanate, and the like.
Preferred examples of carboxylic acid internal anhydride compounds include phthalic anhydride, 3-nitorophthalic anhydride, maleic anhydride, diphenylmaleic anhydride, succinic anhydride, n-octylsuccinic anhydride, 3-sulfophthalic anhydride, alkali or ammonium salt thereof, and 4-sulfophthalic anhydride, alkali or ammonium salt thereof, and the like.
In the present invention, when the carboxylic acid internal anhydride compounds are used, the hydrogen atoms in the carboxyl group and sulfonic acid group, if be existent, can be easily converted into alkali metals or ammonium groups after conclusion of reaction. Namely, a reaction mixture after conclusion of the reaction is poured in alcohol to precipitate the product, which is then taken out and dried to obtain a polyaniline derivative in which M in the formula (V) is hydrogen atom. The hydrogen atom in M is then converted into alkali metal or ammonium group by treating the resultant polyaniline with an aqueous solution of alkali metal hydroxide such as sodium hydroxide or an aqueous alcohol solution.
In the present invention, the substitution reaction caused by the compound represented by the formula (III), (IV) or (V) can be conducted preferably in such a manner that substituent groups Z can be introduced to 0.1-50% of the nitrogen atoms contained in the reduced polyaniline. If the substitution degree is less than 0.1%, the polyaniline derivatives do not have sufficient solubility in organic solvents. If it beyond 50%, it becomes difficult to exhibit conductivity by doping.
It is desirable to subject the N-substituted polyaniline derivative, which has been obtained as described above, to undoping treatment as a post treatment with aqueous ammonia.
Each polyaniline derivative according to the present invention, which can be produced as described above, is soluble not only in N-methyl-2-pyrrolidone and N,N-dimethylacetamide but also in halogenated hydrocarbon solvents such as chloroform, dichloroethane and dichloromethane and ether solvents such as tetrahydrofuran. Using a solution of the polyaniline derivative in one of these solvents, a good selfstanding film can be obtained by casting. The films so formed shows conductivity as high as 10 -3 -10 1 S/cm after it had been doped in a protonic acid such as hydrochloric acid, sulfuric acid, fluoroboric acid or perchloric acid.
EXAMPLES
The present invention will hereinafter be described by following examples.
EXAMPLE 1
(1) Production of reduced polyaniline
4.1 g of aniline and 21.9 g of concentrated hydrochloric acid were dissolved in water to give 100 ml of an aniline solution. The aniline solution was chilled to -5° C. 21.9 g of concentrated hydrochloric acid and 6.28 g of ammonium persulfate were also dissolved in water to give 100 ml of a solution. The latter solution was also chilled to -5° C. and was then slowly added dropwise to the aniline solution, followed by stirring at 5° C. for 4 hours. The thus-obtained polyaniline having a number average molecular weight of 12,000 (as measured by GPC in N- methyl-2-pyrrolidone as a solvent and converted relative to polystyrene) was washed thoroughly with water, followed by undoping treatment with aqueous ammonia.
The resulting soluble polyaniline was dispersed in 200 ml of water, followed by the addition of 50 ml of hydrazine in a nitrogen atmosphere. The mixture thus obtained was continuously stirred for 24 hours at room temperature. The resultant solid precipitate was collected by filtration and then dried, whereby a reduced polyaniline of a grayish white color was obtained.
(2) Production of polyaniline with substituted nitrogen atoms
1 g of the reduced polyaniline so obtained was completely dissolved in 30 ml of N-methyl-2-pyrrolidone. After the reaction system having been thoroughly purged with nitrogen gas, propylene oxide was added in an amount of 0.64 g (100% by mol to nitrogen atoms in the reduced polyaniline), and the resultant mixture was stirred at 80% for 12 hours so that they were reacted. The reaction mixture was poured into 1 litter of water while the resulting mixture was stirred. The resulting precipitate was collected by filtration, dried and then subjected to undoping treatment with aqueous ammonia, whereby a polyaniline derivative with substituted nitrogen atoms was obtained in an amount Of 1.2 g. From the yield of the reaction, the degree Of substitution of N-hydrogen atoms was found to be 31%. The alcoholic hydroxyl group in the substituted group was confirmed by the existence of an IR absorption at 3355 cm -1 .
The polyaniline derivative was soluble in N-methyl-2-pyrrolidone and also showed high solubility in organic solvents such as chloroform, dichloroethane, dichloromethane and tetrahydrofuran. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, chloroform, dichloroethane, dichloromethane, tetrahydrofuran and methanol.
EXAMPLE 2
1 g of the reduced polyaniline used in Example 1 was dispersed in 30 ml of 6N hydrochloric acid. 1.56 g of glycidyl methacrylate was added to the resultant dispersion, which was stirred at 80° C. for 12 hours so that they were reacted. The resulting precipitate was collected by filtration, dried and then subjected to undoping treatment with aqueous ammonia, whereby a polyaniline derivative with substituted nitrogen atoms was obtained in an amount of 1.4 g. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 26%. The alcoholic hydroxyl group in the substituted group was confirmed by the existence of an IR absorption at 3355 cm -1 .
The polyaniline derivative was soluble in N-methyl-2-pyrrolidone and also showed high solubility in organic solvents such as chloroform, dichloroethane, dichloromethane and tetrahydrofuran. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 1.
Example 3
A polyaniline derivative with substituted nitrogen atoms (1.5 g) was obtained in a similar manner to Example 1 except that styrene oxide (1.3 g) (100% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of propylene oxide. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 389%. The alcoholic hydroxyl group in the substituted group was confirmed by the existence of an IR absorption at 3355 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 1. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 1.
EXAMPLE 4
A polyaniline derivative with substituted nitrogen atoms (1.7 g) was obtained in a similar manner to Example 1 except that 1,2-dodcylene oxide (2 g) (100% by mol to nitrogen atoms contained in the reduced pplyaniline) was used in lieu of propylene oxide. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 34%. The alcoholic hydroxyl group in the substituted group was confirmed by the existence of an IR absorption at 3355 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 1. From a solution of the polyaniline derivative i chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 1.
EXAMPLE 5
A polyaniline derivative with substituted nitrogen atoms (1.6 g) was obtained in a similar manner to Example 2 except that epichlorohydrin (1.02 g) (100% gy mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of glycidyl methacrylate. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 59%. The alcoholic hydroxyl group in the substituted group was confirmed by the existence of an IR absorption at 3355 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 1. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.02 S/cm after having been doped with sulfuric acid.
Further, the fill before the doping was successfully dissolved in the same organic solvents as in Example 1.
EXAMPLE 6
A polyaniline derivative with substituted nitrogen atoms (1.2 g) was obtained in a similar manner to Example 1 except that aziridine (0.47 g) (100% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of propylene oxide. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 42%. The primary amino group in the substituted group was confirmed by the existence of absorptions at 3365 and 3290 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 1. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 1.
EXAMPLE 7
A polyaniline derivative with substituted nitrogen atoms (1.2 g) was obtained in a similar manner to Example 1 except that 2-ethyl aziridine (0.789 g) (100% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of propylene oxide. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 26%. The primary amino group in the substituted group was confirmed by the existence of IR absorptions at 3365 and 3290 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 1. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0:01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in example 1.
EXAMPLE 8
1 g of the reduced polyaniline used in Example 1 was completely dissolved in 30 ml of N-methyl-2-pyrrolidone. After the reaction system having been thoroughly purged with nitrogen gas, thiirane and silver halide were added in amounts of 0.66 g (100% by mol to nitrogen atoms contained in the reduced polyaniline) and 0.01 g, and the resultant mixture was stirred at 50° C. for 5 hours to that they were reacted. The reaction mixture was poured into 1 litter of water while the resulting mixture was stirred. The resulting precipitate was collected by filtration, dried and then subjected to undoping treatment with aqueous ammonia, whereby a polyaniline derivative with substituted nitrogen atoms was obtained in an amount of 1.3 g. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 64%. The mercapto group in the substituted group was confirmed by the existence of an IR absorption at 2565 cm -1 .
The polyaniline derivative was soluble in N-methyl-2-pyrrolidone and also showed high solubility in organic solvents such as chloroform, dichloroethane, dichloromethane and tetrahydrofuran. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, chloroform, dichloroethane, dichloromethane, tetrahydrofuran and methanol.
EXAMPLE 9
A polyaniline derivative with substituted nitrogen atoms (1.3 g) was obtained in a similar manner to Example 8 except that 2-ethyl thiirane (0.97 g) (100% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of thiirane. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 31%. The mercapto group in the substituted group was confirmed by the existence of an R absorption at 2565 cm -1 .
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 8. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 1.
EXAMPLE 10
1 g of the reduced polyaniline used in example 1 was completely dissolved in 30 ml of N-methyl-2-pyrrolidone. After the reaction system having been thoroughly purged with nitrogen gas, n-propyl isocyanate was added in an amount of 0.47 g (60% by mol to nitrogen atoms contained in the reduced polyaniline), and the resultant mixture was stirred for 6 hours so that they were reacted. The reaction mixture was poured into 1 litter of water while the resulting mixture was stirred. The resulting precipitate was collected by filtration, dried and then subjected to undoping treatment with aqueous ammonia, whereby a polyaniline derivative with carbamoylated nitrogen atoms was obtained in an amount of 1.2 g. Carbamolylated structure of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1650 and 3400 cm -1 . From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 42%.
The polyaniline derivative was soluble in N-methyl-2-pyrrolidone and also showed high solubility in organic solvents such as chloroform, dichloroethane, dichloromethane and tetrahydrofuran. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.07 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, chloroform, dichloroethane, dichloromethane and tetrahydrofuran.
EXAMPLE 11
A polyaniline derivative with substituted nitrogen atoms (1.4 g) was obtained in a similar manner to Example 10 except that dodecyl isocyanate (1.2 g) (50% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of n-propyl isocyanate. Carbamoylated structure o the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1650 and 3400 bm -1 . From the filed of the reaction, the degree of substitution of N-hydrogen atoms was found to be 33%.
The resultant polyaniline derivative showed high solubility fin the same organic solvents as described in Example 10. From a solution of the polyaniline derivative n chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.02 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 12
A polyaniline derivative with substituted nitrogen atoms (1.2 g) was obtained in a similar manner to Example 10 except that p-chlorophenyl isocyanate 0185 g (50% by mol to nitrogen atoms in the reduced polyaniline) was used in lieu of n-propyl isocyanate. Cabamoylated structure o the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1650 and 3400 cm -1 . From the shield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 25%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.09 S/cm after having been doped the sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 13
A polyaniline derivative with substituted nitrogen atoms (1.3 g) was obtained in a similar manner to Example 10 except that anysyl isocyanate (0.82 g) (50% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of n-propyl isocyanate. Carbamoylated structure of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1650 and 3400 cm -1 . From the yield of he reaction, the degree of substitution of N-hydrogen atoms was found to be 37%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 14
A polyaniline derivative with substituted nitrogen atoms (1.2 g) was obtained in a similar manner to Example 10 except that n-propyl isothiocyanate (0.82 g) (50% by mol to nitrogen atoms contained in the reduced polyaniline) was housed in lieu of n-propyl isocyanate. Thiocabamoylated structure of the resultant polyaniline derivative was confirmed by the existence of an IR absorption at 1250 cm -1 . From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 36%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution o the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0:07 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 15
A polyaniline derivative with substituted nitrogen atoms (1.5 g) was obtained in a similar manner to Example 10 except that dodecyl isothiocyanate (1.2 g) (50% by mol to nitrogen atoms contained in the reduce polyaniline) was used in lieu of n-propyl isocyanate. Thiocarbamoylated structure of the resultant polyaniline derivative was confirmed by the existence of an IR absorption at 1250 cm -1 . From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 40%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.009 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 16
A polyaniline derivative with substituted nitrogen atoms (0.93 g) was obtained in a similar manner to Example 10 except that p-chlorophenyl isothiocyanate 1.32 g (50% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of n-propyl isocyanate. Thiocarbamoylated structure of the resultant polyaniline derivative was confirmed by the existence of an IR absorption at 1250 cm -1 . From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 34%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.01 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 17
A polyaniline derivative with substituted nitrogen atoms (1.1 g) was obtained in a similar manner to Example 10 except that anysyl isothiocyanate (0.90 g) (50% by mol to nitrogen atoms in the reduced polyaniline) was used in lieu of n-propyl isocyanate. Thiocarbamoylated structure of the resultant polyaniline derivative was confirmed by the existence of an IR absorption at 1250cm -1 . From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 11%.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 10. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.1 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 10.
EXAMPLE 18
1 g of the reduced polyaniline used in Example 1 was completely dissolved in 30 ml of N-methyl-2-pyrrolidone. After the reaction system having been thoroughly purged with nitrogen gas, succinic anhydride was added in an amount of 0.553 g (50% by mol to nitrogen atoms contained in the reduced polyaniline), and the resultant mixture was stirred at 60° C. for 6 hours so that they were reacted. The reaction mixture was poured into 1 litter of methanol while the resulting mixture was stirred. The resulting precipitate was collected by filtration, dried. The yield was 1.453 g. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 41%. N-Substituted structure of the resultant polyaniline derivative was confirmed by the existence of IR IR absorptions at 1660 cm -1 assigned to amide groups, 3100-2000 cm 1 assigned to aniline groups and 1595 cm 1 assigned to a carboxylic acid ions.
The polyaniline derivative was soluble in N-methyl-2-pyrrolidone and also showed high solubility in organic solvents such as chloroform, dichloroethane, dichloromethane and tetrahydrofuran. It was soluble in a 0.1 N aqueous solution of sodium hydroxide. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.07 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, chloroform, dichloroethane, dichloromethane and tetrahydrofuran.
EXAMPLE 19
A polyaniline derivative having carboxyl group containing substituent in nitrogen atoms (1.618 g) was obtained in a similar manner to Example 18 except that phthalic anhydride (0.814 g) (50% by mol to nitrogen atoms in the reduced polyaniline) was used in lieu of succinic anhydride. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 38%. N-Substituted structure of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1660cm -1 assigned to amide groups, 3100-2000 cm -1 assigned to aniline groups and 1595 cm -1 assigned to carboxylic acid ions.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 18. It was soluble in a 0.1 N aqueous solution of sodium hydroxide. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.06 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in organic solvents such as N-methyl-2-pyrrolidone, N,N-dimethylacetamide, chloroform, dichloroethane, dichloromethane and tetrahydrofuran.
EXAMPLE 20
A polyaniline derivative having carboxyl group containing substituent in nitrogen atoms (1.458 g) was obtained in a similar manner to Example 18 except that maleic anhydride (0.538 g) (50% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of succinic anhydride. From the yield Of the reaction, the degree Of substitution of N-hydrogen atoms was found to be 42%. N-Substituted state of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1660 cm -1 assigned to amide groups, 3100-2000 cm -1 assigned to anilinium groups and 1595 cm assigned to carboxylic acid ions.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 18. It was soluble in a 0.1 N aqueous solution of sodium hydroxide. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.09 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 18.
EXAMPLE 21
A polyaniline derivative having carboxyl group containing substituent in nitrogen atoms was obtained in a similar manner to Example 18 except that 4-sulfophthalic anhydride (1.25 g) (50% by mol to nitrogen atoms contained in the reduced polyaniline) was used in lieu of succinic anhydride. The resultant polyaniline derivative had polymerization degree: n+m+k=200. The yield was 2.00 g From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 40%. N-Substituted state of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1660 cm -1 assigned to amide groups, 3100-2000 cm -1 assigned to anilinium groups, 1595 cm -1 assigned to carboxylic acid ions and 1190 and 1063 cm -1 assigned to sulfonic acid ions.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 18. It was soluble in a 0.1 N aqueous solution of sodium hydroxide. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.07 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvents as in Example 18.
EXAMPLE 22
A polyaniline derivative having carboxyl group containing substituent in nitrogen atoms (1.025 g) was obtained in a similar manner to Example 21 except that 4-sulfophthalic anhydride was used in an amount of 0.025 g (1% by mol to nitrogen atoms in contained the reduced polyaniline) instead of 1.25 g. The resultant polyaniline derivative had polymerization degree: n+m+k=190. From the yield of the reaction, the degree of substitution of N-hydrogen atoms was found to be 1%. N-Substituted structure of the resultant polyaniline derivative was confirmed by the existence of IR absorptions at 1660 cm -1 assigned to amide groups, 3100-2000 cm -1 assigned to anilinium groups, 1595 cm -1 assigned to carboxylic acid ions and 1190 and 1063 cm -1 assigned to sulfonic acid ions.
The resultant polyaniline derivative showed high solubility in the same organic solvents as described in Example 18. It was soluble in a 0.1 N aqueous solution of sodium hydroxide. From a solution of the polyaniline derivative in chloroform, a self-standing film was satisfactorily obtained by casting. Its conductivity was 0.5 S/cm after having been doped with sulfuric acid.
Further, the film before the doping was successfully dissolved in the same organic solvent as in Example 18.
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Novel polyaniline derivatives soluble in general organic solvents are provided without impairment of the inherent good properties of the corresponding polyanilines. The novel polyaniline derivatives are polymers which substantially comprises a structural unit represented by the following formula (I) ##STR1## wherein m and n are each an integer of 0 or more but m and n are not zero simultaneously, and a structural unit represented by the following formula (II) ##STR2## wherein Z means a group represented by the formula --CHR 1 --CHR 2 --XH, --C(═W)--NH--R 1 or --C(═0)--Y--COOM, where R 1 and R 2 denote each a hydrogen atom, a substituted or unsubstituted alkyl group, a substituted or unsubstituted alkenyl group, a substituted or unsubstituted aryl group or a substituted or unsubstituted benzyl group, X denotes an oxygen atom, a sulfur atom or NH, W denotes an oxygen or a sulfur atom, M represents a hydrogen atom or an alkali metal, and Y denotes a substituted or unsubstituted o-phenylene group, --CR 1 ═CR 2 --or --CRH 1 --CHR 2 --, R 1 and R 2 being the same as described above, said polymer having a degree of substitution of the N-hydrogen atoms of k/(n+2m+k)=0.001-0.5 wherein k is a number of the structural unit represented by the formula (II), and a polymerization degree of n+2m+k=7-2000.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to apparatus of applying glaze granules to tiles while the tiles are at a high temperature.
1. Description of Related Art
Processes for tile-making are known which provide for depositing granular glaze onto the tiles during their baking by heat treatment, i.e., when the tiles are at a high temperature. A process of such kind forms the subject matter of U.S. patent application Ser. No. 07/099,479 which is a divisional application of U.S. patent application Ser. No. 06/816,751 (now abandoned) which is based on Italian patent application No. 19589 A/85, in the name of the present applicant.
The application of the granular glaze onto the hot tiles entails numerous technological, physical and chemical problems, since account has to be taken of the fact that, in this process, tile temperature is propitiously higher than the melting temperature of at least some of the components of the glaze.
A glaze dispenser facing the tiles is subject to heating as a result of the heat transferred to it by the hot tiles, either by irradiation or by convection.
It might be supposed that this difficulty could be overcome by distancing the glaze dispensing unit from the tile, thus reducing the heat transferred to it by the tile. However, applicant has found that the increased fall height of the granular glaze gives rise to serious disadvantages.
In particular, if the fall height is excessive, the glaze becomes selectively subject to the action of the rising air-streams which occur in the presence of the hot tiles located within an environment of lower temperature; the granules of smaller size are clearly more likely to be slowed down by such rising air-streams, which effect a separation between the granules of different size. In addition, when the larger sized granules fall from a greater height, they acquire excessive kinetic energy which causes them to bounce off the surface of the tiles: as a result also of the rising air-stream, the separation of the small-sized fractions during the fall can cause uneven application due to a not perfectly constant and uniform fall of the glaze granules.
Moreover, the fact that the granules falling too fast tend to bounce off the tiles causes unevenness of application on the surface of the tile, especially proximal to the edges, and to the leading edge in particular, it follows that all these factors make it necessary for the fall height of the granular glaze to be kept as small as possible.
The spontaneous heating of the dispenser placed in close proximity to the incandescent tiles is therefore unacceptable, since the nearer the temperature of the dispenser comes to that of the tiles the more the lowest-melting fraction of the glaze is caused to melt, with the result that the melted glaze agglomerates in the dispenser and, in practice, prevents a correct dispensing of the glaze.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above problems by embodying a dispenser which applies the glaze with a low-height fall onto hot tiles, that is, tiles at temperatures higher than the melting temperatures of the glaze. This solution is based on the observation that the largest amount of heat transferred by the hot tile to the dispenser above it is irradiated heat.
It is known that heat exchange by irradiation is proportional to the difference between the fourth powers of the temperatures of the bodies between which the heat exchange takes place.
It has been experimentally demonstrated that cold glaze that falls onto the surface of the tiles drastically reduces irradiation, since the outer surface of the tile come to consist of the glaze itself which, in turn, absorbs heat from the surface layer of the tile. In particular, the rise in temperature of the glaze (with regard to which account has to be taken of the specific heat of the glaze and of the melting temperature of its melting component) clearly occurs with a resulting lowering of the temperature of the surface layer of the tile, there being borne in mind also the low heat transmission coefficient of ceramic bodies such as the support or substrate of a tile.
Thus, according to the invention, the glaze is poured as a cascade or curtain from at least a free edge of a cooled inclined surface, on which the granular glaze fed onto its surface can flow. The glaze is fed onto this inclined surface and, when it falls thereon, loses the kinetic energy that it may possess.
Advantageously, the free edge from which the glaze falls onto the tiles is disposed proximally to the perimetral area of the dispenser, which area is directionally placed so as to lie in the path of approach of the tiles proximal to the dispenser, so that the tiles pass below the body of the dispenser after having received at least part of the granular glaze. In particular, the dispenser comprises a plurality of edges from which the glaze falls, which are transversal to the tile after feed direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics of the invention will become more apparent from an examination of the embodiments thereof described below, with reference to the appended drawings, in which:
FIG. 1 is a diagrammatic, general prespective view of a preferred embodiment of the apparatus according to the invention;
FIGS. 2 and 3 are, respectively, side and plan views of the apparatus in FIG. 1; and
FIGS. 4 and 5 are partial views similar to those in FIG. 2, for different embodiments of the apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1 to 3, a diagrammatic illustration is shown of a furnace 10 in which is formed a gap 11 housing a dispenser device in accordance with the invention, indicated overall by 12.
The furnace 10 is a roller furnace which is per se conventional and therefore not described in detail; the numeral 13 diagrammatically indicates power-driven rollers which transport tiles 14 to within the furnace, wherein they are given the appropriate heat treatment, as is particularly explained in the Italian Patent Application No. 19589 A/85 in the name of the same applicant.
The dispenser 12 is provided with rollers 20 for conveying the tiles, which are an extension of the rollers 13 of the furnace 10.
The means employed for driving the rollers in rotation is not here shown in detail; it can be, for example, of the chain or gear type, as is usual in this kind of equipment.
Preferably, and as shown in the Figures, the rollers 20 have a discontinuous surface so that each tile 14 is supported by resting on discrete points.
This discontinuity can be advantageously obtained by embodying the rollers 20 with a central tubular part thereof 21 provided with annular projections 22, the tubular part 21 being traversed by cooling liquid, preferably water, fed to and taken off from the opposing ends thereof through pipes 23 and rotating joints 24, respectively (FIG. 3).
This configuration of the rollers 20 proves useful in preventing their heat deformation in the event of stoppage and subsequent restarting of the rollers bearing the hot tiles, since when the hot tiles 14 arriving from the furnace 10 on the rollers 20 come into contact with the rollers 20 which, if their movement is stopped, cool rapidly, touching the rollers proximally to a longitudinal portion thereof, the latter tend to undergo deformation and to form a convexity proximal to the generating line having the highest temperature. This deformation, which is the result of thermal disequilibrium, has no tendency to self-compensation and indeed in the first few minutes of operation tends to increase and thereafter gradually ceases. In effect, when the rollers 20 roll in order to convey the tiles, the hottest convex portion of them comes into contact with the tiles 14 and this tends to maintain the thermal disequilibrium between the different longitudinal areas of the rollers 20.
The designing of the rollers 20 so as to provide them with a discontinuous support surface prevents this thermal disequilibrium from arising and persisting, and it also sets a limit on the amount of heat transferred from the tiles 14, to the rollers 20 and makes it more possible to cool the latter without appreciably lowering the tile temperature. There has been seen to be particularly suited to maintaining thermal equilibrium of the rollers, an external surface consisting of annular ribs, which also fulfill the function of distributing the heat circumferentially.
The glaze dispenser 12 is provided with a hopper 25 for receiving the granular glaze, at the base of which a feed mechanism, consisting, for example, of a moving wheel 26 of a kind that prevents clogging of the mass, feeds the glaze onto an oscillating sieve 27.
From this sieve 27, the granular glaze falls onto a set of rotating wheels 30 disposed immediately above the surface of the tiles carried by the rollers 20. These rotating wheels 30 are also provided with cooling in the form of a fluid passing through them, in a manner entirely similar to that of the cooling of the rollers 20.
It should be noted that, when the glaze falls onto the rotating wheels 30, it is decelerated, thus reducing its kinetic energy by impact. This means that the height of the feeding mechanism 26 is not very critical, and the mechanism 26 can therefore be mounted at a convenient distance from the tiles 14 so as not to be subject to dangerous overheating, it again being recalled that the possibility of separation between the different glaze phases during the fall and the irregular accumulation of fine glaze fractions must be minimized. Account must also be taken of the fact that the rotating wheels 30 represent a screen against the radiant heat from the tiles.
Proximally to the rotating distributors wheels 30, below the rollers 20, there is provided a hopper 33 for collecting any glaze that passes through the line of side-by-side tiles brought close to the glaze dispenser 12. This hopper 33 should be constructed so as to reduce the occurrence of chimney effects due to the presence of the hot tiles, and, for this purpose, it is useful for the hopper 33 to have traversal partitions 34 and for the outlet mouth for the collected glaze be in seal with the extractor members.
A dispenser structure of this kind has been found to achieve the objects of this invention satisfactorily. Each of the rotating wheels 30 constitutes, in its upward-facing portion, an inclined double surface from which the glaze falls as a cascade or curtain onto the tiles, more specifically, from the edges which come to be formed by the generating lines of the rotating wheels tangential to the vertical planes.
The rotation of the rotating wheels 30 is not critical as regards the dispensing of the glaze, which they could dispense even if stationary. However, the rotation is extremely useful for continuously varying the portion of surface of the wheels 30 that is exposed to the radiant heat coming from the hot tiles. The wheels 30 thus becoming easier to cool, and the rotation also assures that no portion of the wheels 30 reaches temperatures that can trigger the glaze component melting phenomena and that there do not arise any differential expansions that can deform the wheels 30.
According to the invention, the first of the wheels 30 met by the tiles carried on the rollers 20 (from left to right in FIG. 1) is positioned so that it yields the glaze, by means of one of its edges, to the tiles 14 before they enter the area directly below the dispenser proper. As explained above, this first fall of glaze brings about a drastic diminution of the irradiation of the tiles, resulting in a lowering of the temperature of the tile surface layer, while not causing within the tiles any cooling of mass such as to cause significant thermal disequilibria and inner stresses leading to fissures in the finished tiles.
The wheels 30 complex is therefore subjected to a drastically lower irradiation than would be the case if the tiles travelled below them after not being cooled by the fall of the glaze. Moreover, the wheels 30 form a screen that protects the upper parts of the dispenser both from irradiation and convection.
The existence of a plurality of wheels 30 (rather than only one) allows the area of tiles screened off from them to be enlarged, although maintaining the relatively small diameter of the wheels and thus limiting the glaze fall height in accordance with the objects of the invention.
It has been found advantageous to dispense the glaze by fall from several successive edges, and thus also to improve the distribution over the tiles 14. The glaze falling from the first edge of the dispenser onto the hot tile immediately triggers a softening and melting phenomenon, with the result that the glaze falling from edges subsequently met by the tile in its travel has a lower tendency to bounce.
The tiles 14 carried from the furnace on the rollers 13 and then on the rollers 20, of necessity, have a certain longitudinal and transversal spacing between them, the glaze dispensed by the wheels 30 falling in the area of these spaces between tiles being collected by the lower hopper 33 and optionally recycled into the dispenser hopper 25.
The hopper 33 has screens 34 which form a labyrinth for the glaze, deviate the rising air-streams to outside the glaze application area proper, and can be appropriately cooled to subduct the heat received from the lower side of the tiles 14.
As a result of their being cooled and of the smallness of their contact-zones with the tiles 14, the rollers 20 can be maintained at a temperature distinctly lower than the melting temperature of the lowest-melting component of the glaze, thus preventing the glaze from adhering to the surfaces of the rollers 20.
As stated previously, the rotating wheel 30 configuration of the inclined surface for cascade or curtain pouring of the glaze onto the tiles 14 has been seen to be extremely advantageous for the variety of reasons set out hitherto.
As shown in FIGS. 4 and 5, these wheels can, however, be substituted by surfaces 40 featuring edges 41 from which the glaze falls onto the tiles. The surfaces 40 are preferably formed with a hollow space 42 into which cooling liquid is force-circulated, as with the wheels 30.
The surfaces 40 need not necessarily be static. However, in the interests of a satisfactory distribution and freer flow of the glaze, they can be embodied in a vibrating form, for example, mounted solidly with the sieve 27.
It is also advantageous for the surfaces 40 to number more than one, in order to obtain a gradual, progressive distribution of the glaze over the tiles 14, and a better eveness of the layer.
In particular, FIG. 5 shows a first surface 40 toward the tile feed side so that the tiles arrive below the dispenser already coated with glaze, in accordance with what has been explained above. The other surfaces 40, however, are shown facing in the opposite direction, wherein, it has been found that it is advantageous, as regards a more uniform covering of the front and rear sides, for the glaze granules to have a horizontal component in their fall trajectory, parallel to tile feed and in the same direction.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present embodiments of the invention are for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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An apparatus for applying glaze, in the form of granules, to hot tiles, having a dispenser including at least an inclined surface with a pouring edge for cascade or curtain coating of the glaze onto the hot tiles brought below it, preferably conveyed on rollers. Provision is preferably made for successive pouring edges aligned transversally to the tile conveyor system, and respective inclined surfaces, in particular, in the form of rotating wheels, which are internally traversed by cooling liquid.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. national phase of PCT Appln. No. PCT/KR2010/002592 filed Apr. 26, 2010, which claims priority to Korean application 10-2009-0085114 filed on Sep. 9, 2009 the disclosures of which are incorporated in their entirety by reference herein.
TECHNICAL FIELD
The present invention relates to a system and method for making whole soymilk utilizing bean and its skin together, which method comprises grinding the soy beans with their skin into ultra-fine particles, preferably of a nano scale, after metamorphosing the starch component of the bean into a water-soluble dextrin and sterilizing, using a high pressure rotating heat chamber having an external heating means or an electronic heating means, in which the beans are subjected to roasting and extracting the bean at room temperature for rendering the beans to a porous condition.
BACKGROUND OF THE INVENTION
The conventional method for making soybean milk comprises a step for washing of the beans, removing the skins of the beans by immersing them in water, and boiling and extracting by pressing under hydrothermal conditions.
This kind of manufacturing method makes the problems that about ⅓ of a bean is wasted in the form of a sludge, and at the same time, the nutrient component, including the fiber, the inorganic material etc., was discarded in the form of industrial waste.
To overcome the above problems, a patent (KR 1994-002528) was registered, in which is disclosed collection of the solid material comprising the bean curd dregs by using fermentation in order to solve the loss problem of this nutrient-containing component. And, furthermore a patent (KR 2001-41120) was registered, in which is disclosed to dissolve the solid material of the bean curd dregs by use of conjugated enzymes. However, the above methods have problems that the intrinsic malodorous smell and fishy taste of the beans is not eliminated; and it was also uneconomical to throw the expensive enzyme that are used in the production process for soymilk which is marketed at relatively low price.
Also, a patent (JP59-210861) was published to disclose the method for making soymilk in which an emulsion was mixed while heating, mechanically crushing after defacing the bean eliminating the soybean skin by dipping in water and homogenizing with high pressure.
Another patent (KR 10-0822165) was registered and it discloses a method for making a soymilk in which compressing of beans is carried out in a multi-stage operation using high pressure, while heating with steam, after removal of the bean skin during dipping in water and homogenizing dregs together.
However, all of the above methods need complicated processes with many items of equipment; the malodorous smell is not removed and they have not resolved problems of digesting due to the starch component of the bean; and, also, the prior art processes are unable to effect utilizing of the beans'skin which is containing the protein, the soy-oil and the dietary fiber, and this was rather lost as waste.
This is particularly problematic since in the skin of the black bean is contained, a glycitein, a superior anti-ageing component for the health improvement, but rather the soybean skin had been removed due to the lack of processing technology.
Moreover, a patent (KR10-2005-0068463) was released that discloses how to prepare a soft bean curd using live soy bean powder crushed from the raw beans and boiling with water, but this method has problems in which the bean powders are burning in the heating stage and one cannot make soymilk due to difficulties of filtering and coagulating of the starch of the beans after making the soymilk.
Accordingly, in all of the conventional methods for making soymilk using raw beans, with cooking by heating and squeezing, leaving unresolved the malodorous smell, the intrinsic fishy taste and grassy taste of the beans, as well as digesting problems due to the starch component of the beans. This is leading to customer dissatisfaction.
DETAILED EXPLANATION OF THE INVENTION
Object of the Invention
The object of the present invention is to provide the technology for making a soybean milk after metamorphosing the starch component of the bean into water-soluble dextrin and sterilizing the bean with a heat chamber which is roasting the beans by an external heating means or an electronic heating means, after a cleaning process comprising eliminating impurities, washing and drying, and grinding the whole bean including the bean skin together into an ultra-fine bean particle, preferably nano scale.
Thus, this method is providing a technology for eliminating the malodorous smell such as the fishy smell, or the grassy smell contained in conventional soymilk, improving the digestive action of the soymilk, and substantially enhancing the taste by improving the flavor of the soymilk in accordance with one aspect of the invention.
And also, it provides the useful technology for ingesting a superior anti-aging component (Glycitein) contained in the skin of the black soybean for the production of the soymilk.
Moreover, it provides the technology for manufacturing a soft soy bean milk like a cow milk since the particles of the bean are nano-scale minute, the fragrance and scent to be controlled, and making dairy alternatives for replacing the cow milk and dietary products such as a baby food, ice-cream, yoghurt with the soymilk of the invention.
Technical Solutions
The invention relates to a system and arrangement of apparatus for replacing the conventional sterilization process of soybean milk plant, with the heat chamber of the invention, which is configured to sterilize the soybeans with high temperature after a cleaning process of the beans comprising washing, drying and eliminating impurities. Thereby all of the bacteria parasitizing on the bean are eradicated during this process, and it solves the problem that bacteria proliferate in the precipitation process of the conventional process, and reduces the cost of the system installation by making unnecessary of overhead sterilizers for the manufacturing system of the soybean milk.
Moreover, it provides a manufacturing technology for improving the quality of soymilk by solving the digestive trouble problems of the conventional soymilk, due to the starch component of the bean, eliminating the malodorous smell, such as, the fishy smell or the grassy smell contained in the conventional soymilk, and enhancing the taste by improving flavor through the heating process of over 160 degrees centigrade and metamorphosing the starch component of the bean into the water soluble dextrin.
Also, the invention provides the advantage for saving conspicuously the system manufacturing cost by simplifying the manufacturing process that eliminates the complicated process of boiling and cooling of the soy liquid state of the conventional system.
In addition, the invention improves the quality of the soymilk by utilizing the soybean and its skin together that increases the dietary fiber, protein and anti-ageing component, and increases the yield rate of production since the waste of the sludge, such as, bean curd and bean skin are not produced in the process of this invention.
Moreover, the invention provides the technology of dairy alternatives by replacing the cow milk with the soymilk for making various dairy products since the bean particles of the soymilk of this invention are ultra micro-smashed almost to the cow milk level and mouth-taste feelings are similar to cow milk.
Advantageous Effects
The present invention has the effect to solve the digestive trouble problem since the starch of the bean is metamorphosed to the water-soluble dextrin by heating in the heat chamber using a high temperature.
Also, it has the effect that the manufacturing facility system is simplified and the overhead sterilization process becomes unnecessary since the bacteria parasitic on the bean are completely eradicated in the step of the high temperature heating process.
Moreover, it improves the taste of the soymilk and makes it more delicious, since the starch character of the bean is transformed and the intrinsic malodorous smell of the fishy taste and the grassy smell of the bean is substantially eliminated, and these disappear through the process of roasting the beans at a high temperature in the heat chamber and inflating them by excavation to the room temperature.
Besides, it has the price competitive power since the yield rate is improved over 40% in comparison with the existing soymilk production process since all parts of the soybeans including the skins and the sludge are ground together into nano particles.
Moreover, it has the effect that the cost to build the manufacturing facility is significantly reduced since the manufacturing processor is simple, and the extra-high pressure compression process in multi-phase and boiling/cooling processing are not needed.
Particularly, the invention offers the technology for making the black soybean milk by using the dietary fiber of the ampholyte contained in the soybean and the anti-ageing substance (glycitein) contained in the skin of the black soybean for health.
Also, it provides the technology for making dairy alternatives replacing the cow milk with the soymilk by the process that the bean is ultra micro-smashed to the nano scale particles to be mixed with pure water at high speed and homogenizes to obtain the soymilk substantially devoid of malodorous smells and identically so soft similar to the cow milk. Thereby it offers natural vegetable milk for baby foods and for the peoples who are hesitating to drink cow milk due to the animal growth hormone and the antibiotic agent contained in the cow milk.
In addition, the invention provides the technology to make a new healthy beverage for well-being which preserves the nutrient component of the bean, but the intrinsic malodorous smell eliminated due to molecular bond between the nano particles of the bean and water. Thus, it enables to make entirely new beverages having the nutrient component of the bean, and having a new fragrance and scent combined by added materials such as concentrate of natural fruits or extract of functional materials.
BRIEF DESCRIPTION OF THE DRAWING
The brief explanations of drawings are as follows:—
FIG. 1 is a system configuration diagram in accordance with one embodiment of the invention;
FIG. 2 is production process drawing in accordance with one embodiment of the invention;
FIGS. 3 and 4 are indicative of the configuration diagrams of systems of typically manufacturing a third beverage with a system of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures attached hereto, the configuration of the preferred embodiments, the operations and functions are described in details are as follows. FIG. 1 is a system configuration diagram and FIG. 2 is production process drawing in accordance with one embodiment of the invention. FIGS. 3 and 4 are indicative of the configuration diagrams of systems of typically manufacturing a third beverage with a system of the invention.
Referring to FIG. 1 , this invention is comprising; a selecting means ( 101 ) for picking out with care the impure or decayed beans; a cleaning means ( 102 ) for cleaning the beans by washing with water, steam, or air and drying; a heat chamber ( 103 ) for metamorphosing the starch component of the beans into water soluble dextrin and firstly sterilizing the beans by heating; a heating means ( 104 ) for heating to a temperature above 160 degree centigrade with the heating chamber; a ultra-fine grinding means ( 106 ) for grinding the roasted beans to ultra-fine particle, preferably nano scale; a mixing means ( 107 ) for mixing the ultra-fine bean particles and pure water; a homogenizing means ( 110 ) for homogenizing the mixed liquid; a sterilizing means ( 113 ) for secondly sterilizing the homogenized liquid; and a filling means ( 112 ) for filling the mixed liquid in the packaging means ( 113 ).
In the system, the heating chamber may variously be designed according to the capacity, pressure and heating temperature of the chamber that is rotating so as to avoid burning.
The heating means may be further comprising a rotating high pressure heat chamber in which roasting of the beans at a high temperature over 160 degree centigrade is carried out with the external heating means during rotating and a expansion means ( 105 ) for extracting of the beans into the room temperature for inflating the beans to a porous state, so that in the pertaining step for transforming of the beans to a porous state is achieved, as well metamorphosis of the starch of the bean to the water-soluble dextrin, and thus achieves an improved taste of the soymilk and make it more delicious due to elimination of the intrinsic malodorous smell, also the fishy taste, and the grassy smell of the bean, by means of said processing.
Also the same effect can be obtained even if the heating means comprises an industrial electronic heating means with microwaves for heating the beans to a high temperature to a temperature above 160 degree centigrade.
Also, wherein the mixing neans ( 107 ) of this invention, further comprising a high speed agitating means for combining the ultra-fine particles of the bean and the ultra-fine particle or extract of various materials with pure water, a new mixed beverage, having various taste ingredients and effects can be achieved by mixing.
In the configuration, the ultra-fine grinding means ( 106 ) for grinding the beans of which the starch component of the beans was transformed into the water-soluble dextrin, may be designed in various model according to the process for making the soymilk.
Referring FIG. 2 , in the system composed as described above, the method for making the soymilk is comprising the steps of; selecting ( 202 ) for picking out with care the impure, or decayed beans; cleaning ( 203 ) for cleaning the bean by washing with water, steam, or air, and drying; metamorphosing ( 205 ) the starch component of the beans into the water soluble dextrin by heating to a temperature of above 160 degree centigrade with a heat chamber having a external heating means, and firstly sterilizing the bean by heating; grinding ( 207 ) for grinding the beans with their skins, thereby to ensure the metamorphosis of its starch into dextrin, to ultra-fine particle, preferably less than 1,000 nano scale; mixing ( 210 ) for combining the ultra-fine bean particles and sterilized water with a high speed mixer; homogenizing ( 212 ) for homogenizing the soymilk liquid; and filling ( 213 ) for filling the soymilk liquid in the packaging means ( 215 ) after secondly sterilizing the homogenized bean liquid with a sterilization means ( 214 ).
In the step for metamorphosing ( 205 ) a component of starch of the bean into a dextrin there can be used a rotating heat chamber in which roasting of the beans at a high temperature over 160 degree centigrade, with the external heating means; or roasting the beans with skin in the rotating high pressure heat chamber in which roasting of the beans at a high temperature over 160 degree centigrade with the external heating means during rotating and extracting the bean at room temperature for inflating the beans to a porous state, or roasting at a high temperature over 160 degree centigrade with microwaves by industrial electronic ranges.
Moreover, in the step for mixing, the invention provides the technology for producing various soymilk by mixing the ultra-fine particle with ingredients such as grains, sesamum indicum, and perilla frutescens, which are roasted in the heat chamber for metamorphosing the component of starch of the grains into a dextrin and obtaining a sterilization effect by heating.
Also, if it is preferred that the soymilk of various fruit perfumes (such as, orange soymilk, lemon soymilk, cherry soymilk) by mixing the ultra-fine particle of fruits, or concentrates during the mixing step.
If it is preferred that the soymilk of various kinds is inclusive of functional components (such as, broccoli, green tea, ginseng, red ginseng, plum and a chitosan), the ultra-fine particles or extract of the said components can be mixed in during the mixing step.
If it is preferred that the soymilk is inclusive of coffee, or chocolate, it can be mixed in the form of ultra-fine particle, or concentrate, into the soymilk during the mixing stage.
When the various vitamins are mixed, the vitamin soymilk (such as a vitamin C soymilk, a vitamin D soymilk and a multivitamin soymilk) is manufactured simply and it has the effect that the ingestion pattern of vitamins is diversified to the drinking of vitamins, instead of use of the existing tablet state vitamin.
Furthermore, if it is preferred that the soymilk for breakfast, substitute soymilk contain various kinds of grains and supplements, such as vitamins, minerals for a daily requirement thereof, they can be mixed in the form of ultra-fine particle, or concentrate, with soymilk at the mixing stage.
Referring to FIG. 3 , the invention offers the method for making a new, third, beverage by raising the partial molecular bond between the ultra-fine bean particles of this invention and ultra-fine particles, preferably below 40 nano scale, of various functional materials, such as, fruits, chocolate, coffee, grains, vegetables, ginseng, green tea or chitosan etc., by mixing in water at high speed.
As shown in FIG. 3 , first of all, the method comprises the step for metamorphosing a component of starch of the bean into a dextrin, by heating to a temperature of over 160 degree centigrade, with a heat chamber with sterilizing the beans during the heating process, after a cleaning processing of the beans by washing and drying.
The heating means may be a heat chamber having an external heating means, an electronic heating means, or a rotating high pressure heat chamber, in which the heating of the beans at a high temperature is effectuated during rotating, and extracting of the beans at room temperature for inflating the beans as a porous product.
The heating temperature about the bean is different according to the heating method and nature of the bean. Generally the starch component of the normal bean is metamorphosing into a water soluble dextrin, by heating over 160 degree centigrade and 225 degree centigrade at high pressure heat chamber arrangement.
Due to metamorphosing a component of starch of the bean into a dextrin, it changes the character of the starch and eliminates intrinsic off-flavor of the beans including the grassy smell etc. After the above processing, the beans are ground into the nano-scale preferably below 40 nano by a nano grinding means ( 303 ).
The materials ( 301 ) to add the beverage which selected among fruit, vegetable, grain, ginseng, green-tea, and broccoli are dried and ground into nano scale particle preferably less than 40 nano scale with a nano grinding means ( 314 ).
Accordingly, the nano scale particles ( 304 ) of the bean and the nano scale particles of the functional materials ( 311 ) are mixed with pure water ( 305 ) by the combining rate designed according to the kind and taste of the beverage for manufacturing.
During the above process, the particles of the nano-scale particle of the mixed materials, the nano scale particles of the soybean and the pure water are combining and the molecular bond partly occurs in the mixing step ( 306 ) and it makes the third beverage having a new taste.
The size of particles of materials and combining rate are determined according to the property of the material for mixing to design the taste and use of the new beverage, and the size of the nano particles of the materials to suit the design are controlled by setting of the ultrafine nano grinding means ( 303 / 313 ).
As described, the invention provides a technology to make various third beverages containing various fragrance and nutrient components by combining various kinds of ultra-fine nano particles of the material, nano particles of the soymilk, and pure water.
In the process, the object of the expectation can be accomplished by mixing nano scale particles preferably less than 40 nano scales of functional materials which are extracted from a ginseng, a green-tea, a chitosan etc., and flavoring agent including vitamins, coffee, or chocolate etc., can be added if needed for design.
FIG. 4 is a block diagram of another method for manufacturing a third beverage utilizing beans.
As described before, the starch component of the bean is metamorphosing into a dextrin and sterilizing bacteria parasitizing on the bean by heating process between 160-170 degree centigrade with a heat chamber ( 402 ) having heating means selected from an external heating means or a rotating high pressure heat chamber in which heating of the beans at high pressure during rotating and extracting of the beans at room temperature for inflating of the beans to be porous.
After roasting, the beans, its starch being metamorphosed into dextrin, are ground into the ultra-fine particle until eliminating deleterious flavors of the beans with nano grinding means.
Generally, scent and aroma of all of edible plants are eliminated by ultra-micro-smashing, since the polymer composite (molecularly imprinted polymers) are changing non-directional scentless, if it is ultra-micro smashed into nano scale particle.
In the sensory inspection, it was observed that the scent and aroma of the soybean became extinct if it is split to below 20 nano under. Therefore, depending on how faithfully one is keeping the intrinsic scent and aroma of the beans, the nano pulverization rate of the roasted bean can be established according to the beverage for manufacturing.
Accordingly, a scentless soymilk is made by a high speed mixing means ( 405 ) occurring molecular bonding between the ultra-fine nano particle of the roasted bean and pure water ( 405 ).
The third beverage is made by mixing the scentless soymilk and concentrate material or nano particles of the functional materials, such as, fruit of the mango, banana, pineapple, grape, cherry, etc., together according to the taste and kind of the beverage for manufacturing using a high speed mixing means ( 409 ), and passing through the high pressure homogenizer ( 410 ). Thereby is produced a new beverage which does not have any intrinsic bean smell but is containing the nutrient component of the bean and the functional materials.
According to the scent and taste which one tries to manufacture, the third beverage and the fragrance and nutrition design, it is mixed at various rates. If the fragrance and scent of the soymilk is to be with seasoned, the size of the nano particles of the bean is to be adjusted by controlling the grinding rate for splitting with nano pulverizing means ( 403 ), in order to control the taste and scent and fragrance of the soymilk, or mixing the soymilk from which the fragrance and scent are not lost in the second mixing step ( 409 ).
Moreover, it provides the useful technology of diversifying by the kind of the third beverage by the way which the various edibility spice, the edible coloring, or the functional materials are being added and mixing at high speed according to the taste of the consumer.
It also provides the technology for manufacturing the third beverage which contains various nutrient components of the soymilk and the functional components of ginseng, green-tea, or other functional materials by the way of combining its extract, or its nano scale particles with the soymilk.
Furthermore, it provides the soymilk which is so soft like cow milk because of its ultra-fine particles which are less than 40 nano-scale and the scent and fragrance are controlled arbitrarily, so that it replaces the cow milk for manufacturing dietary products including the various baby foods, ice creams, yoghurts, or etc.
In the invention, the terminology “bean” is including all kinds of beans such as capiulum, pea, horse bean, phaseoli radiati semen, adzuki bean, black soybean, lima bean, and Egyptian beans, etc.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be the embraced therein.
WORKING EXAMPLE 1
After cleaning soybeans with water and drying, the beans with their skin are roasted in a rotating high pressure heat chamber at a temperature of 225 degree centigrade at a pressure of at least 1.1 MPa, using an external gas heating arrangement and extracting the roasted beans at room temperature to obtain a porous bean product and ground the roasted bean into 40 nano grade with a nano pulverizer and, mixed with pure water utilizing a high speed mixer and then passed through a high pressure homogenizer. The soymilk that is obtained is substantially devoid of malodorous smells, such as, grassy smell intrinsic to the bean and is substantially alike to soft, natural cow milk,
WORKING EXAMPLE 2
After cleaning soybeans with water and drying, the beans are roasted with the skins in the rotating heat chamber in which roasting of the beans at high temperatures of 160-170 degree centigrade, without any pressure and they are ground into 30 nano grade with a nano pulverizer and mixed with pure water and passed through a high pressure homogenizer.
There was obtained the soymilk as dairy alternative which is substantially devoid of malodorous smells, such as, grassy and fishy smells usually intrinsic of the bean, and which is as soft as natural cow milk.
WORKING EXAMPLE 3
The orange concentration liquid was mixed with the above soymilk of the working example 2, at the capacitance ratio of 25%, and passed through a high pressure homogenizer. Consequently, the soft orange soymilk, like a cocktailed orange juice, was obtained.
WORKING EXAMPLE 4
The chitosan powder grinded into 40 nano-scales was mixed to the soymilk of the Example 1, at the weight ratio 5% rate, and passed through a high pressure homogenizer. Consequently, the soft chitosan soymilk, which do not influence the taste of the soymilk, were obtained.
WORKING EXAMPLE 5
The green tea powder ground to 40 nano-scale was mixed with the soymilk of the working example 1, at the weight ratio 3% rate, and passed through a high pressure homogenizer. Consequently, the soft green tea soymilk having a soft green color was obtained and drinking of this was giving the feeling as being soft as cow milk.
WORKING EXAMPLE 6
After cleaning of the soybeans and drying, the beans with the skins are roasted in the high pressure heat chamber in which roasting of the beans at a high temperature of over 225 degree centigrade at the pressure of 1.1 MPa, and the roasted beans are extracted into the room temperature for inflating the bean to the porous condition, and the roasted beans are ground into 20 nano scale and mixed with pure water to obtain soymilk.
The orange concentration liquid was mixed with the above soymilk, at the weight ratio 25%, and passed through a high pressure homogenizer. Consequently, the new beverage having an orange flavor, without any smell of bean, was obtained.
INDUSTRIAL APPLICABILITY
1. When a coagulating agent (the chloride salt, sulphate, GDL etc.) is added to the soymilk of the invention, it makes a soft bean curd with improved digestive power since the starch is transformed into dextrin, and the material cost is reduced by up to 40% due to using the bean and its skin together for production, therefore the invention is applicable to the bean curd industry.
2. The present invention provides the technology for making various new beverages to replace the existing carbonated drinks which are prohibited for sale in schools. Therefore, the invention is applicable to a new health beverage industry in making various beverages with fruit perfume, or a chocolate scent for replacing the carbonate drinks.
3. This invention is applicable to diary alternative industry for replacing the existing cow milk which may be containing animal growth hormones and antibiotic agents.
The animal hormones and the antibiotic agents contained in the cow milk are transferring to human body through the milk and it makes people hesitate to drink cow milk and to make baby food.
Therefore, the invention provides the solution to replace the cow milk with soymilk for making various dairy alternatives.
4. This invention is applicable to the vitamin industry for replacing the existing tablet vitamins with a drinkable vitamin which is part of the soymilk for easy drinking.
5. This invention is applicable for third beverage industry for providing various functional beverages for health, such as, a ginseng drink, a green-tea drink and etc., by occurring molecular bonding between the nano particles of the roasted bean and water, and raising nano polymer structure of the materials in non-directional scentless.
6. This invention is applicable to a new well-being beverage industry for providing various functional beverage for health by combining concentrates of various fruits, or spices, since all of the intrinsic smells of the bean disappear when the beans are roasted and ultra micro-smashed, preferably nano scale under 20 nano, but containing the nutrient components of the beans for well-being.
7. It can be applicable to the dairy product processing industry for making ice-cream, sherbet, yogurt, baby food and etc., using the soymilk of the invention since the soymilk of the invention is as soft as cow milk and substantially never gives digesting problems.
REFERENCE NUMERALS LIST
[ FIG. 1 ]
101 : selecting means.
102 : washing and drying means.
103 : heating chamber.
104 : heating means.
105 : expansion means.
106 : ultra-fine grinding means.
107 : mixing means.
108 : pure water supply.
109 : additive feeder.
110 : homogenizer.
111 : sterilizer.
112 : filling means.
113 : packing means.
[ FIG. 2 ]
201 : bean.
202 : selection.
203 : washing and drying.
204 : rotating heat chamber.
205 : metamorphosing starch to dextrin.
206 : expansion.
207 : ultra-fine grinding.
208 : grinding means.
209 : pure water.
210 : mixing.
211 : additive.
212 : homogenization.
213 : filling.
214 : sterilizer.
215 : packaging.
[ FIG. 3 ]
301 : bean.
302 : heat chamber.
303 : nano pulverizer.
304 : nano particle of bean.
305 : pure water supply.
306 : mixing means.
307 : homogenizing means.
308 : sterilization means.
309 : filling means.
310 : packing means.
311 : additive.
312 : drying.
313 : nano pulverizer.
314 : nano particles of additive.
[ FIG. 4 ]
401 : bean.
402 : heat chamber.
403 : nano pulverizing.
404 : nano particle of bean.
405 : pure water.
406 : first mixing.
407 : soymilk.
408 : fruit concentrate.
409 : second mixing.
410 : homogenization.
412 : filling.
413 : packing.
414 : sterilization.
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A method for manufacturing whole soy milk by sterilizing raw beans with the bean skins by heating in a heating chamber, transforming the starch into soluble dextrin, and then grinding the beans into an ultra-fine particle to be manufactured into whole soy milk. When the starch is transformed into dextrin by means of the above-described method, whole soy milk which is as smooth as bovine milk can be manufactured, said whole soy milk being easier to digest and having an excellent taste and flavor due to the removal of the inherent fishy taste and grassy flavor or “stink’ of the beans. By using the entire bean the problem of waste generated in traditional soy milk manufacturing processes is resolved, and soy milk yield is greatly improved. Further, a method is provided for manufacturing whole black soybean milk utilizing the quality anticancer ingredients found in the black bean skins.
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This invention relates generally to an automotive drive unit and more particularly to an automotive final drive unit with a lubricant cooling cover.
BACKGROUND OF THE INVENTION
The rear wheels of a rear drive automobile are driven by a final drive unit that splits the torque received from a longitudinal propeller shaft between the two rear wheels by means of a differential gear set inside a gear housing of the final drive unit. The propeller shaft drives an internal pinion gear that drives an internal ring gear attached to a rotary differential case. The differential case supports equalizing gears that drive two side gears that are attached to drive shafts that are connected to the respective rear wheels.
The bottom of the gear housing is a reservoir that is filled with lubricant that is distributed to the various differential gears during operation of the final drive unit. This lubricant can become quite hot. Consequently, a final drive unit often has lubricant cooling provisions.
European Patent Application 0 067 639 published Dec. 22, 1982 discloses an axle that includes a final drive unit that has a gear housing and a removable cover member. The cover member and an intermediate member provide an internal chamber that has an opening at the top. Lubricant is thrown into the internal chamber through the top opening by the rotating ring gear during operation of the final drive unit. The internal chamber also has an opening at the bottom of the intermediate member that is sufficiently small so that the chamber remains substantially full of lubricant during operation of the final drive unit. Cooling of the lubricant is facilitated by heat conduction through the wall of the removable cover member. The wall may be provided with cooling fins.
SUMMARY OF THE INVENTION
The object of this invention is to provide a final drive unit having a removable cover that provides an improved lubricant cooling arrangement.
A feature of the invention is that the removable cover divides the lubricant delivered by the ring gear for flow through several parallel lubricant cooling conduits.
Another feature of the invention is that the removable cover has several lubricant cooling conduits that are partially formed by embossments in an outer shell of the cover to increase the wall area of the lubricant cooling conduits that is exposed to cooling ambient air.
Still another feature of the invention is that the removable cover has several parallel lubricant cooling channels that are configured to equalize flow rates through the several lubricant cooling channels.
These and other objects, features and advantages of the invention will become more apparent from the following description of a preferred embodiment taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective rear view of a final drive unit equipped with a removable cover that provides a lubricant cooling arrangement according to the invention;
FIG. 2 is section taken substantially along the line 2--2 of FIG. 1 looking in the direction of the arrows;
FIG. 3 is a section taken substantially along the line 3--3 of FIG. 2 looking in the direction of the arrows; and
FIG. 4 is a rear view of the final drive unit shown in FIGS. 1, 2 and 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, a final drive unit 10 of the invention comprises a gear housing 12, a differential gear assembly 14 that is rotatably mounted in the gear housing 12 and a removable cover 16. The gear housing 12 has journal openings 18 and 20 in opposite sides of the gear housing 12. These journal openings include bearing seats for rotatably mounting the differential gear assembly 14 inside the gear housing 12 as best shown in FIG. 2.
The differential gear assembly 14 is drivingly connected to an engine driven propeller shaft (not shown) by a rotary stub shaft 22 that extends through a journal opening in the front of the gear housing 12 (not shown). Stub shaft 22 has a yoke 24 at the outside end for connecting the stub shaft 22 to the propeller shaft by a conventional Cardan type universal joint (not shown). Stub shaft 22 has a pinion gear 26 at the inside end that drives a ring gear 28 of the rotary differential gear assembly 14.
The differential gear assembly 14 is a conventional bevel gear differential of the type that is customarily used in automotive final drives, particularly in final rear drives. A bevel gear differential operates in a well known manner so that its operation need not be described in detail for those skilled in the art to understand the invention. Suffice it to say that the ring gear 28 is attached to and rotates a differential case 30 in one direction or the other whenever the vehicle is in motion. The rotary differential case 30 houses equalizing gears that mesh with side gears that are attached to the inner ends of drive shafts 31.
The differential gear assembly 14 is installed in the gear housing 12 through a large rear opening that is conventionally closed by a removable cover after the differential gear assembly 14 is installed. The removable cover 16 of final drive unit 10 provides an improved lubricant cooling arrangement as explained below.
When cover 16 is attached to gear housing 12, a lubricant reservoir 32 is formed inside the gear housing 12. This reservoir is filled with lubricant 34 to a predetermined fill level so that ring gear 28 forming part of the rotary differential assembly 14 is partially emersed in lubricant 34 in lubricant reservoir 32 as best shown in FIG. 3.
As indicated above, the meshing gears of the differential gear assembly 14 are constantly rotating when the vehicle is in motion, particularly the ring gear 28 and the pinion gear 26 that drives ring gear 28. This constant working of the meshing gears during vehicle operation, along with other internal frictions, produces heat that raises the temperature of lubricant 34 in lubricant reservoir 32. The final drive unit 10 of the invention includes a lubricant cooling system that reduces operating temperature of lubricant 34.
This lubricant cooling system comprises a lubricant cooling passage that is formed in removable cover 16. Cover 16 comprises an outer shell 36 that is fastened to gear housing 12 and an inner shell 38 that nests in the outer shell 36 as best shown in FIG. 2. Outer shell 36 has a peripheral wall 39 and several lands 40 that engage inner shell 38 (FIG. 3) and a fork-like embossment 42 (FIG. 4) that cooperate with inner shell 38 to form the lubricant cooling passage of the invention.
The lubricant cooling passage commences with an inlet 44 that is aligned with rotary ring gear 28 so that ring gear 28 pushes lubricant into the cooling passage via inlet 44 as indicated by the arrows 46 when ring gear 28 rotates in the clockwise direction as viewed in FIG. 3. Inlet 44 is preferably as near the bottom of cover 16 as possible.
Inlet 44 communicates with a horizontal manifold 48. Manifold 48 is just above inlet 44 and preferably extends for substantially the entire width of the drive unit 10 as best shown in FIG. 4. Manifold 48 in turn communicates with a plurality of laterally spaced, vertical conduits 50, 52, 53. Vertical conduits 50, 52, 53 are preferably all spaced laterally of ring gear 28 while vertical conduits 50 on either side of ring gear 28 preferably have a smaller cross section than intermediate conduits 52. End conduits 53 also preferably have a larger cross section than intermediate conduits 52. These relationships, as best seen in FIG. 2, promote a more even distribution of the lubricant supplied from manifold 48 amongst the several vertical conduits 50, 52, 53. Moreover, the cross section sizes can be adjusted to substantially equalize the flow through the several conduits 50, 52, 53.
Vertical conduits 50, 52, 53 each extend from manifold 48 to an outlet 54 that is located well above inlet 44, manifold 48 and the lubricant 34 in reservoir 32. Outlets 54 are preferably located above axis 55 of the differential gear assembly 14 and as high as possible without restricting flow through the outlets to any appreciable degree so as to maximize their height and consequently the cooling effect of vertical conduits 50, 52, 53.
During operation, ring gear 28 pushes lubricant from reservoir 32 into the lubricant cooling passage via inlet 44 where the manifold 48 of the lubricant cooling passage divides the lubricant 32 amongst the several vertical conduits 50, 52, 53 of the lubricant cooling passage. Lubricant flows up conduits 50, 52, 53 and out through several outlets 54 and then returns to reservoir 32 by gravity flow. It should be noted that the majority of the manifold 48 and the conduits 50, 52, 53 forming the lubricant cooling passage of the invention are formed by walls constituting part of the fork-like embossment 42 of the outer shell 48. Consequently, the hot lubricant is not only divided into smaller parcels for cooling but the hot lubricant also flows through a lubricant cooling passage that is mostly exposed to ambient cooling air for improved heat transfer by conduction. Thus the removable cover 16 provides a very efficient radiator for cooling the lubricant in drive unit 10. Moreover, the cooling can be further enhanced by incorporating optional cooling fins 56 on the exterior of outer shell 48 that extend crosswise of the vertical cooling conduits 50, 52, 53 as shown in FIG. 4. Any number of vertically spaced cooling fins 56 can be used. The shells 36 and 38 of cover 16 may be a steel or aluminum sheet metal stamping or an aluminum or aluminum alloy casting.
The removable cover 16 of the invention with its improved cooling arrangement has been illustrated in conjunction with a final drive unit 10 of the type that is used in independent suspensions. The removable cover 16 of the invention is particularly useful in such a drive unit because of a heat transfer area limited to the confines of the gear housing 12 and cover 16. However, the removable cover of the invention can also be used with final drive units that are part of an axle assembly that includes axle tubes extending out the sides of the gear housing that can also be used for heat transfer.
Obviously, many modifications and variations of the present invention in light of the above teachings may be made. It is, therefore, to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A final drive unit for a motor vehicle has a differential gear set rotationally mounted in a gear housing that has a rearward facing cover. The differential gear set includes a differential case driven by a ring gear. The ring gear dips into lubricant in the bottom of the gear housing and pumps a portion of the lubricant through a lubricant cooling passage in the cover having a plurality of vertical parallel open ended conduits connected to a manifold having an inlet at the bottom of the cover.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a completion application of co-pending U.S. Provisional Application 60/051,404, filed Jul. 1, 1997 for "Utensil For Children", the disclosure of which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable.
BACKGROUND OF THE INVENTION
1. Prior Art
It is to be appreciated that one of the major constraints to the utilization of an infant utensil is the potential for injury to the child. As detailed hereinbelow, because of the materials of construction employed herewith the utensil is not only safe but cannot be accidentally swallowed. Moreover, because of the unique configuration of the utensil portion of the device is also defines a teaching utensil in that it teaches the child to utilize, properly, the utensil associated therewith.
Known prior art infant utensils of which applicant is aware, simply do not preclude accidental swallowing while at the same time, teaching the proper utilization thereof. For example, in U.S. Pat. No. 5,479,708, there is disclosed an infant's utensil which includes a handle having a utensil supporting portion which enables interchangability of various utensils. While the device thereof may teach proper grasping or facilitate grasping by an infant, it does not preclude the accidental swallowing thereof.
Therefore, it is to be appreciated that there exists a need for an infant's or a child's utensil which not only enables proper gripping and teaching, but prevents potential injury to the child through the swallowing thereof. It is to this to which the present invention is directed.
2. Field of the Invention
The present invention concerns utensils for children. More particularly, the present invention concerns a "safe" or child safety utensil. Even more particularly, the present invention concerns means and methods for producing a utensil for use by children which is safe and easy to use.
SUMMARY OF THE INVENTION
Thus, and in accordance herewith, there is provided an infant or child safe utensil which, generally, comprises:
(a) a flexible handle portion;
(b) a utensil portion, and
(c) a mouth guard to prevent accidental swallowing.
The mouth guard may be integral with either the handle, the utensil or maybe an element distinct and separate from either the handle or utensil portion and maybe slidably mounted thereonto.
Each of the components hereof is made from a non-toxic material.
The present invention, further, contemplates interchangable utensils such as a child's fork, spoon or brush, be it a hairbrush or toothbrush or the like.
For a more complete understanding of the present invention reference is made to the following detailed description and accompanying drawings. In the drawing like reference characters refer to like parts throughout the several views in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a first embodiment of a utensil for a child in accordance with the present invention;
FIG. 2 is a partial side elevational view of the utensil hereof;
FIG. 3 is a top plan view thereof;
FIG. 4 is a perspective view of a second embodiment hereof;
FIG. 5 is a top plan view of the embodiment of FIG. 4;
FIG. 6 is a perspective view of a third embodiment hereof;
FIG. 7 is a top plan view of the third embodiment hereof, and
FIG. 8 depicts a modification of the third embodiment hereof
DESCRIPTION OF THE PREFERRED EMBODIMENT
As noted hereinabove the present invention provides an infant or child safe utensil which, generally, comprises:
(a) a flexible handle portion;
(b) a utensil portion removably mounted to the handle portion, and
(c) a mouth guard mounted to the handle to prevent accidental swallowing of the utensil.
It is to be appreciated that one of the major constraints to the utilization of an infant utensil is the potential for injury to the child. As detailed hereinbelow, because of the materials of construction employed herewith the utensil is not only safe but cannot be accidentally swallowed. Moreover, because of the unique configuration of the utensil portion of the device is also defines a teaching utensil in that it teaches the child to utilize, properly, the utensil associated therewith.
More particularly, and with reference to FIGS. 1, 2 and 3 there is depicted therein a first embodiment of the present invention and which is, generally, denoted at 10. The device 10 includes a handle portion 12, a utensil end 14 and a mouth guard 16 mounted onto the utensil end at the junction thereof with the handle portion therebetween.
The handle portion 12 is dimensioned of sufficient size to enable grasping thereof by an infant or small child. The handle has an outer surface 18 which is knurled around the periphery thereof, as at 20, to facilitate the grasping thereof. The handle portion 12 is formed from any suitable flexible material such as polyethylene, polypropylene, silicone rubber or other material that can be flexed to prevent injury to an infant in the event of accidental contact therewithin.
The handle portion 12 has a first end 22 and a second opposite end 24. An elongated slot or opening 26 is formed at the end 24 and extends into the interior of the handle, thus, defining a partial bore or the like. As detailed hereinbelow, the partial bore 26 is utilized to secure the utensil end 14 to the handle.
According to the embodiment of FIG. 1, the utensil portion defines a spoon member and includes a spooning portion 28 which is a convex member having an elliptical or otherwise configured dish or basin element 29 having a peripheral ledge 31 formed therearound, which enables the spooning of liquids, soft foods and the like thereinto. A handle 30 is integrally formed with the concave member and projects therefrom. As shown in FIG. 1, the handle 30 has a first end 32 which is integrally formed with the spooning portion 28 and a second or opposite end 34 which projects into the bore 26. The end 34 is secured within the partial bore 26 by any suitable means such as by gluing, sonic welding, heat bonding or the like. Alternately, the end 34 may be removably secured within the bore 26 by friction. This enables interchangeability of the utensil portion of the device 10. Preferably, the utensil portion 14 is formed from a semi-rigid material to preclude accidental injury or the like.
As shown in FIG. 2, the convex member or spooning portion is provided with an upstanding ridge 36 which partially extends about the periphery or peripheral ledge 31 of the convex portion 28, proximate the first end of the handle 30. The ridge 36 tapers from being substantially co-planar with the convex portion to a medial or mid-highest portion which, then, tapers downwardly to a diametrically opposed position on the ledge 31, as shown. The ridge 31 defines a spill or splash guard to prevent the flow of foodstuffs therepast.
The present device or utensil further includes a guard or mouth guard 16 to prevent accidental swallowing or the like. The guard 16 comprises a substantially planar member 40 formed of the same soft pliable material as the handle portion 12. The guard 34 has a central slot 42 to enable the guard to be slid over the handle and emplaced at the junction between the handle portion 34 and the end 24 of the handle portion and is positioned substantially normal or perpendicular thereto.
The guard may be provided with an arcuate configuration for the device to conform to the curvature of the mouth portion of an infant or a small child. Thus, if the infant were to insert the entire utensil portion into its mouth the guard prevents passage past the lips and, if gotten therepast prevents swallowing. The guard may be either removably mountable to the utensil so that it can be used in other environments or, alternatively, the guard may be fixed in place through any suitable mode, such as by gluing, sonic welding, heat bonding or the like.
Referring now to FIGS. 4 and 5, there is depicted therein an alternate embodiment of the present invention and which is generally denoted at 110. Herein, all of the elements are the same, including the handle portion 112, the mouth guard portion 116, the handle 130, the bore 126, the handle having a first end 122 and a opposite end 124, as well as the knurling 120, which parallels the elements of the first embodiment. Additionally, there is the splash or spill guard 136 which is similar to the guard 36 in the first embodiment. Herein, though, the utensil end, generally, denoted at 114 comprises a fork like member having a concave elliptical body 150 having a peripheral ledge 131. The body 150 defines a shell having a concave interior 152. The concave body 150 has a plurality of discontinuities 154, 154', etc., formed therein and which extends inwardly from the ledge toward the center of the interior 152. These discontinuities or serrations define tines such that the utensil becomes a fork. It is to be noted with respect hereto that the tines, which are substantially parallel to each other, are angularly inclined along the horizontal axis with respect to the longitudinal axis of the utensil, per se, and intersects with the longitudinal axis. The intersection with the longitudinal axis may be at any convenient angle. One such convenient angle is 30°. However, it is to be understood that the intersection with the longitudinal axis may be at any convenient angle, including flat (i.e. 0°) if desired. By having the horizontal angular skewing the opportunity for an infant to be stabbed by the tines is minimized. Furthermore, tines are provided with blunt ends or rounded ends as a further safety feature.
It is to be further noted that the ends of each tine lies along the same arc as the balance of the shell and does not extend therebeyond to, again, preclude any injury to the child.
In all other respects, this embodiment is similar to the embodiment of FIG. 1.
Turning now to FIGS. 6 and 7, there is depicted therein a further embodiment of the present invention and, generally, denoted at 210. Herein, the child's utensil takes on a definition of a brush and includes both the handle portion, the guard, as well as the utensil end. In all respects, this embodiment is configured similar to that of the first two embodiments except that the utensil end carries a brush element 214 including a header 216 having a plurality of bristles (not shown) secured thereto and depending therefrom. The bristles may comprise bristles for brushing teeth or for brushing hair.
In FIG. 8, there is depicted therein still a modification of the third embodiment of the present invention wherein the handle is of a reduced diameter handle to facilitate by an even younger infant. The reduced handle portion may be deployed in connection with the other embodiments hereof.
Where friction is used to retain the utensil end in position, a plurality of utensil ends may be interchangeably mounted onto the handle portion so that only a single handle need be employed. Likewise, removable mounting of the mouth guard enhances the interchangeability and compactness of the device.
It is to be appreciated from the preceding that there has been described herein a child's utensil which is safe to use while providing adequate training to teach the child how to utilize the utensil. Furthermore, it is apparent because of the materials of construction and the disposition of the guard that the utensil cannot be swallowed or accidental lodged within the mouth of the infant.
In fabricating the present utensil it is fabricated from non-toxic materials of any well known type.
It is further contemplated that the present invention be defined by a kit including the handle and a plurality of the interchangable utensil portions such as hereinabove described.
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A utensil for infants and toddlers it includes a planar flexible handle portion and a semi-rigid utensil portion. The utensil portion includes a ridge and a handle which engages the handle portion. A mouth guard is included and is disposed at the junction of the handle and handle portion. Included among the utensils are a spoon, fork and toothbrush. A kit of utensils is, also, disclosed.
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FIELD OF THE INVENTION
The present invention relates to intravascular stent implants for maintaining vascular patency in humans and animals and more particularly to a stent in the form of a double wave stent with strut.
BACKGROUND OF THE INVENTION
Percutaneous transluminal coronary angioplasty (PTCA) is used to increase the lumen diameter of a coronary artery partially or totally obstructed by a build-up of cholesterol fats or atherosclerotic plaque. Typically a first guidewire of about 0.038 inches in diameter is steered through the vascular system to the site of therapy. A guiding catheter, for example, can then be advanced over the first guidewire to a point just proximal of the stenosis. The first guidewire is then removed. A balloon catheter on a smaller 0.014 inch diameter second guidewire is advanced within the guiding catheter to a point just proximal of the stenosis. The second guidewire is advanced into the stenosis, followed by the balloon on the distal end of the catheter. The balloon is inflated causing the site of the stenosis to widen. The dilatation of the occlusion, however, can form flaps, fissures and dissections which threaten reclosure of the dilated vessel or even perforations in the vessel wall. Implantation of a metal stent can provide support for such flaps and dissections and thereby prevent reclosure of the vessel or provide a patch repair for a perforated vessel wall until corrective surgery can be performed. It has also been shown that the use of intravascular stents can measurably decrease the incidence of restenosis after angioplasty thereby reducing the likelihood that a secondary angioplasty procedure or a surgical bypass operation will be necessary.
An implanted prosthesis such as a stent can preclude additional procedures and maintain vascular patency by mechanically supporting dilated vessels to prevent vessel reclosure. Stents can also be used to repair aneurysms, to support artificial vessels as liners of vessels or to repair dissections. Stents are suited to the treatment of any body lumen, including the vas deferens, ducts of the gallbladder, prostate gland, trachea, bronchus and liver. The body lumens range in diameter from small coronary vessels of 3 mm or less to 28 mm in the aortic vessel. The invention applies to acute and chronic closure or reclosure of body lumens.
A typical stent is a cylindrically shaped wire formed device intended to act as a permanent prosthesis. A typical stent ranges from 5 mm to 50 mm in length. A stent is deployed in a body lumen from a radially compressed configuration into a radially expanded configuration which allows it to contact and support a body lumen. The stent can be made to be radially self-expanding or expandable by the use of an expansion device. The self expanding stent is made from a resilient springy material while the device expandable stent is made from a material which is plastically deformable. A plastically deformable stent can be implanted during a single angioplasty procedure by using a balloon catheter bearing a stent which has been crimped onto the balloon. Stents radially expand as the balloon is inflated, forcing the stent into contact with the interior of the body lumen thereby forming a supporting relationship with the vessel walls.
The biocompatible metal stent props open blocked coronary arteries, keeping them from reclosing after balloon angioplasty. A balloon of appropriate size and pressure is first used to open the lesion. The process is repeated with a stent crimped on a second balloon. The second balloon may be a high pressure type of balloon, e.g., more than 12 atmospheres, to insure that the stent is fully deployed upon inflation. The stent is deployed when the balloon is inflated. The stent remains as a permanent scaffold after the balloon is withdrawn. A high pressure balloon is preferable for stent deployment because the stent must be forced against the artery's interior wall so that it will fully expand thereby precluding the ends of the stent from hanging down into the channel encouraging the formation of thrombus.
Various shapes of stents are known in the art. They may be a wire stent or a tubular stent and configured with or without struts. Prior art stents have struts and crossovers which are typically welded or formed integrally with the stent or permit only a limited range of movement. Such struts or crossovers may have more structural radial stiffness and lack flexibility in tortuous anatomies. Due to the dynamic motions of the arteries during the cardiac cycles, especially coronary arteries, stiffer stents may be more prone to fatigue and fracture.
U.S. Pat. No. 4,856,516 to Hillstead for "Endovascular Stent Apparatus and Method" discloses a wire first bent into a series of tight bends. The wire is then further bent into a sequence of loops that are connected by half hitch junctions and interconnections which are either aligned or spiral around the circumference of the stent.
U.S. Pat. No. 4,878,906 to Lindemann et al. for "Endoprosthesis for Repairing a Damaged Vessel" discloses a flexible, plastic, thin-walled sleeve molded with various types of circumferential and axial ribs and reinforcements to be used as an endovascular prosthesis. FIGS. 3, 5, 6, 8, and 9 disclose a fixed axial rib.
U.S. Pat. No. 4,886,062 to Wiktor for "Intravascular Radially Expandable Stent and Method of Implant" discloses a two-dimensional zig-zag form, typically a sinusoidal form and without longitudinal struts.
U.S. Pat. No. 4,994,071 to MacGregor for "Bifurcating Stent Apparatus and Method" discloses a wire forming a backbone extending axially along the length of the lattice that extends away from the lattice and is used to construct the interconnecting loops. A series of generally parallel oriented loops interconnected by a sequence of half-hitch connections extend along an axial dimension.
U.S. Pat. No. 5,061,275 to Wallsten for "Self-Expanding Prosthesis" discloses a number of elements having the same direction of winding but being axially displaced relative to each other and crossing a number of elements also axially displaced relative to each other but having the opposite direction of winding to form a braided structure.
U.S. Pat. No. 5,104,404 to Wolff for "Articulated Stent" discloses a stent made up of a number of wires welded together and then connected together with hinges to provide articulation.
U.S. Pat. No. 5,133,732 to Wiktor for "Intravascular Stent" discloses a stent body coiled from a generally continuous wire with a deformable zig-zag structure with a means for preventing the stent body from stretching along its longitudinal axis. A longitudinal wire is attached, preferably by welding to waves of wire at points.
U.S. Pat. No. 5,135,536 to Hillstead for "Endovascular Stent and Method" discloses locations permanently adhered together to form junctions which are generally aligned to form a backbone. Filament portions at each end and location 24 are permanently adhered together to form junctions to prevent the unrolling of the stent.
U.S. Pat. No. 5,195,984 to Schatz for "Expandable Interluminal Graft" discloses a plurality of slots disposed substantially parallel to the longitudinal axis of the tubular members, and adjacent grafts are flexibly connected by a single connector member disposed substantially parallel to the longitudinal axis of the tubular members. Connector members are preferably formed of the same material as grafts and may be formed integrally between adjacent grafts. The end turn of the helix is welded and intermediate welds are formed to stabilize the length of the helix.
U.S. Pat. No. 5,389,106 to Tower for "Impermeable Expandable Indovascular Stent" discloses a pigtail that is passed back along the circumferential sections and is joined to the other end section.
Commonly owned co-pending U.S. Ser. No. 08/633,394 to Boyle for "Joined Sinusoidal Helix Stent" discloses a sinusoidal wave stent which aligns at the off peak to the off valley adjacent locations with a pattern of welds affixing the alignment locations to each other.
Commonly owned co-pending U.S. Ser. No. 08/563,715 to Boyle et al. for "Interwoven Dual Sinusoidal Helix Stent" discloses braided peaks and valleys forming a braided region.
What is needed is a flexible stent design which overcomes the prior art inflexibility resulting from welding or twisting junctions at the crossovers of wires yet does not lengthen or shorten when used in tortuous anatomies and which has good coverage without being prone to fracture or fatigue as a result of repeated flexions with an artery.
SUMMARY OF THE INVENTION
The present invention is accomplished by providing a radially expandable stent for implantation within a body vessel, comprising a first and second elongated element having a series of peaks alternating with valleys forming a wave shape therein. The first elongated element is interwoven with the second elongated element in a series of crossovers, with each crossover forming a symmetrical intersection and each successive pair of crossovers defining a loop. The interwoven first and second elongated elements are wound into a hollow cylindrical shape with at least one longitudinal strut extending parallel to a longitudinal axis of the hollow cylindrical shape and passing through at least one of the loops along the hollow cylindrical shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a first wire segment;
FIG. 2 is a plan view of a first and second wire segment showing four crossovers;
FIG. 3 is a plan view of a stent of the present invention mounted on a balloon catheter; and
FIG. 4 is an enlargement of area 4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The double wave stent is designed to be flexible and to have high fatigue and fracture resistance while at the same time conforming to the dynamic motions of the arteries. It also avoids lengthening and shortening of the stent upon expansion. Applicant's crossovers 75 are not fixed points between the first wire segment 15 and the second wire segment 25. Strut 20 is affixed only at its proximal and distal end. This lack of fixation reduces the possibility of fracture and fatigue while increasing stent flexibility in tortuous anatomies.
A typical stent is formed with a wire segment which is formed into a sinusoidal wave form helix pattern the length of the stent by a means such as passing the wire through gears such as those disclosed in U.S. Pat. No. 2,153,936 issued to Owens et al. As shown in FIGS. 1 and 2 a first wire segment 15 and a second wire segment 25 are formed into a sinusoidal wave form Helix pattern.
The first wire segment 15 is crossed over the second wire segment 25 at a point midway between a peak 60, 70 and valley 55, 65 Each peak 60, 70 and valley 55, 65 pair form a wave 30. The valleys of the first wire segment 15 are aligned along the same longitudinal axis as the valleys of the second wire segment 25. The peaks of the first wire segment 15 are aligned along the same longitudinal axis as the peaks of the second wire segment 15. The crossovers 75 of the first wire segment 15 alternate going over and under the second wire segment 25. The first wire segment 15 and the second wire segment 25 are not affixed to each other at crossovers 75. Unlike the prior art with welded or twisted crossovers, the wires are able to slide over each other causing less fatigue and potential fracture as arteries such as the coronary arteries flex.
After the crossovers 75 are created, the helix is wound in barber pole fashion over a cylindrical form such as a mandrel. The present invention shown in FIG. 3, depicts a radially expandable stent 10 in the form of a hollow cylinder defined by a sequence of wire elements 40a-f with each of the wire elements 40a-f extending 360 degrees around the cylinder. A peak 60, 70 and valley 55, 65 pair constitute a wave. Three to four waves per 360 degree revolution constitute an element 40 and are preferred for coronary applications. Applicant's invention is not limited to coronary applications, however, and can, for example, be used in peripheral and other applications. Those skilled in the art would recognize that the number of waves per revolution depends on the diameter of the stent and the desired stiffness.
The wire elements 40a-f have extendible, sinusoidal zig-zags formed by smooth bends such as alternating peaks 60 and valleys 55. As shown, the peaks 60 and valleys 55 are shaped in a generally longitudinal direction along the cylinder at one point and then reverse their direction so that the peaks 60 and valleys 55 may open as the wire element 40a is expanded. Also as shown, the wire elements 40a-f are uniformly spaced along the cylinder and the peaks 60 and valleys 55 are uniformly spaced around the cylinder. The adjacent wire elements 40a-f are flexibly connected together in an end-to-end fashion by means of helical winding. The wire elements 40a-f have a plurality of extendible portions, such as peaks 60 and valleys 55 which permit the wire elements to be expanded from a first diameter covering 360 degrees of the cylinder to a second, expanded diameter covering 360 degrees of the expanded cylinder.
A typical coronary stent may have the following dimensions. The stent wire 15 can have a diameter of about 0.001 inches to about 0.015 inches. The preferred form of the sinusoidal wave of the wire segment is a length of about 0.150 inches to about 0.090 inches and a wave amplitude of between about 0.050 inches and about 0.080 inches. Any wave length and amplitude combination that would provide adequate vessel 50 hoop strength and vessel 50 coverage is appropriate. The stent 10 must expand evenly and permit the balloon 35 to expand evenly. The stent 10 of this invention and balloon can be transported via a standard #7 or #8 French guiding catheter. Once on location, the stent 10 can be expanded radially by the expansion of the balloon 35; a ratio of 2.75:1 can be achieved with a wire diameter of approximately 0.005 inches and an initial stent diameter of 0.060 approximately inches.
A forming mandrel sequence can provide a gradual reduction in the stent 10 outer diameter by the use of applied finger pressure under microscopic observation. For a coronary sized stent it is possible to go directly from a 0.150 inch stent outer diameter to a 0.065 inch stent outer diameter by placing stent 10 directly onto the balloon 35 from the forming mandrel and make an acceptable stent, but it is more difficult to maintain proper alignment of the stent wires by doing so. Thus it is preferred that the stent 10 is further processed from a 0.150 inch diameter forming mandrel by pressing it onto a 0.100 inch diameter forming mandrel, thereafter pressing it onto a 0.080 inch diameter forming mandrel and finally pressing it onto a 0.065 inch diameter forming mandrel before being applied to the balloon 35. Those skilled in the art would recognize that a variety of acceptable mandrel sizes could be used in the forming sequence depending on the desired stent size.
After the stent 10 has been reduced to the objective outer diameter, the stent is terminated as follows. The proximal end of the first wire segment 15 is attached to the second wire segment 25. The proximal end of the second wire segment is attached to the closest adjoining element 40-a. The distal end of the first wire segment 15 is attached to the second wire segment 25. The distal end of the second wire segment is attached to the closest adjoining element 40-f.
Strut 20 is affixed by attaching the proximal end to a location on the second wire segment 25 distal to the first wire segment proximal loop attachment 45 to form the strut proximal loop attachment 90. The distal end of strut 20 is threaded through loops 100 parallel to the longitudinal axis of the stent 10. The distal end of strut 20 is then attached to a location on the second wire segment 25 distal to the first wire segment distal loop attachment 80 to form the strut distal loop attachment 95. The proximal end of the first wire segment 15 is terminated by affixing it to the second wire segment 25 to form the first wire segment proximal loop attachment 45. The distal end of the first wire segment 15 is terminated by affixing it to the second wire segment 25 to form the first wire segment distal loop attachment 80. The second wire segment 25 proximal end is terminated by affixing it to the closest adjoining element 40a to form the second wire segment proximal loop attachment 50. The second wire segment 25 distal end is terminated by affixing it to the closest adjoining element 40f to form the second wire segment distal loop attachment 85.
The attachments 45, 50, 80, 85, 90 or 95 could be done by manually looping them. Those skilled in the art will recognize other means of end attachments which include twisting, biocompatible adhesive, brazing, crimping, welding or stamping. The strut 20 can be attached either before or after the forming mandrel sequence. It is however, easier to form the strut after the forming mandrel sequence has reduced the stent 10 to its objective size.
Applicant's strut 20 is free to move within loops 100 with the dynamics of artery movement thereby resulting in less fatigue and fracture potential. Prior art struts which are welded or integral have more structural radial stiffness but lack flexibility in tortuous anatomies. The stiffer the stent, the more prone it is to fatigue and fracture. Applicant's strut 20 is not affixed except at the proximal and distal ends. It is free to flex in tortuous anatomies yet provides additional coverage. Applicant's strut 20 controls longitudinal deformation by resisting shortening or elongation of the stent 10 during expansion or compression because it is affixed at its proximal and distal ends. The free floating strut 20 slides freely between waves 30 yet adds radial (hoop) stiffness. Additional longitudinal stiffness and arterial support can be achieved by adding additional struts 20 through a series of loops 100 running longitudinally throughout the stent 10.
The balloon expandable stent 10 can be made of an inert, biocompatible material with high corrosion resistant that can be plastically deformed at low-moderate stress levels such as tantalum, the preferred embodiment. Other acceptable materials include stainless steel, titanium ASTM F63-83 Grade 1, niobium or high carat gold K 19-22. A self-expanding device can be made by the use of superelastic (nickel titanium) NiTi such as Nitinol manufactured by Raychem or Forukawa. The struts 20 can be made of a different material and/or be of a different diameter than the first wire segment 15 and second wire segment 25.
After formation, the stent 10 is placed over a suitable expandable diameter device such as an inflatable balloon 35 which is typically used for angioplasty procedures. A stent can be implanted during a single angioplasty procedure by using a balloon catheter bearing a stent 10 which has been crimped by hand or with a suitable crimping tool (not shown) onto balloon 35. Manually squeezing the stent 10 over the balloon 35 is also acceptable. The stent 10 is radially expanded as the balloon 35 is inflated, causing the stent 10 to contact the body lumen thereby forming a supporting relationship with the vessel walls. As the balloon 35 expands, so does the stent 10. The expanding balloon 35 together with the stent 10 compresses the plague in the stenosis and prevent possible reocclusion. When the angioplasty procedure is completed, the balloon 35 is deflated and withdrawn leaving the stent 10 firmly implanted within the vessel. The previously occluded vessel is recannalized and patency is restored. Any protrusions are undesirable because they are conducive to turbulent blood flow and potential formation of thrombosis. The stent 10 is centrally located and positioned with respect to the length of balloon 35. The stent 10 turns are evenly spaced so that when the stent 10 is expanded, the stent 10 will provide even support inside the vessel and resist external loading.
The preceding specific embodiments are illustrative of the practice of the invention. It is to be understood, however, that other expedients known to those skilled in the art or disclosed herein, may be employed without departing from the scope of the appended claims.
______________________________________No. Component______________________________________10 Stent15 First Wire Segment20 Strut25 Second Wire Segment30 Wave35 Balloon40a-f Element45 First Wire Segment Proximal Loop Attachment50 Second Wire Segment Proximal Loop Attachment55 Valley First Wire Segment60 Peak First Wire Segment65 Valley Second Wire Segment70 Peak Second Wire Segment75 Crossover80 First Wire Segment Distal Loop Attachment85 Second Wire Segment Distal Loop Attachment90 Strut Proximal Loop Attachment95 Strut Distal Loop Attachment100 Loop______________________________________
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A radially expandable stent for implantation within a body vessel, comprising a first and second elongated element having a series of peaks alternating with valleys forming a wave shape therein. The first elongated element is interwoven with the second elongated element in a series of crossovers, with each crossover forming a symmetrical intersection and each successive pair of crossovers defining a loop. The interwoven first and second elongated elements are wound into a hollow cylindrical shape with at least one longitudinal strut extending parallel to a longitudinal axis of the hollow cylindrical shape and passing through at least one of the loops along the hollow cylindrical shape.
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This is a continuation of application Ser. No. 020,103, filed on Feb. 27, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the vapor deposition of a semiconductor of a compound of elements of the groups III.V, in which a semiconductor of a compound of elements of the groups III.V having an improved electron mobility can be formed on a substrate of a single crystal of alumina by the metal-organic chemical vapor deposition. Furthermore, the present invention relates to a semiconductor element having an improved surface smoothness in a semiconductor layer, which is prepared according to the above-mentioned process.
2. Description of the Prior Art
The technique of utilizing a semiconductor of a compound of elements of the groups III.V for a light-emitting element or light-receiving element has recently been markedly developed, and for example, the technique of forming a semiconductor of a compound of elements of the groups III.V, such as GaAs, on a single crystal substrate by the gas phase epitaxial growth has attracted attention. In the case where a substrate of a single crystal of alumina is used, an advantage is attained in that a high transmission of rays having a wavelength of 0.2 to 5 μm is obtained, and therefore, application of this semiconductor to various devices is expected. For example, when this semiconductor is used for LED, emission of light from the substrate side is possible, and when the semiconductor is used for a photoelectric conversion device, receipt of light on the side of the substrate is possible.
As means satisfying this demand, there has already been proposed the metal-organic chemical deposition method (ordinarily called "MOCVD method") for forming a GaAs film on a substrate of a single crystal of alumina (Journal of Applied Physics, Vol. 42, No. 6 (1971), page 2519).
More specifically, according to this proposal, a GaAs film is epitaxially grown on a substrate of a single crystal of alumina by the chemical vapor deposition (CVD) method using trimethyl gallium (Ga(CH 3 ) 3 ) as an organic metal gas and arsine (AsH 3 ) as a reactive gas.
According to this process, however, many lattice defects are formed in the interface between the alumina single crystal substrate and the GaAs single crystal film, and therefore, a film thickness larger than 20 μm is necessary for obtaining a high electron mobility, and improvement of the crystallinity of this film is desired.
Furthermore, according to the conventional process, convexities and concavities are readily formed on the surface of the GaAs film, and the light emission efficiency is drastically reduced in the light-emitting element comprising this semiconductor. When this semiconductor is used for an element of a transistor or IC, fine processing is impossible. Accordingly, utilization of these film devices is inhindered.
Therefore, development of a semiconductor of a compound of elements of the groups III V having a smooth surface is desired, but formation of a semiconductor of a compound of elements of the groups III.V having a smooth surface on a substrate of a single crystal of alumina has not been reported.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a process for the vapor deposition of a semiconductor of a compound of elements of the groups III.V, in which formation of lattice defects in the interface between an alumina single crystal substrate and a film of a semiconductor of a compound of elements of the groups III.V is controlled and even if a compound semiconductor film having a relatively small thickness if formed, a high electron mobility is attained.
Another object of the present invention is to provide a semiconductor element which is characterized in that i forming a semiconductor of a compound of elements of the groups III.V having a smooth surface on an alumina single crystal substrate and using this semiconductor for various film devices such as a light-emitting element and IC, the characteristics of these devices are not degraded by convexities and concavities on the surface of the semiconductor.
Still another object of the present invention is to provide a process for the preparation of a semiconductor element having the above-mentioned excellent property.
More specifically, in accordance with one fundamental aspect of the present invention, there is provided a process for the production of a semiconductor element by introducing a gas of an organic metal compound of an element of the group III and a gas containing an element of the group V into a reaction chamber in which a substrate of a single crystal of alumina is arranged and epitaxially growing a III.V compound semiconductor by the thermal decomposition vapor deposition of the compound of the elements of the groups III.V, said process comprises, in combination, the steps of (A) heating the substrate at a temperature of 400° to said 550° C., introducing the gas of the organic metal compound of the element of the group III and the gas containing the element of the group V into the reaction chamber and forming a film of a compound of the elements of the groups III.V on the surface of the substrate by the vapor deposition, (B) heating the substrate obtained at the step (A) at a temperature higher than 550° C. but lower than 750° C. and introducing the gas containing the element of the group V to anneal the film of the compound of the elements of the groups III.V, and (C) maintaining the substrate obtained at the step (B) at a temperature higher than 550° C. but lower than 750° C. and introducing the gas of the organic metal compound of the element of the group III and the gas containing the element of the group V to effect the gas phase growth of a compound semiconductor of the elements of the groups III.V with the film of the III.V compound film obtained at the step (B) being as the nucleus.
In accordance with another aspect of the present invention, there is provided a semiconductor element comprising a single crystal sapphire substrate and a film of a gallium-arsenic semiconductor formed on the substrate by the epitaxial growth, wherein the off angle to the epitaxial growth plane from the plane (0001) of the crystal of the sapphire substrate is larger than 0° but smaller than 5° , the film of the gallium-arsenic semiconductor has a thickness of at least 1 μm and the surface of the film of the gallium-arsenic semiconductor has such a smoothness that the maximum height roughness is smaller than 0.1 μm (smaller than 0.1 S).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a CVD apparatus for use in carrying out the process of the present invention.
FIG. 2 shows curves illustrating the relations between the electron mobility and the annealing time, observed in the examples of the present invention.
FIG. 3 is a diagram illustrating the off angle to the epitaxial growth plane from the plane (0001) of the crystal sapphire substrate.
FIGS. 4 through 6 are electron microscope photographs of the surfaces of GaAs epitaxial films obtained by maintaining the substrate at 590° C., 620° C. and 650° C., respectively, in the examples of the present invention.
FIGS. 7 through 10 are electron microscope photographs of the surfaces of GaAs epitaxial films obtained by setting the epitaxial growth plane of the substrate at 0.5°, 2°, 4° and 6°, respectively, in the examples of the present invention.
In FIG. 1, reference numeral represent the following members.
1: reaction chamber, 2: susceptor, 3: alumina single crystal substrate, 13: bubbler, 14: thermostat tank, 9, 10, 11 and 12: mass flow controllers, a and b: electron mobility curves.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to embodiments in which a GaAs film is formed on an alumina single crystal substrate.
The present invention is characterized in that the above-mentioned three steps (A), (B) and (C) are conducted in sequence according to the MOCVD method using a CVD apparatus described hereinafter, and according to the present invention, by dint of this characteristic, a high electron mobility can be attained even if the film thickness is small.
At the step (A), the temperature of the alumina single crystal substrate is set at a level lower than the substrate temperature adopted at the subsequent steps (B) and (C), and a Ga element-containing gas and an As element-containing gas are introduced into a reaction chamber and a nucleus necessary for the growth of a crystal is formed by the CVD method. For this purpose, it is sufficient if the substrate temperature is set at 400° to 550° C., preferably 430° to 530° C. If the substrate temperature is lower than 400° C., the nucleus of GaAs is not grown, and if the substrate temperature exceeds 550° C., a homogeneous nucleus is not grown and defects are formed in the interface.
It is preferred that the thickness of the film formed at the step (A) be 100 to 700Å, though the preferred thickness differs to some extent according to the heat annealing conditions at the step (B).
At the step (B), the GaAs film formed at the step (A) is heat-annealed to improve the crystallinity of GaAs. The substrate temperature necessary for this heat annealing is higher than 50° C. but lower than 750° C., preferably from 570° to 730° C. If the substrate temperature is outside this range, the electron mobility is not improved. If the substrate temperature is elevated, the vapor pressure of As of the GaAs film is elevated and therefore, it is necessary to introduce the As element-containing gas into the reaction chamber. The annealing time is generally 0.1 to 100 minutes and preferably 1 to 80 minutes.
At the subsequent step (C), a crystal of GaAs is grown of the GaAs film having improved crystallinity. Namely, the Gas element-containing gas and As element-containing gas are introduced into the reaction chamber, and the substrate temperature is set at a temperature higher than 550° C. but lower than 750° C., preferably 570° to 730° C., whereby these gases are thermally decomposed and the epitaxial growth of GaAs is effected on the GaAs film grown at the step (A).
In the present invention, a gas of a trialkyl gallium such as Ga(CH 3 ) 3 or Ga(C 2 H 5 ) 3 is sued as the Ga element-containing gas, and a gas of AsH 3 or AsCl 3 is used as the Gas element-containing gas. As the carrier gas, there may be used H 2 or an inert gas (Ar, N 2 , He, Ne or the like). Of course, if desired, a minute amount of a gaseous compound of a doping element, such as a silane, may be incorporated into the gas to be supplied.
In the present invention, in order to further improve the crystallinity of GaAs, the following preparation conditions may be adopted to the steps (A), (B) and (C).
Namely, at the step (A), it is preferred that the molar volume ratio of the As element-containing gas introduced into the reaction chamber to the Ga element-containing gas introduced into the reaction chamber (hereinafter referred to as "(As)/(Ga) ratio") be at least 10, especially 50 to 200, and the total gas pressure within the reaction chamber to set at 50 to 760 Torr.
At the step (B), it is preferred that the amount of the As element-containing gas be set at 0.1 to 5% by volume, especially 0.5 to 2% by volume, based on the total amount.
At the step (C), it is preferred that the (As)/(Ga) ratio and the total gas pressure be the same as those adopted at the step (A). It also is preferred that the growth of GaAs be effected so that the total thickness of the GaAs film is at least 1 μm, especially at least 3 μm.
Incidentally, in each of the examples given hereinafter, at the step (C), Si 2 H 6 gas is introduced into the reaction chamber as well as the reactive gases and carrier gas to incorporate 0.01 to 1 ppm of Si into GaAs during the growth, and the electron mobility of the film is determined.
The CVD apparatus for sue in carrying out the process of the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 1 illustrates a CVD apparatus of the radio frequency inductive heating type. A susceptor 2 is arranged in a reaction chamber 1, and an alumina single crystal substrate 3 for forming a GaAs film thereon is mounted on the susceptor 2. A high frequency coil 4 is wound around the reaction chamber 1 and a high frequency power source (not shown) is connected to the coil 4 so that when a high frequency power is applied to the high frequency coil 4, the susceptor 2 is induction-heated.
A diluting gas such as H 2 or Ar is sealed in a first tank 5, an As element-containing gas is sealed in a second tank 6 and Si 2 H 6 gas is sealed in a third tank 7. The diluting gas from the first tank 5 is passed through a refiner 8 and the refined gas is supplied as a carrier gas. The flow rate of this gas is adjusted by mass flow controllers 9 and 10. The flow rates of the gases released from the second tank 6 and third tank 7 are adjusted by mass flow controllers 11 and 12. Reference numeral 13 represents a bubbler filled with a Ga element-containing liquid substance such as Ga(CH 3 ) 3 , and reference numeral 14 represents a thermostat tank for maintaining the bubbler 13 at a predetermined temperature. The diluting gas in the first tank 5 is passed through the refiner 8 and introduced into the bubbler 13 by the mass flow controller 10, whereby the liquid substance in the bubbler 13 is gasified and is introduced into the reaction chamber 1. Furthermore, the diluting gas is released through the mass flow controller 9 and is sued as the carrier gas for the gases in the second tank 6 and third tank 7. A super high vacuum exhauster 15 and an exhaust gas treating device 16 are connected to the reaction chamber 1. Vacuum gas discharge is performed within the reaction chamber 1 before formation of the film by using the super high vacuum exhauster 15 to remove the residual gas in the reaction chamber 1, and the As compound in the exhaust gas is removed by the exhaust gas treating device 16. Incidentally, each of reference numerals 17, 18 and 19 represents a gas-adjusting valve of the tank and each of reference numerals 20, 21, 22, 23, 24 and 25 represents a valve.
In the CVD apparatus having the above-mentioned structure, before the steps (A) through (C), the substrate 3 which has been subjected to a predetermined cleaning treatment is fixed on the susceptor 2 so that the cleaned surface of the substrate 3 is located above, and the interior of the reaction chamber 1 is evacuated to about 10 -7 Torr and the substrate 3 is induction-heated by the high frequency coil 4. If the substrate 3 is heated to a predetermined temperature, this temperature is maintained. Subsequently, the gas-adjusting valve 17 of the first tank 5 is opened and the valves 21, 22 and 23 are fully opened, and the flow rate of the diluting gas is set at a predetermined level by the mass flow controller 9 and the diluting gas is introduced into the reaction chamber 1.
Then, at the step (A), the gas-adjusting valve 18 of the second tank 6 is opened and the As element-containing gas is supplied while adjusting the flow rate to a predetermined value by the mass flow controller 11. Furthermore, the valve 20 is closed and the valves 24 and 25 are fully opened, and the diluting gas is introduced into the bubbler 13 to obtain a Ga element-containing gas. The feed rate of tis gas can be set by the pressure in the bubbler 13, which is determined by the temperature of the thermostat tank 14 and the flow rate of the diluting gas set by the mass flow controller 10.
At the subsequent step (B), the valves 20 and 24 are closed so that the Ga element-containing gas is not used, and the temperature is elevated to a level higher than the substrate temperature at the step (A) by induction heating.
Then, at the step (C), the valves 20 and 24 are fully opened again to introduce the Ga element-containing gas into the reaction chamber 1 and grow a crystal of GaAs. Incidentally, in the measurement of the electronmobility, in order to incorporate a minute amount of Si into this GaAs, the gas-adjusting valve 19 of the third tank 7 is filled with Si 2 H 6 gas is fully opened and a predetermined amount of Si 2 H 6 gas is fed into the reaction chamber 1 while adjusting the flow rate by the mass flow controller 12.
According to the present invention, the film formed at the step (A) is annealed and crystallized at the step (B), and at the step (C), the semiconductor film is epitaxially grown, whereby formation of lattice defects in the interface between the substrate and the semiconductor film is controlled and a high electron mobility is obtained even if the film thickness is relatively small.
FIG. 2 illustrates the relation between the annealing time at the step (B) and the electron mobility of the element in Example 1 described hereinafter. From FIG. 2, it is seen that the electron mobility is assuredly increased by annealing.
The gallium-arsenic semiconductor of the present invention has an electron mobility of 3500 to 4500 cm 2 /Vsec in the state doped with Si 2 H 6 when the film thickness is, for example, 6 μm.
In accordance with one preferred embodiment of the present invention, a sapphire single crystal substrate is used as the alumina single crystal substrate and the epitaxial growth of a GaAs semiconductor is performed so that the off angle θ to the epitaxial growth plane of the semiconductor from the plane (0001) of the substrate is larger than 0° but smaller than 5°, preferably 0.5 to 4°, especially preferably about 2°. If the off angle is set within the above-mentioned range, the surface smoothness of the GaAs semiconductor is prominently improved.
Referring to FIG. 3 illustrating the plane azimouth of the sapphire single crystal substrate, which is of the hexagonal system, the plane (0001) (generally called "plane C") is present in the direction rectangular to the c-axis of the crystal, and the epitaxial growth plane D is set at an off angle θ toward the plane (1102) (generally called "plane D") from this plane C.
This setting of the epitaxial growth plane D is accomplished by chamfering an existent sapphire substrate by a diamond cutting tool so that the GaAs-adhering plane of the single crystal substrate has a predetermined off angle from the plane (0001) of the single crystal. Preferably, in preparing a sapphire substrate by the Edge-defined Film-fed Growth method (EFG method), a single crystal is grown so that the surface of the sapphire substrate has a predetermined off angle to the plane (0001) of the sapphire crystal, whereby a sapphire substrate to be used in this preferred embodiment can be obtained. More specifically, high-purity alumina is fused in an inert atmosphere and a molybdenum die for the growth of a ribbon-like sapphire single crystal, which has a split in the interior thereof, is located so that the die falls in contact with the melt. The alumina melt is caused to rise to the top end portion of the die by the capillary action, and a sapphire seed having predetermined azumith and size is brought into contact with the alumina melt on the top end portion of the die. Then, the seed is pulled up to effect the growth of a sapphire single crystal. By deviating the sapphire seed from the die slit by the above-mentioned off angle θ in the transverse direction, a sapphire single crystal substrate to be used in this embodiment can be obtained.
According to the present invention, by adjusting the off angle to the epitaxial growth plane on the sapphire substrate within the above-mentioned range, it is possible to impart such a surface smoothness as defined by a maximum height roughness smaller than 0.1 μm (smaller than 0.1 S), especially smaller than 0.05 μm, to the formed gallium-arsenic semiconductor. FIGS. 7, 8, 9 and 10 are electron microscope photographs of the surface of GaAs films formed at off angles of 0.5°, 2°, 4° and 6°, respectively, in Example 4 given hereinafter. It is seen that if the off angle is 0.5 to 4°, especially about 2°, the surface smoothness is prominently excellent.
In this embodiment of the present invention, by adjusting the substrate temperature at 600° to 640° C., especially 610° to 630° C., at the step (C), that is, at the epitaxial growth step, while adjusting the off angle of the epitaxial growth plane within the above-mentioned range, the surface smoothness of the GaAs film can be further prominently improved. If the substrate temperature is lower than 600° C., fine dents are formed on the entire surface of the film, and if the substrate temperature exceeds 640° C., gentle convexities are formed on the entire surfaces.
FIGS. 4, 5 and 6 are electron microscope photographs of the surfaces of epitaxial films formed at substrate temperatures of 590° C., 620° C. and 650° C., respectively, in Example 3 given hereinafter. It is seen that the film of FIG. 5 (620° C.) is excellent in the surface smoothness.
As is apparent from the foregoing description, according to the present invention, since the three-stepped growth process including heat annealing is adopted, the electron mobility can be increased even if the thickness of the grown epitaxial film is small, and therefore, a high-quality film electronic device can be provided at a high manufacturing efficiency and a reduced manufacturing cost.
Furthermore, according to the present invention, since the epitaxial growth surface of the formed semiconductor has a good smoothness, if this semiconductor element is used as a light-emitting element, the light emission efficiency can be increased. Moreover, if the semiconductor element of the present invention is used as an element of a transistor or IC, since fine processing can be performed on the surface of the film of the semiconductor, various film devices can be manufactured. The semiconductor element of the present invention can be especially advantageously applied to the production of a photocoupler. Still further, according to the preparation process of the present invention, a semiconductor element excellent in the surface smoothness can be obtained only by controlling the growth temperature of the substrate having an epitaxial growth plane and the off angle of this growth plane within predetermined ranges. Accordingly, the production can be easily controlled, and the quality is stabilized and the production yield is increased.
Incidentally, in the foregoing illustration, the epitaxial growth of the GaAs film alone has been described. However, as is obvious to those skilled in the art, similar advantages can be attained if the present invention is applied to the production of semiconductors having a part of GaAs substituted by Al, P or In, such as Ga x Al 1-x As, GaAs x P 1-x and Ga x In 1-x As, and other III.V compound semiconductors.
The present invention will now be described in detail with reference to the following examples that by no means limit the scope of the invention.
EXAMPLE 1
By using the CVD apparatus shown in FIG. 1, a GaAs film was formed on an alumina single crystal substrate and the electron mobility was measured.
More specifically, a C-plane alumina single crystal substrate was set on the susceptor 2, and at the step (A), H 2 gas was introduced from the first tank 5 and AsH 3 gas was introduced at a flow rate of 30 sccM from the second tank 6 to the reaction chamber 1. Bubbling hydrogen was introduced into the bubbler 13 through the mass flow controller 11 to gasify liquid Ga(CH 3 ) 3 . The Ga(CH 3 ) 3 gas was introduced at a flow rate of 0.6 sccM into the reaction chamber 1. The flow rate of all the gases introduced into the reaction chamber 1 was set at 3500 sccM, the substrate temperature was set at 470° C. and the total reaction pressure was set at 100 Torr, and gas phase growth was conducted for 1 minute under these conditions. Thus, a GaAs film having a thickness of 400 Å was formed at the step (A).
At the subsequent step (B), the substrate temperature was set at 620° C., and the valves 20 and 24 were closed to reduce the flow rate of the Ga(CH 3 ) 3 to zero. Other conditions were the same as at the step (A), and heat annealing was carried out. In this example, the annealing time was changed as shown in FIG. 2, and the electron mobility of the GaAs film obtained at the subsequent step (C) was measured.
At the step (C), the valves 20 and 24 were opened, and the Ga(CH 3 ) 3 gas and AsH 3 gas were introduced into the reaction chamber 1 at flow rates of 1.2 sccM and 96 cssM, respectively. Simultaneously, Si 2 H 6 gas was introduced at a flow rate of 10 or 25 sccM into the reaction vessel 1 from the third tank 7 (Si 2 H 6 was contained at 2 ppm in H 2 ). Other conditions were the same as at the step (B). Thus, a GaAs film having a thickness of 6 μm was grown on the GaAs film obtained at the step (A).
With respect to GaAs epitaxial films obtained according to the above-mentioned procedures while changing the annealing time at the step (B), the electron mobility at room temperature was measured. The obtained results are shown in FIG. 2. Incidentally, this electron mobility was determined by measuring the Hall effect.
In FIG. 2, marks and show the results obtained at the Si 2 H 6 gas flow rates of 10 sccM and 25 sccM, respectively, and a and b are electron mobility curves obtained at these flow rates, respectively. In this example, the electron densities of the GaAs films obtained at the Si 2 H 6 gas flow rates of 10 sccM and 25 sccM were about 1.5×10 16 /cm 3 and about 4×10 16 /cm 3 , respectively.
From FIG. 2, it is seen that the electron mobility increases with increase of the annealing time. Accordingly, it is considered that the crystallinity of the GaAs film obtained at the step (A) is improved depending upon the logarithm of the annealing time and the electron mobility of the GaAs epitaxial film grown on this film is correspondingly increased.
In case of a GaAs epitaxial film (having a thickness of 6 μm) grown by conducting only the step (C) without performing the steps (A) and (B) in this example, the electron mobility was about 2500 cm 2 /Vsec. Accordingly, it is understood that if the steps (A), (B) and (C) are performed according to the present invention, the electron mobility is prominently increased.
EXAMPLE 2
In this example, the thickness of the GaAs film formed at the step (A) was changed and the electron mobility was measured.
GaAs epitaxial films were prepared in the same manner as in Example 1 except that the Si 2 H 6 gas flow rate at the step (C) was set at 10 sccM and the annealing time was set at 20 minutes, and the electron mobility was measured. The obtained results are shown in Table 1. Incidentally, in each of the samples shown in Table 1, the electron density was about 1.5×10 16 /cm 3 .
TABLE 1______________________________________Film Thickness (Å) Electron Mobility (cm.sup.2 /Vsec)______________________________________200 3500400 3800600 3300______________________________________
As is apparent from Table 1, if the film thickness is within the range of from 100 to 700 Å, the electron mobility is prominently improved.
EXAMPLE 3
By using the CVD apparatus shown in FIG. 1, three GaAs epitaxial films were formed according to the abovementioned three-stepped growth process while adjusting the substrate temperature to 590° C., 620° C. and 650° C., respectively, at the steps (B) and (C), and the surface stages of these GaAs films were examined.
More specifically, a C-plane alumina single crystal (the off angle of the epitaxial growth plane of the substrate was 0.5°) was set on the susceptor 2. At the step (A), H 2 gas was introduced into the reaction chamber 1 from the first tank 5 and AsH 3 gas was introduced at a flow rate of 30 sccM into the reaction chamber 1 from the second tank 6. Bubbling hydrogen was introduced into the bubbler 13 through the mass flow controller 11 to gasify liquid Ga(CH 3 ) 3 , and the Ga(CH 3 ) 3 gas was introduced at a flow rate of 0.6 sccM into the reaction chamber 1. The flow rate of all the gases introduced into the reaction chamber 1 was set at 3500 sccM, the substrate temperature was set at 470° C. and the reaction pressure was set at 100 Torr, and the gas phase growth was carried out for 1 minute under these conditions. Thus, a GaAs film having a thickness of 400 Å was formed at the step (A).
At the subsequent step (B), the substrate temperature was set at 590° C., 620® C. or 650° C., and the valves 20 and 24 were closed to reduce the flow rate of the Ga(CH 3 ) 3 to zero. Other conditions were the same as at the step (A), and heat annealing was carried out for 5 minutes.
At the step (C), the valves 20 and 24 were opened, and the Ga(CH 3 ) 3 gas and AsH 3 gas were introduced into the reaction chamber 1 at the flow rates of 1.2 sccM and 96 sccM, respectively. Other conditions were the same as at the step (B) and the substrate temperature was the same as at the step (B). Thus, a GaAs film having a thickness of 6 μm was epitaxially grown on the GaAs film formed at the step (A).
The surface of the so-obtained GaAs epitaxial film was photographed at an inclination angle of 60° from the sample surface by a scanning type electron microscope. Photographs of the samples obtained at the substrate temperatures of 590° C., 620° C. and 650° C. are shown in FIGS. 4, 5 and 6, respectively. In each photograph, the magnifying factor was 2500 magnifications.
As is apparent from FIGS. 4 through 6, an excellent surface smoothness was obtained at the substrate temperature of 620° C. (FIG. 5), while fine dents or convexities and concavities were formed at the substrate temperature of 590° C. (FIG. 4) or 650° C. (FIG. 6).
The surface roughness of the GaAs films shown in FIGS. 4 through 6, measured by a surface roughness meter, were 0.3 S, 0.08 S and 1.0 S, respectively.
EXAMPLE 4
The crystal growth was performed on a C-plane alumina single crystal substrate while adjusting the off angle of the epitaxial growth plane to 0.5°, 2°, 4° and 6°, and the surface states of GaAs epitaxial films were examined.
More specifically, four substrates differing in the off angle of the epitaxial growth plane as mentioned above were prepared, and on each of these substrates, a GaAs epitaxial film was formed under the same conditions as adopted in Example 3 except that the substrate temperature at the steps (B) and (C) was set at 20° C. The surfaces of the obtained films were photographed at an inclination angle of 75° from the sample surface by using a scanning type electron microscope. Photos of the samples obtained at the off angles of 0.5°, 2°, 4° and 6° are shown in FIGS. 7, 8, 9 and 10, respectively. In each photo, the magnifying factor was 2500 magnifications.
From FIGS. 7 through 10, it is seen that each of the samples obtained at the off angles of 0.5°, 2° and 4° (FIGS. 7 through 9) had a good surface smooth and the sample obtained at the off angle of 2° (FIG. 8) was especially excellent in the surface smoothness. On the other hand, convexities and concavities were apparently observed on the surface of the sample obtained at the off angle of 4° (FIG. 4).
The surface roughness of the GaAs films shown in FIGS. 7 through 10, measured by a surface roughness meter, were 0.08 S, 0.03 S, 0.08 S and 0.3 S, respectively.
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Disclosed is a process for the production of a semiconductor element by introducing a gas of an organic metal compound of an element of the group III and a gas containing an element of the group V into a reaction chamber in which a substrate of a single crystal of alumina is arranged and epitaxially growing a III.V compound semiconductor by the thermal decomposition vapor deposition of the compound of the elements of the groups III.V, said process comprises, in combination, the steps of (A) heating the substrate at a temperature of 400° to 550° C., introducing the gas of the organic metal compound of the element of the group III and the gas containing the element of the group V into the reaction chamber and forming a film of a compound of the elements of the groups III.V on the surface of the substrate by the vapor deposition, (B) heating the substrate obtained at the step (A) at a temperature higher than 550° C. but lower than 750° C. and introducing the gas containing the element of the group V to anneal the film of the compound of the elements of the groups III.V, and (C) maintaining the substrate obtained at the step (B) at a temperature higher than 550° C. but lower than 750° C. and introducing the gas of the organic metal compound of the element of the group III and the gas containing the element of the group V to effect the vapor deposition of a compound semiconductor of the elements of the groups III.V with the film of the III.V compound film obtained at the step (B) being as the nucleus.
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This is a continuation-in-part of copending application Ser. No. 225,079, filed on July 27, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The present invention is concerned with flexible conductive strips and more particularly, conductive lighting strips which can be used for display cases, shelves and other areas where an array of lighting elements may follow irregular contours or borders.
Typically, display case shelving has been illuminated by affixing a lighting fixture such as a fluorescent bulb or a line of incandescent bulbs within a reflective shield to the front underside of a top shelf. Such lighting sources, however, do not provide optimum illumination. In fact, they tend to distort colors as compared to their appearance in natural sunlight, and, when incandescent lamps are used, they tend to be wasteful of power. Because color is an important feature of most items placed in a display case, it is preferable that more natural illumination be provided.
Moreover, most available lighting fixtures are relatively bulky or are of the fluorescent type which do not provide the proper lighting for the display of most objects. A small, flexible, low voltage illumination strip would be most desirable for such diplay case applications.
Strip lighting which follows the contours of an architectural feature, or which outlines and illuminates special features of a structure, is typically created using conventional wiring which includes a plurality of lamp sockets spaced at desired intervals. "Christmas tree" lighting is an example of this variety. Such strip lighting is typically wired in series and if one bulb fails the whole strip fails through an open circuit. A painstaking bulb by bulb inspection is then required to find the failed unit or units. Parallel wiring, on the other hand, would be preferable, since burnt out bulbs can be quickly located and replaced. However, heavier gauge wiring is necessary because the current that must be supplied in a parallel circuit is equal to the product of the current in one lamp times the number of lamps.
The strip lighting employed in the prior art is generally unattractive and not easily fastened in place. Further, conventional, small gauge wiring necessary for an inconspicuous installation can have relatively high resistivity over long runs which adversely affects the brightness that is available. What is required, therefore, is strip lighting that can be both flexible and of low resistivity. Further, it should lend itself to the parallel wiring of the component lighting elements with the required high conductivity and which can be easily concealed or obscured from view.
SUMMARY OF THE INVENTION
An object of the present invention is to provide low profile strip lighting having flexibility and low resistivity combined with an excellent light spectrum.
In general the present invention is embodied in an improved display lighting apparatus comprised of an electrically conductive strip that is adapted to be easily fastened to any surface and has a pair of conductors. Each conductor of the strip has substantial current capacity and is adapted to be connected to a corresponding power terminal of a power source, which may be the output terminals of a low voltage power supply transformer.
The electrically conductive strip includes two generally parallel lengths of conductive foil each approximately 1/2' to 3/4' wide in the preferred embodiments covered by an insulative film except for a narrow strip near the interior longitudinal edges of the two lengths of foil. Lamp socket members are held by a spacer to the strip and are electrically connected across the two foil strips. Light fixtures or lamps may then be plugged into these sockets to provide a strip of illumination, particularly effective with display case shelving.
By adapting the flexible strip to receive other types of socket members, the present invention can be adapted to provide a power source for electrical accessories other than lights.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and features of the present invention will be more fully apparent to those skilled in the art to which the invention pertains from the ensuing detailed description thereof, regarded in conjunction with the accompanying drawings wherein like reference numerals refer to like parts throughout and in which:
FIG. 1 is a bottom perspective view of a length of strip lighting with a lamp socket assembly attached thereto;
FIG. 2 is an enlarged cross-sectional view taken along line 2--2 of FIG. 1, in the direction of the appended arrows with a light bulb shown in dotted lines;
FIG. 3 is a cross-sectional view of a length of unfolded strip lighting showing the placement of conductive material upon the laminar surface in a first embodiment;
FIG. 4 is a cross-sectional view of a length of unfolded strip lighting showing the placement of insulative material over the conductive material;
FIG. 5 is a cross-sectional view of the strip lighting of the present invention in an unfolded configuration having a socket thereon;
FIG. 6 is a view of the strip of FIG. 5 showing a first fold;
FIG. 7 is a view of the strip of FIG. 6 showing a second fold;
FIG. 8 is cross-sectional view of an alternate embodiment of a laminate strip with conductive strips placed thereon;
FIG. 9 is a view of the strip of FIG. 8 showing a first fold;
FIG. 10 is a view of the strip of FIG. 9 having a socket thereon and showing a second fold;
FIG. 11 is a cross-sectional view of yet another embodiment of a wider laminate strip with conductive strips placed thereon;
FIG. 12 is a view of the strip of FIG. 11 having a socket thereon and showing a first and second fold;
FIG. 13 is a view of the strip of FIG. 12 showing a third fold;
FIG. 14 is a view of the strip of FIG. 13 showing a fourth fold;
FIG. 15 is a cross-sectional view of a length of unfolded strip lighting material showing the placement of conductive material upon insulative film in yet another embodiment;
FIG. 16 is a cross-sectional view of the strip lighting showing the placement of insulative material upon the conductive material;
FIG. 17 is a cross-sectional view of the strip lighting of FIG. 16 showing the use of a second insulative material to seal the gap between the conductive strips;
FIG. 18 is a cross-sectional view of the strip lighting of FIG. 17 having a socket thereon and showing the placement of a third insulative material upon the conductive strips;
FIG. 19 is a cross-sectional view of the strip lighting of FIG. 18 showing the completed strip assembly prior to folding; and
FIG. 20 is a cross-sectional view of the strip lighting of FIG. 19 with the longitudinal edges folded one over the other.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The details of the construction of strip lighting 10 are shown in FIGS. 1 and 2. FIG. 1 shows the fully insulated strip lighting assembly 10 mounted for illumination purposes. FIG. 2 shows an enlarged cross-sectional view of the fully assembled strip lighting assembly. From FIG. 1, it can be seen that a typical strip 10 includes an insulating laminate 12, which surrounds a conductive pair 14, 16 to which a socket element 18 has been attached. A pair of pin receptacles 20, 22 is in electrical contact with the conductor pair 14, 16 and is adapted to connect to a source of power 24. As seen, the strip 10 is mounted on a substrate 26, which may be a structural element whose contours can be followed.
In the cross-sectional view of FIG. 2, the strip 10 is shown enlarged so that the various components and their interrelationships can be visualized. In FIG. 2, the length of laminate strip 12 has already been folded over as will be described below. It is at the exposed portions 28 and 30 of the two foil strips 14 and 16 that the electric contact is made with pin receptacle sockets 20 and 22. Socket 20 is soldered, or otherwise electrically connected, to the exposed strip 28 and socket 22 is electrically connected to exposed strip 30. After electrically connecting the exposed strip 28 of foil portion 14 and exposed strip 30 of foil portion 16 to the sockets 20 and 22, respectively, the laminate strip 12 is then folded cover. Firstly, edge 32 is folded over the base of the sockets 20 and 22 and then, edge 34 is folded over edge 32 also over both of the sockets.
This provides the fully insulated assembly, as shown in FIG. 1, except for the two exposed sockets 20, 22 into which a bulb, such as bulb 36, may be inserted. Although an exposed bulb 36 is shown in FIG. 2, other lighting fixtures may be alternatively used. For instance, a bulb and reflector assembly, (not shown) might be used. In this manner, a reflector may be aimed so that light emitted by the bulb is directed toward a desired object. Thus, the same strip may contain exposed bulbs, such as bulb 36, or bulb and reflector assemblies.
Thus, an exceptionally flexible strip lighting assembly can easily be provided with illumination appropriate to articles on display shelves. It is not necessary that a bulb be plugged in each of the sockets in the event less light is desirable. The lengths of strip lighting 10 may be mounted under the front edge of the shelves of a display case. Alternatively, it may be provided under the side edges, the back edge or along the middle of the underside of any of the shelves. Thus, the concept is, of course, not limited to lighting along the front edge of a display case. Nor is the concept limited to display case lighting. The strip lighting assembly can be used wherever low voltage natural illumination is sought. It can be used to illuminate foot paths or along theatre aisles at floor level. It can also be used to display items in showcases, china cabinets and breakfronts.
The flexible strip lighting assembly can be folded in such a fashion as to provide variant spacing between the lamps. By folding and overlapping the strip, the distances between lamps can be changed according to various lighting and architectural requirements.
The flexible strip assembly can also be easily adapted to provide a power source for various electrical accessories other than lights. Other types of socket members which are adapted to provide power to electrical accessories can be affixed to the flexible strip, providing a flexible, parallel power source.
The present invention also includes a method of fabricating the flexible electrically conductive strip means, as shown in FIGS. 3-7. As shown in FIG. 3, two conductive strips 14 and 16 are placed on a strip of insulative material 36 in generally parallel relationship to the longitudinal axis. Strips 14 and 16 are aligned on insulative material 36 in a parallel fashion but are separated from one another by a gap 38 of about one-sixteenth of an inch.
As shown in FIG. 4, a first insulator strip 40 is then placed over the foil strip 14 and a second insulator strip 42 is placed over the foil strip 16. The first and second insulators 40 and 42 cover the foil strips 14 and 16 except for the two narrow, exposed portions 28 and 30.
As seen in FIG. 5, the first and second insulator strips 40 and 42 are laminated to strip 12 at the ends 32 and 34. A socket 20 of socket element 18 is soldered, or otherwise electrically connected, to the exposed conductive strip 28 and a socket 22 of socket element 18 is electrically connected to the exposed conductive strip 30. After the electrical connections are made, the laminated strip 12 is then folded over.
Turning next to FIG. 6, edge 32 is folded over the base of the sockets 20 and 22 covering the exposed portions of the conductive strips 28 and 30. Then, as seen in FIG. 7, edge 34 is folded over edge 32 also covering both of the sockets 20 and 22 and the previously exposed portions 28 and 30. The resulting fully insulated assembly of FIG. 7, also seen in FIG. 2, shows the bulb 36 inserted into the two exposed sockets 20 and 22.
A first alternatative embodiment of a method of fabricating the present invention is shown in FIGS. 8-10. The first alternative embodiment involves the use of a wider insulative strip 44 upon which the conductive strips 14 and 16 are placed, as seen in FIG. 8. The longitudinal edges of the insulative strip 44 are then folded over conductive strips 14 and 16 respectively.
FIG. 9 shows the fold of the first edge of insulative strip 44, allowing conductive strip 28 to remain exposed. FIG. 10 shows the fold of the opposite edge of insulative strip 44 allowing conductive strip 30 to remain exposed. Again sockets 20 and 22 are electrically connected to the exposed strips 28 and 30. As in FIGS. 6 and 7, the edges 32 and 34 of strip 12 are then folded over the exposed portions 28 and 30 and the sockets 20 and 22 to provide the fully insulated assembly of FIG. 2.
In yet another alternative embodiment of the product and process, as shown in FIGS. 11-14, a single flexible insulative substrate 46 may be employed that is substantially wider than the pair of ribbon conductors 14 and 16. In this embodiment, as seen in FIG. 12, a first fold leaves a substantial width of double thickness insulative film 48 adjacent to the partially covered conductive ribbon 14. A second fold from the opposite edge partially covers the other conductive ribbon 16.
As before, apertures are made through the exposed strips 28, 30 of the conductive ribbons 14, 16 and the underlying insulative material 46, through which socket pins can be electrically connected to the ribbon cable. The socket elements 18 are placed below the insulative substrate and the contacting pins come "up" through the conductive ribbons. The pins are placed in good electrical connection either by soldering or swaging into place.
Finally, the double thickness of insulative material 48 extending beyond both ribbon cables 14 and 16 is folded to the center in overlapping folds, substantially in thirds so that the edge 32 from the first fold is the fold is the fold line for the overlapping fold from the other side. The folded portions may be kept in place either by an adhesive or by a heat seal or bond.
The present embodiments of this invention are thus to be considered in all respects as illustrative and not restrictive; the scope of invention being indicated by the appended claims rather than the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
In yet a further embodiment, illustrated in FIGS. 15-20, insulation is placed between the conductive strips to minimize the risk of arcing and to preclude the possibility that the conductive strips might come into contact with each other.
In FIG. 15, as in other embodiments, wide conductive strips 50 and 52 are placed longitudinally, in a nearly parallel fashion, along an insulative film 54 as in the earlier embodiments. The conductive strips 50 and 52 are placed upon the insulative film 54 and are separated from one another by a gap 56 of about one-sixteenth of an inch. In this embodiment, the strips 50, 52 are each preferably wider than 1/2" and run to 3/4" in width. Typically, the insulative film 54 is a three mil, heat sensitive, opaque polyester film with a heat sensitive adhesive, although any flexible material with insulative properties will do. The conductive strips 50 and 52 are adhered to the first insulative film 54 and, as illustrated in FIG. 16, a second polyester film 58, substantially the same width and length of the insulative film 54, is then placed on top of the conductive strips 50 and 52. As illustrated in FIG. 17, The second insulative film 58 is heat sealed to the first film 54 and also seals the gap 56 between conductive strips 50 and 52.
As illustrated in FIG. 18, holes are punched through film layers 54 and 58, and through exposing conductive strips 50 and 52 near the adjacent edges so that electrical sockets 60 and 62 can be connected to conductive strips 50 and 52 by soldering. The soldering process incidentally burns away some of the second insulative film 58.
A third insulative film strip 64, which may be composed of pressure sensitive tape, is used to cover any of the exposed portions of conductive strips 50 and 52 and the soldered connections and to ensure that no conductive elements are exposed, as illustrated by FIG. 19.
FIG. 20 illustrates the finished flexible strip after the first longitudinal edge 66 and the second longitudinal edge 68 have been folded over each other. The folded edges 66 and 68 minimize the area and volume of the strip while maintaining the high current available with the parallel conductive strips of 1/2" or greater width.
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A strip lighting assembly utilizes a film covered pair of copper foil strips to which one or more sockets have been connected. The assembly is produced by placing foil strips on one side of a wide insulating film, placing strips of the same insulating film material over the foil partially covering same, installing lamp sockets from the opposite side through the film and exposed foil and finally, overlapping the film edges to cover the exposed foil. The disclosure covers both the product and the method employed to produce it.
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The present invention relates in general to patterning techniques utilized in the fabrication of devices such as multi-analyte biosensors utilized for environmental monitoring and medical diagnostic purposes as disclosed in U.S. application Ser. No. 09/145,993, filed Sep. 3, 1998, now abandon, as a division of parent application Ser. No. 08/816,337, filed Mar. 13, 1997, now U.S. Pat. No. 5,858,801 issued Jan. 12, 1999, the disclosure of which is incorporated herein by reference and with respect to which the present disclosure is a continuation-in-part.
BACKGROUND OF THE INVENTION
Because of their exquisite specificity, biological molecules, including antibodies, have been employed in biosensors. Biosensors are devices capable of identifying and quantifying a target chemical. Biosensors are highly sensitive to their analyte (the chemical species to be detected for an antibody-based biosensor, the analyte is the antigen to the antibody). They are able to detect quantities as small as 10 −15 gram. They are also extremely specific toward the analyte because of the unique ability of the antibodies to recognize their target species at the molecular level.
The present state of the art in antibody-based biosensors is illustrated by the various commercially available immunoassays. An immunoassay is a chemical test based on the use of antibodies to bind the molecule to be detected. In these assays, an antibody specific to the analyte (the “capture antibody”) is immobilized onto a solid surface. This surface is then exposed to the sample to be analyzed and the immobilized antibodies bind some of the analyte present in the sample. After the surface is washed, it is immersed in a solution of a second antibody (the “signal antibody”) specific to the same analyte. The signal antibody is conjugated (attached chemically) to a radioactive, fluorescent, or enzymatic label, so that it can be detected with high sensitivity. The amount of the signal antibody bound to the analyte is determined by the amount of radioactivity, intensity of fluorescence, or quantity of enzymatic reaction product, which in turn is proportional to the quantity of antigen in the sample. In the case of the enzyme label, the enzyme converts molecules of an added colorless reactant to colored reaction products. The intensity of the color change is read by a spectrophotometer. This type of assay is called enzyme-linked immunosorbent assay (ELISA). Examples of commercially available ELISA test kits are home pregnancy tests and environmental monitoring tests for BTEX (benzene, toluene, ethylbenzene, and xylene), PAH's (polynuclear aromatic hydrocarbons) or PCB's (polychlorinated biphenyls) in water. ELISA assays are also used in the military for battlefield detection of chemical and biological warfare agents. A disadvantage of these immunoassay kits is that a separate kit is required for each antigen or closely related family of antigens being tested for. Not only is this costly and labor consuming when many antigens must be tested for, but it can also result in dangerous time delays as when chemical and biological warfare agents are being tested for on the battlefield.
It would be desirable to provide a single device that could perform multiple immunoassay tests at the same time. The test results of such a device would be read and evaluated automatically. In order to achieve this, each type of antibody must be precisely and discretely located on the test surface. Cross contamination of the antibodies must be avoided. Moreover, such devices should be inexpensive and easy to manufacture.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a new device using multiple antibodies on a substrate to perform multiple immunoassay tests.
Another object of this invention is to provide a new device using multiple antibodies on a substrate to perform multiple immunoassay tests whose results can be read automatically.
A further object of this invention is to provide a new, inexpensive method of producing a device using multiple antibodies to perform multiple immunoassay tests.
Yet another object of this invention is to provide a new method of patterning multiple antibody types in discrete groups in precise locations.
These and other objects of this invention are achieved by providing a serial process for producing a multiple antibody patterned substrate by (1) coating an antibody-adsorbent substrate with an antibody-resistant material, (2) removing a portion of the antibody-resistant material by mechanical scribing to produce a bare site on the antibody-adsorbent substrate having a precise size, shape, and location on the substrate, (3) adsorbing molecules of a selected antibody on to the bare site on the antibody-adsorbent substrate, (4) rinsing the substrate to remove unadsorbed antibody molecules, (5) coating the antibody-adsorbent substrate with more of the antibody-resistant material to cover the bare surface of the substrate between the newly adsorbed antibody molecules, and (6) repeating steps (2) through (5) until each of the antibodies has been adsorbed at its specific site on the antibody-adsorbent substrate.
Alternatively, the multiple antibody patterned substrate is produced by a parallel process of (1) coating an antibody-adsorbent substrate with an antibody-resistant material that is resistant to the adsorption of antibodies, (2) simultaneously removing portions of the antibody-resistant material by mechanical scribing to produce bare sites on the antibody-adsorbent substrate having precise sizes and shapes and each site having a precise location which corresponds to a specific antibody, (3) adsorbing molecules of each antibody to its specific bare site on the antibody-adsorbent substrate, (4) rinsing the substrate to remove unadsorbed antibodies, and (5) coating the antibody-adsorbent substrate with more of the antibody-resistant material to cover the bare surface of the substrate between the adsorbed antibody molecules.
Another aspect of this invention is a biosensing device having (A) an analyte-capturing structure comprising (1) an antibody-adsorbent substrate, (2) two or more antibodies adsorbed to the substrate, wherein each antibody is located at a specific site on the substrate apart from the other antibodies, and (3) an antibody-resistant material covering the substrate between the adsorbed molecules of the antibodies for immobilization thereof at discrete locations, and (B) means for determining the types and quantities of the analytes captured by the antibodies.
BRIEF DESCRIPTION OF DRAWING
A more complete appreciation of the invention and many of its attendant advantages will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:
FIG. 1 is a block diagram of an antibody patterning fabrication process, in accordance with an economical embodiment of the present invention;
FIG. 2 is a side view of apparatus for mechanical removal of coating from the surface of a substrate, associated with the patterning fabrication process diagrammed in FIG. 1; and
FIG. 3 is a partial top plan view observed from section line 3 — 3 in FIG. 2, with schematically diagrammed apparatus components associated therewith.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention provides methods of producing biosensor substrates or chips having multiple antibodies patterned on them. Each antibody is present on the substrate in a specific amount and at a specific location. As a result the output of the substrate can be read automatically to identify and quantify the antigens or analytes present in a sample. The antibodies are separated from each other by an antibody-resistant coating on the substrate which reduces the danger of cross-reactivity between antibody sites and of nonspecific adsorption of antigen. Finally, the methods provide means of patterning many antibodies on a single substrate. This provides the device with the ability to detect multiple chemical species (analytes) or to detect a single species with multiple binding affinities, giving the device a wide range of response and reset times.
The multiple-antibody patterned substrate may be prepared by using either a serial process (as in the examples) or a parallel process. In the serial process, an antibody-adsorbent substrate is coated with an antibody-resistant material. The substrate is then placed in vacuum and an ion beam is used to sputter (etch) away the antibody-resistant coating to expose the surface of the antibody-adsorptive substrate at a selected area. Alternatively, a laser beam could be used to burn or ablate away the antibody-resistant coating to expose the surface. In still another variation, the antibody-resistant material could be precisely removed by mechanical scribing using atomic force microscopy. The substrate is then incubated in a first antibody which results in a large concentration of the first antibody adsorbing on the exposed surface of the antibody-adsorptive material and very little antibody adsorbing on the antibody-resistant coating. The substrate is then rinsed to remove any unadsorbed antibody while leaving the antibody adsorbed to the antibody-adsorbing substrate. Next the substrate is again coated with the antibody-resistant coating. This is a conventional procedure called blocking the surface and it results in any bare surface between the adsorbed antibody molecules being covered with antibody-resistant material. When the other antibodies are applied later they will not be able to attach to this area of the antibody-adsorbent substrate and contaminate it; also antigens will not be able to attach to this area of the substrate. The procedure is then repeated at a new site with a new antibody and this is continued until all the desired antibodies are on the substrate. A final antibody-resistant coating is applied to block the surface around the last antibody adsorbed.
Ion beam sputtering (etching) is used to remove the antibody-resistant coating and expose precise areas of antibody-adsorbent substrate at precise locations. This feature is critical to the production of automated biosensors. The shaping and positioning of the exposed areas may be achieved by using masks or by using a programmable ion beam sputtering device. A high spatial resolution of ion beams permits large numbers of antibody locations to be produced on the substrate. In an alternative embodiment, a laser beam is used to burn or ablate off the antibody-resistant coating in place of ion beam sputtering. Precise shaping and positioning of the exposed areas can be achieve by using masks with the laser or by using a programmable laser. Mechanical scribing using atomic force microscopy provides yet another method of precisely shaping and positioning the exposed areas.
On an industrial scale, it may be preferable to use a parallel process to produce the multiple antibody patterns on the substrates. An ion beam sputtering machine with masks or a programmable ion beam sputtering machine would be used to etch a large number of bare spots on the antibody-adsorbent substrate at once. Alternatively, a laser with a mask or a programmable laser could be used to ablate or burn off the antibody-resistant material from the antibody-adsorbent substrate at a large number of spots at one time. Such removal of anti-body resistant material could also be achieved by mechanical scribing using atomic force microscopy. In the next step, an array of micropipets could be used to deliver each antibody to the correct bare spot (site) and none other. The coating of antibody-resistant coating which separates the etched areas from each other is critical in this process to prevent the cross contamination of antibodies, or adsorption of the antigen in unwanted areas. Ink jet printing technology might be used in place of the micropipets. A final antibody-resistant coating is then applied to block or cover the bare substrate surface around each of the adsorbed antibody molecules. This step is necessary to prevent antibody contamination of the substrate during storage or use of the device, or to allow a false positive reading due to nonspecific antigen adsorption.
The antibody-adsorbent substrate may be composed of any material conventionally used to physically adsorb proteins or antibodies. The adsorption should be a spontaneous, physical process. In general, any hydrophobic material should be suitable for this purpose. Polystyrene and polypropylene are the two most commonly used. However, many other hydrophobic polymeric materials such as polyethylene or copolymers of polyethylene and polypropylene will also work well. The use of cross-linking agents or other chemical agents to chemically bind the antibodies to the substrate are excluded from the processes of this invention.
The antibody-resistant coating is composed of a material which is resistant to antibody (protein) adsorption and which can be etched away in high yield and resolution by using ion beam sputtering or be ablated away by a laser beam, or be removed by mechanical scribing. Examples of preferred antibody-resistant coatings include (1) bovine serum albumin, (2) gelatin, (3) lysozyme, (4) octoxynol, (5) polysorbate 20, and (6) polyethylene oxide-containing block copolymer surfactants. Octoxynol can be represented by the formula
Wherein n is preferably from 9 to 10. The antibody-resistant polyethylene oxide-containing block copolymer surfactants include those containing polyethylene oxide-polypropylene oxide copolymer blocks and those containing polyethylene oxide-polybutylene oxide copolymer block. These surfactants are discussed by Jin Ho Lee et al. In “Protein-resistant surfaces prepared by PEO-containing block copolymer surfactants”, Journal of Biomedical Materials Research , Vol. 23, pp. 351-368 (1989), herein incorporated by reference in its entirety. The more preferred antibody-resistant coatings are bovine serum albumin, gelatin, and lysozyme, with bovine serum albumin being the most preferred.
The multiple antibody patterned substrates of this invention function as multiple analyte or antigen capturing structures that are suitable for automatic analysis. Each analyte is identified by the position (site) of the antibody that captures it on the substrate. Conventional radioactive, fluorescent, or enzymatic labels can be used to mark the captured analytes for detection and measurement. The amount of radioactivity, intensity of fluorescence, or quantity of enzymatic reaction product (color change) is proportional to the quantity of the specific analyte captured by the specific antibody at the specific site. The quantity of analyte capture will be proportional to the concentration of the analyte present in the test environment (solution, air, blood, water, etc.) and the quantity of the capturing antibody present on the substrate at that site. The quantity of the antibody is controlled by the conditions under which the antibody was originally adsorbed on the antibody-adsorbent substrate and by the area of bare substrate available for antibody adsorption. The intensity of the label signals from the various sites on the substrate provides a complete picture of the concentrations of the analytes found in the test environment.
In regard to the foregoing description, various examples are presented as specific embodiments in U.S. Pat. No. 5,858,801 aforementioned. Pursuant to the disclosure hereinafter set forth, an embodiment for patterning many antibodies in parallel by selective removal of antibody resistant coating material from discrete locations on the surface of an antibody adsorbent substrate, is presented. Such coating removal step is performed in such a manner as to achieve a drastic reduction in fabrication time by limitation to mechanical or physical patterning of plural antibodies in parallel on a substrate.
As diagrammed in FIG. 1, an antibody adsorbent substrate 10 initially undergoes a surface coating step 12 . The substrate according to one embodiment is made of polystyrene and has an approximate dimension of 10×5 mm. Such substrate 10 undergoes coating 12 with an antibody resistant material such as bovine serum albumin (BSA) by immersion of the substrate in a 1% w/v solution of the BSA at room temperature for approximately 30 minutes, followed by step 14 for antibody immobilization by rinse in an antigen such as phosphate buffered saline (PBS) for 2 hours under a temperature of 37° C. The BSA coating was then selectively removed from discrete locations on the substrate surface in accordance with coating removal step 16 , followed by another PBS rinse step 18 before application of selected antibodies in parallel to coating free locations on the substrate in accordance with step 20 . The process is completed by a contamination preventing rinse in deonized water as step 22 . An important aspect of the foregoing diagrammed process resides in the coating removal step 16 , which is physical or mechanical in nature as a result of the use of a macro-stylus for mechanical scribing 24 as denoted in FIG. 1, which does not involve any chemical or biological activity as in the case of ion beam sputtering, to not only reduce material costs but to also reduce processing time. While sputtering type of coating removal step disclosed in U.S. Pat. No. 5,858,801 produced a clean enough polystyrene substrate surface for antibody adsorption, it was found that use of mechanical scribing for coating removal pursuant to the present invention is also capable of providing a sufficiently clean polystyrene substrate surface for antibody adsorption.
Antibody patterning using a stainless steel scribe was demonstrated by use in the preparation of two samples, as a much faster approach than ion beam sputtering for removal of BSA from a polystyrene surface. Such mechanical scribing took just a few seconds for each area scribed as part of a procedure otherwise similar to that for patterning with ion beam sputtering. The BSA was selectively removed along an approximately 100 μm wide line by scribing the sample surface with the stainless steel scribe (Techni-Tool, Plymouth Meeting, Pa.) using a pressure of approximately 2×10 7 Pa, followed by a rinse in PBS. The precise value of the pressure is not expected to be critical, provided it is above the threshold for displacing BSA. The sample was then immersed in a solution of the R-α-G antibody. The antibody binds to the clean polystyrene surface exposed by the scribe, but not to the BSA-coated polystyrene. The sample was then rinsed in PBS, blocked by immersing in BSA solution for 30 minutes at room temperature, and rinsed in PBS. Then, the sample surface was scribed again, along a line intersecting and approximately perpendicular to the first line. Following a PBS rinse, the sample was immersed in a solution of R-α-C, the antibody that does not bind the fluorescently labeled antigen. This was followed by a PBS rinse, a BSA block and a PBS rinse. Finally, the sample was immersed in a solution of the fluorescently labeled antigen, G-α-M/FITC. To rule out nonspecific adsorption of antibody or antigen on undesired areas of the surface, and demonstrate functionality of the first antibody, one of the two samples was fabricated by reversing the order of antibody immobilization.
FIGS. 2 and 3 schematically illustrate an example of mechanical scribing 24 , simultaneously applied to many positions on a surface associated with the selective coating removal step 16 denoted in FIG. 1 . Such coating removal may be performed for example on the surface of a base 26 supporting a flat, horizontally movable platform 28 onto which the polystyrene substrate 10 to be patterned is adjustably positioned underlying a stylus array 30 of pixels for simultaneous removal of antibody resistant coating from discrete locations on the substrate 10 . The stylus array 30 is supported by means of some frame structure 32 attached to the base 26 having an internally threaded nut 34 through which a finely threaded screw 36 extends. Such screw 36 is attached at its lower end to the stylus array 30 and is rotatably driven by motor 38 for lowering the array of pixels into scribing contact with the substrate 10 under appropriate force for removal of the BSA coating in response to lateral movement of the substrate 10 in two perpendicular intersecting directions imparted to the substrate through supporting platform 28 . As denoted by way of example in FIG. 3, schematically diagrammed precision motors 40 and 42 impart such movement to the platform 28 under substrate motion control 44 causing the stylus pixels of array 30 to effectively remove the coating from discrete locations on the substrate 10 for subsequent antibody adsorption.
The foregoing described mechanical scribing type of coating removal is most effective in conjunction with the parallel antibody immobilization rinsing approach to antibody patterning, so as to provide for inexpensive fabrication of single-use substrates in conjunction with charge-coupled detectors.
Obviously, other modifications and variations of the present invention may be possible in light of the foregoing teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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Substrates are patterned with antibodies attached thereto at discrete locations from which absorption resistant coating is removed by selectively controlled mechanical scribing contact to avoid chemical removal so as to decrease fabrication costs and increase fabrication speed.
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PRIORITY
[0001] This application is a continuation application of U.S. Ser. No. 13/522,612 which was filed on Jul. 17, 2012 and is still pending. That application, in turn, was the entry into the national phase in the U.S. of International Application No. PCT/JP2011/051218 which was filed on Jan. 24, 2011. That application in turn claimed priority to Japanese Application No. 2010-012510 which was filed on Jan. 22, 2010.
TECHNICAL FIELD
[0002] The present invention relates to a hand joint supporter which can support wearer's daily motion, and particularly, to a hand joint supporter having a taping function of improving stability of the hand joints, thereby reducing the burden on the hand joints and also preventing an inflammation of the tendons of the hand.
BACKGROUND ART
[0003] A supporter for wrist restraint in the related art has a supporter main body which is formed in an approximately tubular shape, can expand and contract at least in the circumferential direction among the circumferential direction and the longitudinal direction, and can cover a site from the vicinity of the wrist of the forearm section to at least the vicinity of the bases of the four fingers except for the thumb, an opening portion for the thumb formed in the supporter main body, and a support which extends along the longitudinal direction on the little finger side of the supporter main body inserted into a pocket, wherein the support is provided so as to be able to extend from at least the vicinity of the wrist of the forearm section on which the support is mounted, to the side portion on the little finger side of the palm over a pisiform bone site (refer to PTL 1, for example).
CITATION LIST
Patent Literature
[0004] [PTL 1] JP-A-2005-549
SUMMARY OF INVENTION
Technical Problem
[0005] The supporter for wrist restraint in the related art is a supporter for restraining the movement of the wrist as a conservative therapy in a case where a bruise, a sprain, or an inflammation of the tendon develops in the wrist, and is not provided with a support on the thumb side and the back side of the hand and the palm side of the hand. In particular, in the supporter for wrist restraint in the related art, as the support, a support which bends when an external force or a load is added thereto is also included. However, it is regarded as being formed so that the fixed feeling is not lost by the bending, and is formed of, for example, synthetic resin, metal, carbon fiber, glass fiber, wood, or the like.
[0006] For this reason, in the supporter for wrist restraint in the related art, there is a problem in that after the approximately tubular supporter main body is formed, a process of attaching the support to the supporter main body by sewing, tack fixing, attachment, adhesion, or the like is required, so that the manufacturing process is complicated.
[0007] The present invention has been made to solve the problem as described above and has an object to provide a hand joint supporter in which the manufacturing process of disposing a support that is a separate body from a supporter main body to the supporter main body is not required, while reducing the burden on the hand joints, so that it is possible to prevent an inflammation of the tendons of the hand.
Solution to Problem
[0008] A hand joint supporter according to the invention includes: a first anchor section which is knitted to go around one end of a tubular knitted fabric and makes the tubular knitted fabric tighten on the forearm of the wearer; a second anchor section which is knitted to go around the other end of the tubular knitted fabric, surrounds portions corresponding to the second metacarpal bone, the third metacarpal bone, the fourth metacarpal bone, and the fifth metacarpal bone in the vicinity of the carpometacarpal joint in at least the third metacarpal bone of the wearer, and makes the tubular knitted fabric tighten on the palm and the back of the hand of the wearer; a hole anchor section which is formed as an approximately circular through-hole in the vicinity of the second anchor section in the tubular knitted fabric to insert the thumb of the hand of the wearer therethrough; and a supporting section which is knitted to extend in the length direction of the tubular knitted fabric over portions corresponding to the carpometacarpal joints of the wearer on the front face and/or back face side of the tubular knitted fabric and is connected to the first anchor section and the hole anchor section, thereby supporting the hand joints of the wearer, wherein the stretch resistance of the first anchor section in the circumferential direction of the tubular knitted fabric is larger than the stretch resistance of a base fabric section in the circumferential direction of the tubular knitted fabric, and the stretch resistance of the supporting section in the length direction of the tubular knitted fabric is larger than the stretch resistance of the base fabric section in the length direction of the tubular knitted fabric.
Advantageous Effects of Invention
[0009] In the hand joint supporter according to the invention, the hand joints of the wearer are stabilized by performing the inhibiting of the palmar flexion and/or the dorsal flexion of the hand joints, and a load which is applied to a tendon that is located at the hand joints is reduced, so that an inflammation of the tendons of the hand can be prevented.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1( a ) is a front view showing a schematic configuration of a hand joint supporter related to the first embodiment, FIG. 1( b ) is a back view of the hand joint supporter shown in FIG. 1( a ), FIG. 1( c ) is a left side view of the hand joint supporter shown in FIG. 1( a ), FIG. 1( d ) is a right side view of the hand joint supporter shown in FIG. 1( a ), and FIG. 1( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 1( a ).
[0011] FIG. 2 is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 1 .
[0012] FIG. 3( a ) is an explanatory diagram for describing the joints and the bones of the hand, FIG. 3( b ) is an explanatory diagram for describing the position of a supporting section with respect to the hand of a wearer, FIG. 3( c ) is an explanatory diagram for describing another position of the supporting section with respect to the hand of the wearer, and FIG. 3( d ) is an explanatory diagram for describing still another position of the supporting section with respect to the hand of the wearer.
[0013] FIG. 4 is an explanatory diagram for describing sites for measuring elongation rates in the hand joint supporter shown in FIG. 1( a ).
[0014] FIG. 5( a ) is an explanatory diagram for describing an experimental motion, FIG. 5( b ) is graphs showing the verification results by a surface electromyogram of the flexor carpi ulnaris muscle in the hand joint supporter shown in FIG. 1 , FIG. 5( c ) is graphs showing the verification results by a surface electromyogram of the flexor carpi radialis muscle in the hand joint supporter shown in FIG. 1 , and FIG. 5( d ) is graphs showing the verification results by a surface electromyogram of the biceps brachii muscle in the hand joint supporter shown in FIG. 1 .
[0015] FIG. 6( a ) is a graph showing the measurement results of the amount of work of a hand joint palmar flexion moment with respect to each test subject for verifying the operation and effects of the hand joint supporter shown in FIG. 1 , and FIG. 6( b ) is a graph showing the average value of the measurement results shown in FIG. 6( a ).
[0016] FIG. 7( a ) is a graph showing the measurement results of the amount of work of a hand joint dorsal flexion moment with respect to each test subject for verifying the operation and effects of the hand joint supporter shown in FIG. 1 , and FIG. 7 ( b ) is a graph showing the average value of the measurement results shown in FIG. 7( a ).
[0017] FIG. 8( a ) is a front view showing the schematic configuration of a hand joint supporter related to the second embodiment, FIG. 8( b ) is a back view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( c ) is a left side view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( d ) is a right side view of the hand joint supporter shown in FIG. 8( a ), and FIG. 8( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 8( a ).
[0018] FIG. 9( a ) is a front view showing the schematic configuration of another hand joint supporter related to the second embodiment, FIG. 9( b ) is a back view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( c ) is a left side view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( d ) is a right side view of the hand joint supporter shown in FIG. 9( a ), and FIG. 9( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 9( a ).
[0019] FIG. 10( a ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 8 , and FIG. 10( b ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 9 .
DESCRIPTION OF EMBODIMENTS
First Embodiment of the Invention
[0020] In FIGS. 1 and 2 , a hand joint supporter 10 is made of a tubular knitted fabric which is knitted by circular knitting by a hosiery knitting machine (for example, a type of knitting machine (the number of needles: 256) manufactured by Lonati Co.), and is a supporter which comes into close contact with the body surface of the wearer, thereby assisting the hand joints of the wearer.
[0021] The hand joint supporter 10 has a desired function such as a taping function by performing different knitting with respect to a base fabric section 1 that is a knitted fabric which is knitted in a plain stitch, a rib stitch, a tuck stitch, a float stitch, a pile stitch, or the like by using an upper thread, an under thread, and a rubber thread as knitting yarn. In addition, the base fabric section 1 related to this embodiment is a knitted fabric which is knitted in a tuck stitch (hereinafter referred to as a tuck stitch knitted fabric).
[0022] Here, the tuck stitch knitted fabric is a knitted fabric in which a certain loop is not made temporarily when knitting the fabric and loops are made together when knitting the next course. In addition, in this embodiment, in consideration of a balance with density, the number of tucks is set to be twice. However, the number is not limited thereto.
[0023] The hand joint supporter 10 has a first anchor section 2 which is knitted to go around one end (an upper end 10 a ) of the tubular knitted fabric and makes the hand joint supporter 10 tighten on the forearm of a wearer.
[0024] The first anchor section 2 is knitted such that the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 (the tubular knitted fabric) is larger than the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 . That is, when tension in a case where a certain elongation has been imparted to a material from a state where elongation is not imparted is set to be F, the tension of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 is set to be F H1 , and the tension of the first anchor section 2 in the circumferential direction H of the hand joint supporter 10 is set to be F H2 , the first anchor section 2 has such a magnitude relationship of F H2 >F H1 that it has a strong tightening force in the circumferential direction H of the hand joint supporter 10 , compared to the base fabric section 1 .
[0025] Specifically, by making the first anchor section 2 be a knitted fabric knitted in a moss stitch (hereinafter referred to as a moss stitch knitted fabric), it is possible to make the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 large with respect to the base fabric section 1 that is the tuck stitch knitted fabric.
[0026] In addition, the moss stitch knitted fabric is a knitted fabric in which a plain stitch and a tuck (a structure in which no loop protrudes over a given course and a plurality of loops protrude over the subsequent course) appear alternately or every few courses in the course direction and the wale direction. For this reason, in the first anchor section 2 , the plain stitch and the tuck are used in combination, whereby it is possible to make protuberances or openwork stitches on the surface of a knitted fabric and a mesh pattern, such as a moss, appears.
[0027] In this manner, the first anchor section 2 is knitted to surround the forearm of a wearer, and the stretch resistance of the first anchor section 2 in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 , whereby it is possible to fix the hand joint supporter 10 to the forearm of a wearer and suppress slipping-off of the upper end 10 a of the hand joint supporter 10 during palmar flexion of the hand joints. Further, the first anchor section 2 is connected to a supporting section 4 (described later), thereby also functioning as an anchor of the supporting section 4 .
[0028] Further, the hand joint supporter 10 has a second anchor section 3 which is knitted to go around the other end (a lower end 10 b ) of the tubular knitted fabric, surrounds portions corresponding to a second metacarpal bone 102 , a third metacarpal bone 103 , a fourth metacarpal bone 104 , and a fifth metacarpal bone 105 in the vicinity of metacarpophalangeal joints 110 of a wearer, and makes the hand joint supporter 10 tighten on the palm and the back of the hand of the wearer, as shown in FIG. 3( a ).
[0029] The second anchor section 3 is knitted such that the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of a buffer section 5 (described later) in the circumferential direction H of the hand joint supporter 10 . That is, when the tension of the second anchor section 3 in the circumferential direction H of the hand joint supporter 10 is set to be F H3 and the tension of the buffer section 5 in the circumferential direction H of the hand joint supporter 10 is set to be F H5 , the second anchor section 3 has such a magnitude relationship of F H3 >F H5 that it has a strong tightening force in the circumferential direction H of the hand joint supporter 10 , compared to the buffer section 5 .
[0030] Specifically, by making the second anchor section 3 be a moss stitch knitted fabric, it is possible to make the stretch resistance thereof in the circumferential direction H of the hand joint supporter 10 large with respect to the buffer section 5 that is a mesh stitch knitted fabric which will be described later.
[0031] In this manner, the second anchor section 3 is knitted to surround the palm and the back of the hand of a wearer and the stretch resistance of the second anchor section 3 in the circumferential direction H of the hand joint supporter 10 is larger than the stretch resistance of the buffer section 5 in the circumferential direction H of the hand joint supporter 10 , whereby it is possible to fix the hand joint supporter 10 to the palm and the back of the hand of a wearer and suppress slipping-off of the lower end 10 b of the hand joint supporter 10 during palmar flexion of the hand joints.
[0032] In addition, if a tightening force on the palm and the back of the hand of a wearer by the second anchor section 3 is too strong, the gaps between the fingers (the second finger (the index finger or the forefinger), the third finger (the middle finger), the fourth finger (the ring finger), and the fifth finger (the little finger)) of the hand of a wearer cannot be fully opened, thereby causing interference with work such as keyboard operation of a personal computer.
[0033] For this reason, the hand joint supporter 10 related to this embodiment is made such that the density of the second anchor section 3 is adjusted (for example, to make a tightening force thereof about 10% smaller with respect to the first anchor section 2 ), whereby the movement of the fingers of the hand with the hand joint supporter 10 worn thereon is not prevented. That is, it is preferable that the hand joint supporter 10 related to this embodiment have a magnitude relationship of F H2 >F H1 >F H3 >F H5 so as to have a moderate tightening force in the circumferential direction H of the hand joint supporter 10 .
[0034] A hole anchor section 11 is formed as an approximately circular through-hole in the vicinity of the second anchor section 3 in the hand joint supporter 10 to insert the first finger (the thumb or the big finger) of the hand of a wearer therethrough.
[0035] In addition, the hole anchor section 11 related to this embodiment is made by making a cut in the tubular knitted fabric which becomes the hand joint supporter 10 , folding a cut edge back to the inside of the tubular knitted fabric, and sewing it using a sewing machine. However, the hole anchor section 11 may also be formed by knitting without cutting out the tubular knitted fabric. In particular, it is preferable that a sewn section constituting the hole anchor section 11 be formed as a flexible bellows by using a sewing thread having high stretch property and increasing the number of stitches per inch of the sewing machine, to reduce a pressing force which is imparted on the thumb of a wearer.
[0036] The hole anchor section 11 positions the hand joint supporter 10 with respect to the hand joints of the wearer by inserting the thumb of the hand of the wearer therethrough and also suppresses the rotational movement in the circumferential direction H or the parallel displacement in the length direction L of the hand joint supporter 10 , thereby being able to prevent a position shift. Further, the hole anchor section 11 is connected to the supporting section 4 (described later), thereby also functioning as an anchor of the supporting section 4 .
[0037] The supporting section 4 is knitted to extend in the length direction L of the hand joint supporter 10 over portions corresponding to carpometacarpal joints 120 of a wearer on the front face and/or back face side of the hand joint supporter 10 and is connected to the first anchor section 2 and the hole anchor section 11 , thereby supporting the hand joints of the wearer. That is, the supporting section 4 is locked at the first anchor section 2 on the forearm side of a wearer and locked at the hole anchor section 11 on the hand side of the wearer.
[0038] In addition, the supporting section 4 related to this embodiment is knitted in an approximately rectangular shape. However, as long as it extends in the length direction L of the hand joint supporter 10 over the portions corresponding to the carpometacarpal joints 120 of the wearer, the shape thereof is not limited thereto.
[0039] Further, the supporting section 4 is knitted such that the stretch resistance thereof in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . That is, when the tension of the base fabric section 1 in the length direction L of the hand joint supporter 10 is set to be F L1 and the tension of the supporting section 4 in the length direction L of the hand joint supporter 10 is set to be F L4 , the supporting section 4 has such a magnitude relationship of F L4 >F L1 that it has a strong tightening force in the length direction L of the hand joint supporter 10 , compared to the base fabric section 1 .
[0040] Specifically, by making the supporting section 4 be a knitted fabric in which a tuck stitch and a plating stitch are used in combination (hereinafter referred to as a tuck stitch-plating stitch knitted fabric), it is possible to make the stretch resistance in the length direction L of the hand joint supporter 10 large with respect to the base fabric section 1 that is a tuck stitch knitted fabric.
[0041] In addition, in the tuck stitch-plating stitch knitted fabric, expansion and contraction of the supporting section 4 in the length direction L of the hand joint supporter 10 is moderately suppressed by additionally feeding another knitting yarn (for example, woolly nylon yarn) in addition to the ground knitting yarn of the tuck stitch, and another knitting yarn is cut at the boundary between the supporting section 4 and the base fabric section 1 (a cut boss).
[0042] In this manner, the supporting section 4 is knitted to extend in the length direction L of the hand joint supporter 10 over the portions corresponding to carpometacarpal joints 120 of the wearer on the front face and/or back face side of the hand joint supporter 10 , and the stretch resistance in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . In this way, the supporting section 4 limits the palmar flexion and/or the dorsal flexion of the hand joints of a wearer, thereby being able to secure stability of the hand joints and also reduce the load that is applied to a tendon which is located at the hand joints.
[0043] In particular, in a case where the hand joint supporter 10 is not worn, if a pain is present in the hand joints, a burden is also applied to the elbow joint or the like which compensates for an overload on the hand joints, so that there is a fear that a secondary pain may be induced. For this reason, in a person for whom the frequency of using the fingers or the hand joints is high and pain is present in the elbow or the front of the shoulder joint, pains of the elbow and the shoulder joint, which result through a chain reaction from a pain of the hand joints, can be reduced by wearing the hand joint supporter 10 .
[0044] In addition, the supporting section 4 is disposed on the front face (the palm of the hand) side of the hand joint supporter 10 , thereby limiting the dorsal flexion of the hand joints of the wearer, and is disposed on the back face (the back of the hand) side of the hand joint supporter 10 , thereby limiting the palmar flexion of the hand joint of the wearer. For this reason, depending on pain of the hand joints of the wearer, in the case of wanting to limit the dorsal flexion of the hand joints, the hand joint supporter 10 in which the supporting section 4 is disposed only on the front face (the palm of the hand) side is also acceptable, and in the case of wanting to limit the palmar flexion of the hand joints, the hand joint supporter 10 in which the supporting section 4 is disposed only on the back face (the back of the hand) side is also acceptable.
[0045] In particular, it is preferable to dispose the supporting sections 4 on the front face and back face sides of the hand joint supporter 10 , because the front face and the back face of the hand joint supporter 10 become symmetrical, so that the hand joint supporter 10 can double as left-hand and right-hand supporters.
[0046] Further, in a case where the supporting section 4 along with the base fabric section 1 which is knitted between the supporting sections 4 that are on the front face and back face sides of the tubular knitted fabric extends only from the vicinity (the first anchor section 2 ) of radiocarpal joints 130 to the vicinity of the carpometacarpal joints 120 , as shown in FIG. 3( c ), a holding feeling of the wrist cannot be obtained and the above-described operation and effects by the supporting section 4 cannot be obtained.
[0047] In contrast to this, in a case where the supporting section 4 and the base fabric section 1 extend from the vicinity (the first anchor section 2 ) of the radiocarpal joints 130 to the vicinity (the second anchor section 3 ) of the metacarpophalangeal joints 110 , as shown in FIG. 3( d ), as well as being unable to fully open the gaps between the fingers of a wearer, the palm and the back of the hand of a wearer are tightened, thereby being accompanied by a pain.
[0048] Therefore, it is preferable that the supporting section 4 and the base fabric section 1 extend from the vicinity (the first anchor section 2 ) of the radiocarpal joints 130 to the metacarpal bone bodies (the approximate middles of the second metacarpal bone 102 , the third metacarpal bone 103 , the fourth metacarpal bone 104 , and the fifth metacarpal bone 105 ), as shown in FIG. 3( b ).
[0049] In addition, in the movement of the hand joints, in addition to the palmar flexion and the dorsal flexion, radial flexion and ulnar flexion are included, and the radial flexion and the ulnar flexion are motions which are frequently used in daily life, and according to the motion, the frequency of occurrence of De Quervain syndrome that is an inflammation of the tendons extending toward the thumb from the hand is high. In contrast to this, the supporting section 4 and the base fabric section 1 limit the radial flexion and the ulnar flexion of the hand joints of a wearer, whereby prevention and improvement of De Quervain syndrome can be expected.
[0050] The buffer section 5 is a knitted fabric surrounded by the second anchor section 3 , the hole anchor section 11 , the supporting section 4 , and the base fabric section 1 in the hand joint supporter 10 and is a knitted fabric making flexibility be provided between the second anchor section 3 and the supporting section 4 .
[0051] The buffer section 5 is knitted such that the stretch resistance thereof in the length direction L of the hand joint supporter 10 is smaller than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 . That is, when the tension of the buffer section 5 in the length direction L of the hand joint supporter 10 is set to be F L5 , the buffer section 5 has such a magnitude relationship of F L1 >F L5 that it has a weak tightening force in the length direction L of the hand joint supporter 10 , compared to the base fabric section 1 .
[0052] Specifically, by making the buffer section 5 be a knitted fabric knitted in a mesh stitch that is a knitting structure having good air permeability (hereinafter referred to as a mesh stitch knitted fabric), it is possible to make the stretch resistance in the length direction L of the hand joint supporter 10 small with respect to the base fabric section 1 that is a tuck stitch knitted fabric.
[0053] In addition, the mesh stitch knitted fabric is a knitted fabric in which a certain loop is not made temporarily when knitting the fabric and loops are made together when knitting the next course and which stretches well by being knit in the form of a mesh.
[0054] In this manner, in the buffer section 5 , the stretch resistance thereof in the length direction L of the hand joint supporter 10 is smaller than the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 , whereby the buffer section 5 does not tighten the palm and the back of the hand of the wearer, thereby preventing constriction of blood flow as well as allowing the gaps between the fingers of a wearer to be fully open, so that a feeling of discomfort is not caused to the wearer.
[0055] In addition, in the hand joint supporter 10 related to this embodiment, due to the knitted fabric of each site described above, the stretch resistance of the base fabric section 1 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the first anchor section 2 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the first anchor section 2 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the second anchor section 3 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the second anchor section 3 in the length direction L of the hand joint supporter 10 is larger than the stretch resistance of the buffer section 5 in the length direction L of the hand joint supporter 10 . Further, the stretch resistance of the supporting section 4 in the circumferential direction H of the hand joint supporter 10 is approximately equal to the stretch resistance of the base fabric section 1 in the circumferential direction H of the hand joint supporter 10 .
[0056] Therefore, the hand joint supporter 10 related to this embodiment satisfies a magnitude relationship shown by the following expression (1) in the tension F in the length direction L of the hand joint supporter 10 . However, in the following expression (1), F L2 is the tension of the first anchor section 2 in the length direction L of the hand joint supporter 10 , and F L3 is the tension of the second anchor section 3 in the length direction L of the hand joint supporter 10 .
[0000] [Expression 1]
[0000] F L4 >F L1 >F L2 >F L3 >F L5 (1)
[0057] Further, the hand joint supporter 10 related to this embodiment satisfies a magnitude relationship shown by the following expression (2) in the tension F in the circumferential direction H of the hand joint supporter 10 . However, in the following expression (2), F H4 is the tension of the supporting section 4 in the circumferential direction H of the hand joint supporter 10 .
[0000] [Expression 2]
[0000] F H2 >F H1 ≈F H4 >F H3 >F H5 (2)
[0058] In addition, in this embodiment, as ground knitting yarn which is used in the moss stitch, the tuck stitch, and the mesh stitch, an upper thread which is nylon yarn having a thickness of 70 deniers and is composed of two pieces of knitting yarn, an under thread which is nylon yarn having a thickness of 30 deniers and is composed of two pieces of knitting yarn, and a rubber thread which is covering yarn (DCY: double covered yarn) in which two pieces of nylon winding yarn each having a thickness of 40 deniers are wound around a polyurethane core yarn having a thickness of 260 deniers are used. However, the threads are not limited to these materials.
[0059] For example, as the upper thread, it is preferable to select a natural fiber such as cotton, wool (cashmere, lamb, Angora, or the like), silk, or hemp, a chemical fiber such as acrylic, a material having a sweat absorbing, quick-drying, or body temperature adjusting function, or the like according to the cost of the hand joint supporter 10 or the needs of a wearer. Further, as the under thread, it is preferable to select an ester, FTY (filament twisted yarn), or an antibacterial, deodorant, or odor eliminating material according to the cost of the hand joint supporter 10 or the needs of a wearer.
[0060] Further, the woolly nylon yarn (pattern yarn) in the tuck stitch-plating stitch knitted fabric (the supporting section 4 ) is composed of two pieces of knitting yarn each having a thickness of 100 deniers.
[0061] Here, the results of measurement of elongation rates (the percentage of the difference between the length when elongated (an elongated dimension) and the original length (the original dimension) to the original length) measured with respect to the respective sites (refer to FIG. 4 ) of the hand joint supporter 10 made according to the above-described knitting yarn and knitted fabrics by using a stretch tester (tensile load: 4 kg) are shown in Table 1 below.
[0000]
TABLE 1
Original
Elongated
Elongation
dimension
dimension
rate
Measured site
[cm]
[cm]
[%]
Circled
Circumferential
8.5
22.0
158.8
number 1
direction H of
the first
anchor section 2
Circled
Circumferential
9.7
28.0
188.7
number 2
direction H of
the second
anchor section 3
Circled
Circumferential
9.0
24.0
166.7
number 3
direction H
over the base
fabric section
1 and the
supporting
section 4
Circled
Length
7.2
10.0
38.9
number 4
direction L of
the base fabric
section 1
Circled
Length
7.2
9.0
25.0
number 5
direction L of
the supporting
section 4
[0062] In addition, since the elongation rates in Table 1 represents the fact that the larger the value, the more easily the knitted fabric is elongated and the tension F in the above-described expressions (1) and (2) represents the fact that the larger the value, the more difficult it is for the knitted fabric to be elongated (the larger the tightening force), an inequality sign showing the magnitude relationship of the elongation rates and an inequality sign showing the magnitude relationship of the tension F become opposite to each other.
[0063] Next, the result of verification of the operation and effects of the hand joint supporter 10 related to this embodiment will be described.
[0064] In the first experiment, in a case where the hand joint supporter 10 is worn on the right wrist (hereinafter referred to as the time of wear) of a test subject (a 26-years-old healthy male, no anamnesis in any of the four limbs) and a case where the hand joint supporter 10 is not worn (hereinafter referred to as the time of non-wear), a state where the test subject holds in the right hand a frying pan weighing 300 g with a 1 kg weight placed therein, and the brachium and the forearm of the right arm are approximately perpendicular to each other was maintained for 30 seconds ( FIG. 5( a )).
[0065] At this time, in the experiment, the myogenic potentials of the biceps brachii muscle (the muscle which bends the elbow) and the flexor carpi ulnaris muscle and the flexor carpi radialis muscle (the muscles which bend the wrist) for the final 5 seconds were measured by a surface electromyogram ( FIG. 5 ). In addition, “MyoResearch” manufactured by Noraxon, Inc. was used in the measurement of the surface electromyogram.
[0066] As shown in FIGS. 5( b ) and 5 ( c ), it can be seen that in the case of the time of wear, compared to the case of the time of non-wear, since the myogenic potentials (the average amplitudes and the muscle integrated values) of the flexor carpi ulnaris muscle and the flexor carpi radialis muscle are lowered, loads on the flexor carpi ulnaris muscle and the flexor carpi radialis muscle are reduced, so that the burden on the hand joints is reduced. In particular, the hand joint supporter 10 reduces the burden on the hand joints, thereby being able to prevent an inflammation of the tendonds of the hand.
[0067] Further, as shown in FIG. 5( d ), it can be seen that in the case of the time of wear, compared to the case of the time of non-wear, since the myogenic potential (the average amplitude and the muscle integrated value) of the biceps brachii muscle is lowered, a load on the biceps brachii muscle is reduced, so that the burden on the hand joints is reduced.
[0068] In the second experiment, in a case where the hand joint supporters 10 are worn on the right wrists of three test subjects (healthy adult males, average age: 29±3.6-years-old, average height: 169.7±4.9 cm, and average weight: 64.3±11.9 kg) (the time of wear) and a case where the hand joint supporter 10 is not worn (the time of non-wear), the hand joints of the test subjects were palmar-flexed and dorsal-flexed in a state where the brachium of the right arm of each test subject is approximately vertical and the forearm of the right arm of each test subject is approximately horizontal. In the experiment, the amount of work of a hand joint palmar flexion moment of each test subject was measured ( FIG. 6 ), and the amount of work of a hand joint dorsal flexion moment of each test subject was measured ( FIG. 7 ).
[0069] As shown in FIGS. 6 and 7 , it can be found that in all the test subjects, at the time when the hand joint supporter 10 is worn, the amount of work of a hand joint palmar flexion moment and the amount of work of a hand joint dorsal flexion moment become large compared to the time of non-wear.
Second Embodiment of the Invention
[0070] FIG. 8( a ) is a front view showing the schematic configuration of a hand joint supporter related to the second embodiment, FIG. 8( b ) is a back view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( c ) is a left side view of the hand joint supporter shown in FIG. 8( a ), FIG. 8( d ) is a right side view of the hand joint supporter shown in FIG. 8( a ), and FIG. 8( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 8( a ). FIG. 9( a ) is a front view showing the schematic configuration of another hand joint supporter related to the second embodiment, FIG. 9( b ) is a back view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( c ) is a left side view of the hand joint supporter shown in FIG. 9( a ), FIG. 9( d ) is a right side view of the hand joint supporter shown in FIG. 9( a ), and FIG. 9( e ) is a plan view and bottom view of the hand joint supporter shown in FIG. 9( a ). FIG. 10( a ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 8 , and FIG. 10( b ) is a perspective view showing a wearing state of the hand joint supporter shown in FIG. 9 . In FIGS. 8 to 10 , the same symbol as that in FIGS. 1 and 2 denotes the same or equivalent section, and explanation thereof is omitted.
[0071] In each drawing described above, the hand joint supporter 10 related to this embodiment is configured to have, in addition to the configuration in the first embodiment, an anchor reinforcing section 12 which is made of a second tubular knitted fabric that is knitted by circular knitting continuously from the second anchor section 3 of the tubular knitted fabric and which spans between the palm and the back of the hand of a wearer in the webbing between the index finger and the middle finger of the wearer, the webbing between the middle finger and the ring finger, and/or the webbing between the ring finger and the little finger, thereby being engaged with the webbing of the wearer. In addition, in the anchor reinforcing section 12 , for example, a mesh stitch knitted fabric which stretches well is used as the second tubular knitted fabric, whereby a strong pressing force is not imparted to the webbing between the index finger and the middle finger of the wearer, the webbing between the middle finger and the ring finger, and/or the webbing between the ring finger and the little finger, so that a feeling of discomfort is not induced in the wearer.
[0072] It is conceivable that the anchor reinforcing section 12 related to this embodiment has, for example, two engagement portions (a first engagement portion 12 a and a second engagement portion 12 b ) which are engaged with the webbing between the index finger and the middle finger of a wearer and the webbing between the ring finger and the little finger, as shown in FIGS. 8 and 10( a ), or three engagement portions (a first engagement portion 12 a , a third engagement portion 12 c , and a second engagement portion 12 b ) which are engaged with the webbing between the index finger and the middle finger of a wearer, the webbing between the middle finger and the ring finger, and the webbing between the ring finger and the little finger, as shown in FIGS. 9 and 10( b ).
[0073] In particular, since compared to the hand joint supporter 10 shown in FIGS. 8 and 10( a ), the hand joint supporter 10 shown in FIGS. 9 and 10( b ) covers each finger up to the vicinity of the proximal interphalangeal joints of the index finger, the middle finger, the ring finger, and the little finger of a wearer and the number of engagements of the engagement portions of the anchor reinforcing section 12 with the webbings of a wearer is large, so that the contact area with the fingers of the wearer is large, it is possible to stably support the hand joints of the wearer.
[0074] In this manner, the hand joint supporter 10 related to this embodiment more reliably supports the hand joints of a wearer by hooking the engagement portions of the anchor reinforcing section 12 on a single or a plurality of webbings, so that the burden on the hand joints is reduced, whereby an inflammation of the tendons of the hand can be prevented.
[0075] In addition, the second embodiment is different from the first embodiment only in that the anchor reinforcing section 12 having a single or a plurality of engagement portions is newly disposed at the second anchor section 3 of the hand joint supporter 10 , and except the above-described operation and effects by the anchor reinforcing section 12 , the same operation and effects as those of the first embodiment are obtained.
REFERENCE SIGNS LIST
[0000]
1 : base fabric section
2 : first anchor section
3 : second anchor section
4 : supporting section
5 : buffer section
10 : hand joint supporter
10 a : upper end
10 b : lower end
11 : hole anchor section
12 : anchor reinforcing section
102 : second metacarpal bone
103 : third metacarpal bone
104 : fourth metacarpal bone
105 : fifth metacarpal bone
110 : metacarpophalangeal joint
120 : carpometacarpal joint
130 : radiocarpal joint
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A hand joint supporter which can reduce the load on hand joints includes a first anchor section for tightening the wearer's forearm with a tubular knitted fabric, a second anchor section for tightening the palm and back of the wearer's hand with the fabric and a hole anchor section formed as a roughly circular through-hole in the vicinity of the second anchor section. A supporting section extends lengthwise in the fabric across the part covering the caprometacarpal joint and is joined to the first anchor section and the hole anchor section so as to support the wearer's hand joints. Stretch resistance, in the circumferential direction of the fabric of the first anchor part is larger than that of a base fabric section, and stretch resistance, in the length width direction of the fabric, of the supporting section is larger than that of the base fabric section.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of co-pending Ser. No. 08/152,333 filed Nov. 12, 1993, which is a division of Ser. No. 07/694,179, filed May 1, 1991, now abandoned, which is a continuation-in-part of Ser. No. 07/386,831 filed Jul. 31, 1989, now abandoned, which is a continuation of Ser. No. 07/099,818, filed Sep. 21, 1987, now abandoned.
This invention relates to plasticized polyvinyl halide resins reinforced with glass fibers, and articles made from such compositions.
Rigid polyvinyl halide resins, such as polyvinyl chloride are used for injection molded or extruded articles. The PVC exhibits strength and creep resistance at temperatures up to its glass transition temperature. To increase the stiffness or modulus of the PVC glass fiber reinforcement can be added. Low molecular weight PVC is chosen, particularly for injection molding applications because of the flowability.
Because high molecular weight PVC exhibits a higher viscosity, its use in injection molding is discouraged. It does not fill the molds adequately because of its limited flow. This is unfortunate because the higher molecular weight PVC exhibits better creep resistance at temperatures above the glass transition temperature of the material. Although the flowability of high molecular weight PVC can be improved with the addition of a plasticizer, this addition lowers the glass transition temperature of the material. This lowering of the glass transition temperature would indicate that creep resistance and stiffness at higher temperatures will be consequently lowered.
Although fiber reinforced rigid low molecular weight PVC exhibits adequate flow in the molding process, higher strength at high use temperatures is sought Therefore, new composition which would have the balance of flow and higher strength at high use temperatures are desired.
SUMMARY OF THE INVENTION
In one aspect, this invention is a polyvinyl halide composition comprising a mixture of polyvinyl halide resin, a plasticizer, and a reinforcement material dispersed in the resin and plasticizer mixture.
In another aspect, this invention is an article prepared from the above-described polyvinyl halide composition in a process wherein the composition is subjected to molding conditions.
In yet another aspect, this invention pertains to a composite of a reinforced, plasticized polyvinyl halide composition (A) in contact with (B) a composition having adhesion to (A). Preferably (B) comprises a thermoplastic compound with the most preferred composition being an unreinforced, plasticized polyvinyl halide composition. A process for producing said composition and composite is also disclosed. The composite can further comprise a component (C) selected from the group consisting of a metal article such as a steel or aluminum article either coated or uncoated as in an automotive body panel, a thermoset polymeric article, and a thermoplastic article. Said component (C) is integrally bonded to at least one of the surfaces of (A) and (B). Said composite in the elemental embodiment is comprised of component (A) integrally bonded with (B). Component (A) comprises: a plasticized, polyvinyl halide resin, wherein said resin exhibits an intrinsic viscosity measured according to ASTM D1243 of above 0.9, preferably said resin has an intrinsic viscosity of from 1.0 to 1.7 and most preferably said resin has an intrinsic viscosity of from 1.0 to 1.4; a plasticizer present at a level of from about 15 weight parts to about 150 weight parts per 100 weight parts polyvinyl halide resin in (A), preferably plasticizer is present from 20 weight parts to 55 weight parts per 100 weight pans polyvinyl halide in (A); and a fibrous reinforcing material selected from the group consisting of glass mat, woven glass or non woven glass fibers, stainless steel shavings, polymeric fibers, such as aramid, polyamide, polymethacrylate, fibrous derivatives of cellulose and the like. Component (A) can further comprise an elastomeric material, for example, SBR, NBR, MBS, polyacrylate, ABS, urethane, copolyester, styrenic block rubbers and combinations thereof. Elastomeric materials, if present, are added in minor proportions with polyvinyl halide without detracting from the physical properties of melt flow, storage modulus, and temperature sag resistance in (A).
The preferred reinforcement material is a high modulus material with glass fibers being the most preferred. Reinforcement material is present in (A) at from 5 to 300 weight parts per 100 weight parts polyvinyl halide resin in (A), preferably reinforcement material is present from 20 to 200 weight parts and most preferably present from 40 to 100 weight parts of reinforcement material per 100 weight parts polyvinyl halide resin in (A). Either said component (A) alone or said composite of (A) and (B) exhibit a storage modulus at 121° C. of from about 5.33 10 6 dynes/cm. 2 to about 1.33 10 9 dynes/cm. 2 , and preferably exhibit a storage modulus at 210° C. of from 1×10 7 to 1×10 8 dynes/cm. 2 .
Component (B), in intimate contact with component (A) for the composite, comprises any material which will form a decorative and/or functional component in contact with at least one surface of (A). Alternatively component (B) can include a coating, laminate or co-extruded material providing a surface and is further treated with a decorative material such as a coating or paint. For instance, (B) can be a thermoplastic decorative compound overlying (A) to provide a mar resistant finish, the color, texture or appearance being matched to suit the styling preference of the designer. Preferred materials comprising (B) are pigmented or unpigmented thermoplastic compounds having adhesion to polyvinyl halide surf aces and include PVC, plasticized PVC,, styrene derivatives, urethane derivatives, acrylic derivatives, acrylonitrile derivatives, polyester derivatives and mixtures of these composition in compounds recognized in the an for providing a functional and/or aesthetic appearance in contact with (A). Specifically, compositions comprising styrene-acrylonitrile polymers, methacrylate polymers, aliphatic polyurethane as well as impact modified versions are suitable materials for component (B). The most preferred material comprises a plasticized, stabilized polyvinyl halide composition absent said fibrous material.
The composition and composite provide sag resistance at elevated temperatures as contributed by (A) and unexpected enhanced impact properties as contributed by the combination of (A) and (B).
Despite the fact that adding the plasticizer to the resin lowers the glass transition temperature, the composition exhibits better strength at 121° C. than rigid polyvinyl halide compositions which have higher glass transition temperatures. The plasticizer improves the flowability of the composition while the crystalinity of high I.V. polyvinyl chloride and dispersed reinforcement material enhance the strength at high temperatures. The compositions of this invention are useful in the manufacture of plastic molded articles requiring high use temperatures under low load conditions. Examples of such articles include window surrounds, automotive body side moldings attached to body panels, arm rests and covers in automobiles, and in window frames.
DETAILED DESCRIPTION OF THE INVENTION
The polyvinyl halide polymers used in this invention are prepared from vinyl halide monomer. Especially preferred polyvinyl halide polymers are polyvinyl chloride polymers, and the remainder of the specification will discuss the aspects of the invention in reference to polyvinyl chloride. Any of the conventional processes for making such polymers such as mass, suspension, solution or emulsion polymerization can be used. Mass and suspension polymerizations are the preferred processes. The process to be described is a suspension process. When using the suspension process, suitable dispersing agents or suspending agents, such as known in the art, may be used. Examples of suitable dispersants are partially hydrolyzed polyvinyl alcohol, cellulose ether, starch, gelatin, and the like. The level of dispersant used will be less than about 0.5 part by weight per 100 parts by weight of monomer. Excellent results are obtained with from 0.05 to 0.3 pan by weight of dispersant per 100 pans by weight of monomer.
The polymerization is initiated with a free radical catalyst The monomer-soluble or oil-soluble catalysts that may be used in the polymerization process to produce the polyvinyl chloride polymer used in this invention are the alkanoyl, aroyl, alkaroyl, and aralkanoyl diperoxides and mono-hydroperoxides, azo compounds, peroxy ester, percarbonates, and other free radical type catalysts. As examples of such catalysts, there may be named benzoyl peroxide, lauryl peroxide, diacetyl peroxide, diisopropylbenzene hydroperoxide, 2,4-dichlorobenzoyl peroxide, naphthyl peroxide, t-butyl perbenzoate, di-t-butyl perphthahte, isopropyl percarbonate, acetyl cyclohexane sulfonyl peroxide, disecondary butyl peraxydicarbonate, 5-butyl peroxyneodecanoate, di-normal propyl peroxydicarbonate, azo-bisisobutyronitrlle, a,a'-azodfisobutyrate, 2,2'-azo-bis-(2,4-dimethyl valeronitrile), and many others. The particular free radical catalyst employed will depend upon the monomeric material(s) being polymerized, the molecular weight and color requirements of the polymer, the temperature of polymerization, etc. Insofar as the amount of catalyst employed is concerned, it has been found that an amount in the range of about 0.005 parts by weight to about 1.00 parts by weight, based on 100 parts by weight of the monomer or monomers being polymerized, is satisfactory. However, it is preferred to employ an mount of catalyst in the range of about 0.01 part by weight to about 0.20 part by weight based on 100 part by weight of monomer(s).
The suspension polymerization process to produce the PVC polymers of this invention is carried out at any temperature which is normal for the monomeric material to be polymerized. Preferably, a temperature in the range of about 0° C. to about 70° C. is employed, more preferably from about 20° C. to about 55° C. In order to facilitate temperature control during the polymerization process, the reaction medium is kept in contact with cooling surfaces cooled by water, brine, evaporation, etc. This is is accomplished by employing a jacketed polymerization reactor wherein the cooling materials are circulated through the jacket throughout the polymerization reaction. This cooling is necessary since free radical polymerization reaction are exothermic in nature. It is understood, of course, that a heating medium can be circulated through the jacket, if necessary.
Although the polymer can be a copolymer of the vinyl or vinylidene halide and an ethylenically unsaturated monomer, it is preferred that the polymer or resin be a homopolymer of polyvinyl chloride. Homopolymers have physical crosslinks of high melting crystallites. The presence of high melting crystallites is evidenced by low sagging at elevated temperature by an unsupported sample under it's own weight. Polyvinyl halide homopolymers and copolymers which do not have sufficient levels of crystallites will exhibit poor elevated temperature sag resistance and are not suitable for use in the present invention. Another way of differentiating from unsuitable Polyvinyl halide copolymers for use in this invention pertains to the modulus of elasticity and permanent modulus index of the copolymer. Copolymers having a modulus of elasticity of less than 10,000 pounds per square inch per ASTM-D747 and a permanent modulus index of less than 3,000 pounds per square inch are not suitable for use in the present invention. Said permanent modulus index is defined as the 100% tensile modulus of a composition containing 17 pans dioctyl phthalate per hundred parts of copolymer and is elaborated in U.S. Pat. No. 3,892,692. Such copolymers inherently possess inadequate strength above their Tg.
The presence of an appreciable level of randomly incorporated comonomers lowers the incidence of polyvinyl halide crystallites within the polymer. Thus, homopolymers and copolymers which, in the compound form exhibit a degree of sag at 120° C. of greater than about 5 cm. using a sample cantilevered 10 cm. from a horizontal support, are not suitable in this invention; sag being measured as the distance from a horizontal line parallel to the plane of the sample support and the unsupported edge of a 0.125 inch thick by 1.0 inch wide sample extending 4 inches (10 cm.) from it's fixed support, and measured after a 1 hour heat soak at 120° C. (method A). Random copolymers of a copolymerizable comonomer such as an olefin present at 4 weight parts per 100 weight pans of vinyl halide monomer can have detrimental effects on the elevated temperature sag resistance of the composition. Block copolymers of homopolymer PVC are suitable, provided the crystallites in the polyvinyl halide polymer are not substantially eliminated so that sag resistance as outlined above rises above about 5 cm at 120° C. after one hour.
The intrinsic viscosity (I.V.) as measured by ASTM D1243 is an indication of molecular weight and has been correlated with the minimum average molecular weight range for the polyvinyl halide polymers suitable for use in the present invention. The polyvinyl chloride homopolymers having an I.V. of above about 1.0, that is, 0.9 I.V. or above, will have a sufficient crystallinity such that, in the plasticized state in combination with reinforcement the composition will provide the minimum acceptable elevated temperature sag resistance. The higher molecular weight assists in building rubbery strength at temperatures above the glass transition temperature of PVC. Any polyvinyl halide polymer with a molecular weight sufficient to provide a plasticized reinforced composition having a storage modulus at 121° C. of at least about 1.33 10 7 dynes/cm. 2 is suitable. The molecular weight of a polyvinyl halide polymer within the suitable range may be selected in relation to the amount of plasticizer or reinforcement to be added, but typically will be above about 1.0, that is, from 0.9 I.V. to 2.4 I.V., preferably from about 1.0 to about 1.7 and most preferably from 1.0 to 1.4 I.V.
The plasticizers useful in this invention are any of the conventional plasticizers used with polyvinyl halides and in particular, polyvinyl chloride. Included are plasticizers suitable for PVC and include those taught in The Technology of Plasticizers, Sears and Darby, John Wiely and Sons, New York (1982) ch.4, incorporated herein by reference. A suitable plasticizer may be polymeric, or monomeric such as a high Tg solid or a low Tg material, the preferred plasticizers being liquids. The amount of plasticizer employed is the minimum amount necessary to impart a desired flow rate to the polyvinyl chloride composition as measured by spiral flow. Spiral flow is a measure of the extent of injection melt flow under a fixed work input and predicts limitations in size and configuration of injection molding dies suitable for a given resin compound. The test employs a graduated 60-inch spiral flow mold with a standard cross section die such as a 1/8 inch by 3/16 inch rectangular cross section die used in conjunction with a Arbug injection molding machine. Generally, the mold temperature is set at 55° C., the injection melt pressure is constant at 27 psi with a 6-s injection time, 18-s clamp time, and a 5-s mold open time, giving a total cycle time of 29 s. A screw of 25 mm with L/D=18 was used. Stock temperature at the nozzle is standardized also. Spiral flow is proper when the polymer is able to flow into the pattern of the mold used. The extent of flow will vary depending on the molecular weight of the plasticizer, the molecular weight of the polyvinyl halide polymer as well as the mount of reinforcement or other material employed. With the use of a relatively lower molecular weight polyvinyl halide polymer within the specified range of I.V. a relatively lesser mount of plasticizer may be required to yield adequate spiral flow, while using a large mount of reinforcement and/or filler may require the use of a higher mount of plasticizer. It is desirable that enough plasticizer is added to impart a spiral melt flow in a 0.36 by 0.16 inch channel of above about 40 inches, and preferably of from about 50 to about 70 inches. Typically, for the high molecular weight polymers contemplated for use in this invention, the mount of plasticizer can range from about 15 pans per hundred polyvinyl halide (resin) to about 100 parts per hundred resin, and preferably from about 20 pans per hundred resin to about 55 parts per hundred resin.
Examples of suitable plasticizers include the phthalates, epoxides, aliphatic diesten, phosphates and polyesters. Preferred are the phthalates and epoxides. Examples of preferred phthalates include dioctyl phthalate, diisooctyl phthalate, diisodecylphthalate; and mixed alkyl esters such as heptyl, nonyl and undecyl phthalate. Preferred epoxides include epoxidized soybean oil, and expoxidized linseed oil. As used in the present invention, a single plasticizer can be employed, as well as blends of different types of plasticizers. An example of a preferred blend is a blend of 85 pans per hundred pans resin of dioctyl phthalate and 5 pans per hundred parts resin of epoxidized soybean oil.
The reinforcement material used in this invention is any material which can be mixed into and subsequently dispersed in the plasticized polyvinyl chloride mixture in a desired amount and which will not detrimentally effect the flowability (e.g. spiral flow) of the plasticized polyvinyl chloride mixture but which will increase or enhance a physical property of the mixture at the use temperature. Preferably, the property increased is storage modulus, although improved creep resistance, and the like are also desirable improvements. The amount of such reinforcement will vary according to the type used, the molecular weight of the polyvinyl chloride polymer, and the level of plasticizer used. Typically, for the high molecular weight polyvinyl chloride polymers and plasticizer level contemplated for use in this invention, the amount of reinforcement used to increase the storage modulus can range from about 5 parts per hundred resin to about 300 weight parts per hundred weight pans PVC resin, and preferably from about 20 weight parts to about 55 weight parts per 100 weight parts PVC. The most preferred amount of reinforcement material present is from 40 to 100 weight parts of reinforcement material per 100 weight pans of PVC.
Examples of suitable reinforcement materials sufficient to improve strength include glass, either mat, woven or non woven fibers; stainless steel shavings; polymeric fibers, such as aramid or cellulosic fibers, and combinations of more than one of these. The preferred material is glass fibers. Alternatively glass fibers are present in addition to a filler such as calcium carbonate. In yet another alternative, glass, calcium carbonate and an elastomeric material are present. The mount of glass used can range from about 5 percent to about 40 percent by weight, and preferably from about 10 to about 30 percent by weight.
The glass used in this invention can be sized or non-sized. A preferred sizing and coupling agent are disclosed in U.S. Pat. No. 4,536,360 to Rahrig, incorporated herein by reference.
The plasticized reinforced polyvinyl chloride composition of this invention can also contain other additives such as pigments, fillers, impact modifiers, processing aids, lubricants, and the like. Suitable materials which provide these function are known in the art.
To prepare the composition, it is desirable to first mix the amount of plasticizer needed to provide the desired flowability with the polyvinyl chloride resin and then add the amount of reinforcement material. As a result of the mixing, the reinforcement material, whether initially in long glass fibers or not, will be crushed and broken, and will be dispersed relatively uniformly throughout the mixture. The articles to be made from the composition will generally be prepared at high temperature under pressure. The temperature is high enough to fuse the resin particles, and the pressure is high enough to extrude an article, force the molten composition into the mold pattern, coextrude a composite article, or co-inject the material with another component. Typically such temperatures range from about 175° C. to about 235° C., and preferably from about 180° C. to about 210° C. The pressures are generally those encountered in inject/on molding and extrusion, co-extrusion, co-injection or laminating processes. The composition is also useful in compression molding, although this process is not favored as a commercial process.
The plasticized reinforced polyvinyl chloride composition has substantial strength under low load condition at high temperature. Its storage modulus at 121° C. can range from about 5×10 6 to about 1.33 10 9 dynes/cm 2 , and preferably from about 1.33 10 7 to about 1×10 8 dynes/cm 2 . An alternative sag test, hereinafter Method B is similar to Method A except that a sample strip 0.125 inch thick by 1 inch wide is cantilevered 1.5 inches (3.8 cm) from the horizontal support. Sag using method B is expressed in degrees and measured as the angle between the plane tangent to the deflected surface nearest the tip of the unsupported sample and the horizontal plane parallel to the supporting surface. Suitable compositions or composites of this invention exhibit less than 10°, preferably less than 5° and more preferably about 0° sag after exposure to 120° C. for 30 minutes. The measured angle is taken from a line tangential from the deflected surface and a horizontal line parallel with the undeflected surface, the cantilever distance being 1.5 centimeters. Where sag is reported in terms of Method A, as outlined above, this represents the distance between the horizontal line taken along the undeflected surface and the deflected edge of the sample that is cantilevered 4.0 inches (10 cm) from the edge of the support. This sag measurement under method A was taken at various temperatures ranging from 80° to 120° C.
The following examples illustrate the concept of this invention, but do not limit the scope of the claims.
EXAMPLE 1
A molding is prepared by injection molding from the following ingredients (unless stated otherwise, all pans are in pans per hundred resin):
______________________________________Compound Amount______________________________________A polyvinyl chloride homopolymer 100resin (intrinsic viscosity of 1.6)Hycar ® 2301 × 120 8(Rubber process aid)Dioctyl Phthalate 85Barium/Cadmium 3(Heat Stabilizer)Calcium Carbonate 100Carbon Black 0.3Oxidized polyethylene 0.3(Lubricant)Paraffin Wax 0.3(Lubricant)Glass Fiber 33______________________________________
The PVC process aid, plasticizer, stabilizer, filler, pigment and lubricants are powder mixed in a Henschel mixer. The powder mixture is heated and sheared to a melt in Buss Kneader compounding equipment. A second port on the Buss Kneader is equipped with a feeding screw, through which the glass fibers are added. The melt and glass mixture is sheared to uniformly disperse the glass throughout the melt. The mixture is then pelletized, and this pelletized compound is then molded into 0.125 inch thick bars at 200° C. melt temperature on an injection molding machine with a 75 ton clamp pressure. The mixture exhibits a spiral melt flow in a 0.16 inch by 0.36 inch channel of 55 inches. The mixture is cooled to allow it to solidify, and the following oven test is performed.
A 1.5 inch long 0.125 inch thick bar was placed in a clamp in an oven. After subjecting the piece to 121° C. for 30 minutes, the piece exhibited 0° sag. The storage modulus of the piece at 121° C. is greater than about 1×10 7 dynes/cm 2 .
EXAMPLE 2
A second molding is prepared from the above-described composition in a similar manner, except that 74 weight parts glass per 100 weight parts PVC are used rather than 10 weight percent The mixture exhibits a spiral melt flow of about 46 inches. After subjecting a bar having the same dimensions as in Example 1 to 121° C. for 30 minutes, the bar exhibited 0° sag. The storage modulus at 121° C. is greater than 1×10 7 dynes/cm 2 .
EXAMPLE 3
A composition was prepared by combining in a Henschel mixer 100 weight pans of a homopolymer PVC having an I.V. of 1.4, 10 weight pans of a crosslinked rubber used in the previous examples, 35 weight parts of Santicizer® 711 believed to represent a mixed phthalate ester (C 7 -C 9 -C 11 ), 3 weight parts of a dimethyl tin di-isooctylthioglycolate stabilizer, 0.3 weight parts carbon black, 0.5 weight parts of oxidized polyethylene, and 0.5 weight parts of paraffin wax. This mixture was heated and sheared to a melt in a Buss Condux kneader equipped with a second port as in the previous example for introducing 64 weight parts of 10 micron (0.254 μm) diameter by 6.3 mm (0.25 in.) chopped glass fibers (Owens Coming Inc.). Glass fibers were thus introduced. The uniformly fluxed mixture was pelletized. The pellets were molded into 0.125 inch (3.18 ram) thick bars at 200° C. on a 75 ton injection molding machine.
The composition of example 3 will exhibit an adequate spiral melt flow. A six inch (15.2) by 0.125 inch (3.18 min.) thick molded bar was secured and cantilevered such that four inches (10 cm.) of sample extended beyond its support. Oven sag testing was performed at temperatures given in Table 1 below.
EXAMPLE 4
A composition was prepared by combining in a Henschel mixer, 100 wt. parts of a homopolymer PVC having an I.V. of 1.4, 10 wt. parts of the crosslinked rubber used in the previous examples, 40 wt. parts of Santicizer® 711, 3 wt. parts of a dimethyl tin di-isooctylthioglycolate stabilizer, 0.3 wt. parts carbon black, 0.5 wt. parts of oxidized polyethylene, and 0.5 parts of paraffin wax. This mixture was heated and sheared to a melt in a Buss Kondux kneader equipped with a second port as in the previous example for introducing 66 wt. parts of 10 micron (0.254 μm) diameter by 6.3 mm (0.25 in.) chopped glass fibers (Owens Corning Inc.). Glass fibers were thus introduced. The uniformly fluxed mixture was pelletized. The pellets were molded into 0.125 inch thick bars at 200° C. on a 75 ton injection molding machine.
The composition of example 4 will exhibit an adequate spiral melt flow. A six inch (15.2 cm.) long by 0.125 inch (3.17 ram) thick molded bar was cantilevered such that four inches of sample extended beyond its support. Oven sag testing was performed for 1 hour at the temperatures given in table I below.
COMPOSITE IMPACT PROPERTIES
The compositions of Examples 3 and 4 were heated in an oven and extruded into strips. The single layer strips were cut to size for testing. Other single layer strips (A) were hot laminated to a plasticized, unreinforced stabilized PVC film (B) and compression molded to simulate a co-extruded composite. The 2-layered (capped) strips and the untapped single layer strips were evaluated at room temperature (RT) for instrumented puncture impact expressed as maximum force in pounds (N), peak energy and absolute energy in ft.-lb./in. (J/M). Instrumented puncture impact testing is based on drop dart impact test as in (ASTM-D2444). Testing of capped strips simulates the actual performance of a fabricated composite useful for example in body side molding and bumper strips in particular, for the automotive industry.
______________________________________ EXAMPLE 3 4 uncapped capped uncapped capped______________________________________Max. Force 192 244 143 198Lb. force (N) (860) (1085) (636) (880)Peak Energy 29 33 21 33Ft.-lb./in. (J/M) (1547) (1761) (1120) (1761)Absolute Energy 59 73 51 65Ft.-lb./in. (J/M) (3148) (3896) (2721) (3469)______________________________________
As is noted from the above data, Examples 3 and 4 exhibit higher instrumented puncture impact for the capped embodiment compared with the single layer, ie. uncapped strips. This is in contrast to a conventional multicomponent article of a thermoplastic over a metal strip. In such an embodiment, it has been observed that impact strength of a metal core/thermoplastic composite is not greater than the impact strength of the metal component alone. In other words, the thermoplastic component does not contribute to the design strength of the assembled article and there is thus no synergy of strength enhancement between the metal and the overlying thermoplastic. Whereas, in the present invention, directed to the above exemplified article, impact properties were consistently improved for the thermoplastic composite as contributed to component (B) and seen in the impact strength of the capped strips. This was unexpected.
COEFFICIENT OF LINEAR EXPANSION
The Examples 3 and 4 were extruded into strips and evaluated for determination of their coefficient of linear thermal expansion (COE) as expressed in in/in °C.×10 -5 (ASTM-D696) between -30° C. and +30° C. In addition, COE was measured at elevated temperature between +30° C. and +30° C. per the Test Procedures of the automotive Composite Consortium 1990, Automotive Composite Consortium, Section 9.2.
______________________________________ Example 3 4______________________________________COE.sup.1 1.7 1.5COE.sup.2 0.4 0.4______________________________________.sup.1 (-30-+30° C.) (in/in. · °C. ×10.sup.-5).sup.2 (+30-+80° C.) (in/in. · °C. ×10.sup.-5)______________________________________Reference Materials--COE (in/in. · °C. × 10.sup.-5) between -30°C. AND +30° C.:Steel 0.8Aluminum 1.3Stainless Steel 1.9Glass reinforced Polypropylene 2.0Rigid PVC 6.5Polyphenylene oxide (PPO) 1.4______________________________________
It is noted the unexpected advantage of reduced COE for Examples 3 and between +30° C. and +80° C. Comparison with the reference materials illustrates a desirable closer match between the COE of the metals and the composite of the invention. This property is useful in articles derived from the composite in contact with such materials. The reinforced composite COE is lower than the COE for polypropylene, rigid PVC and similar to polyphenylene oxide engineering thermoplastic. One economic advantage therefore lies in the use of the composition of the present invention as compared to higher cost engineering thermoplastics such as PPO.
CO-EXTRUDED COMPOSITE
The composite of this invention can be co-extruded. This process is derived from the melt-forming of a multicomponent article from two or more than two process streams, hereinafter termed co-extrusion for the sake of simplicity. The compositions of Examples 3 and 4 were each co-extruded in a laboratory co-extrusion device to produce a 24 mm×2 mm core reinforced strip (A) capped with an outer co-extruded un-reinforced cap (B) of approximately 0.002 inches. The cores consisted of Examples 3 and 4 compositions and the outer cap consisted of a flexible, un-reinforced, plasticized, stabilized PVC composition. Such a cap can thus be utilized as a decorative, weatherable, mar resistant component and can be neutral, clear or formulated with colorants and/or pigments in addition to weatherability improving additives understood in the Art.
The preferred materials for (B) have advantages owing to the mutual adhesion between thermoplastics. This mutual adhesion is high for the preferred plasticized PVC composition of (B) and obviates the need for adhesive means which are generally required to permanently adhere dissimilar components. Owing to the sag resistance of the core reinforced plasticized PVC at elevated temperatures, the molded, extruded, co-molded or co-extruded article can withstand elevated continuous use temperatures without sagging when attached to a substrate, for example a metal panel at several discrete points.
In the conventional article, a metal core is combined with a thermoplastic molding composition. A surface of the metal component, for example, is attached or adhered to a panel by attachment or adhesive means respectively. One aspect of this invention resides in the attachment of the reinforced plasticized polyvinyl halide composition or a composite to a metal panel. The low COE at elevated temperature for the composition is preferably not significantly different than the panel material. This reduced difference in expansion allows for improved permanence of adhesion of the composition when adhered to a panel. Moreover, there is reduced stress between the composition and the attachment means which would otherwise create stresses in the composition leading ultimately to buckling distortion or adhesive failure. This is a critical consideration where adhesive means are used since, at elevated temperatures there is typically a reduction in flexural modulus and static shear strength of adhesives. The increased stress on the adhesive can be disruptive to the established bond and greater failure of bonds and sagging of the article might result. Thermal expansion as well as sagging are greatly minimized by the use of the composite of the present invention. Attachment of the composition or composite to the panel material is enhanced along with weight savings and improved design simplicity and reliability.
OVEN SAG RESISTANCE
Examples 3 and 4 were evaluated for sag by Method A at various elevated temperatures in an oven after a one hour heat soak. The sample cantilevered strips extended four inches (10 cm.) beyond the support. The distance was measured from the deflected tip to the height of the support.
TABLE 1______________________________________ Example 3 Example 4Temperature Sag (cm.) Sag (cm.)______________________________________ 80° C. 0.4 0.5 90° C. 0.6 0.6100° C. 0.8 0.6110° C. 1.5 1.0120° C. 1.5 1.4______________________________________
As can be seen in the oven sag results in Table 1, Examples 3 and 4 molded plasticized reinforced compositions exhibit good sag resistance. It is preferred to achieve a sag resistance of less than about 5 cm. under these conditions, and most preferably, sag is less than about 2 cm. for a 10 cm. cantilevered sample after 1 hour at 120° C. By comparison, for a rigid conventional molded fiber reinforced PVC compound there is an upper limit on I.V enabling the minimum flowability. Such a rigid lower I.V. PVC even with a higher Tg would have deflected completely, exhibiting no sag resistance (10 cm. sag) at 120° C. The sag resistance exhibited by the compositions of this invention represents a significant strength improvement at temperatures above the Tg for the PVC composition. This evidences the critical importance of crystallites present in PVC which are not disrupted even at which is a least 40 degrees Celsius (120° C.) above the glass transition temperature. In addition, it is shown above that Example 4 which contained 40 wt. pans of phthalate plasticizer compared to 30 wt. parts for Example 3, did not exhibit increased sag at elevated temperatures and is unexpected since the Tg for this example is lower than the Tg for example 3. This is a desirable feature relative to the contribution of plasticizer for further enhanced processibility.
Various changes and modifications may be made in carrying out the present without departing from the spirit and scope thereof. These changes are to be considered as part of the invention. While in accordance with the Patent Statutes, the best mode and preferred embodiment has been set forth. The scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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Compositions, composite articles and process for producing same are provided from a reinforced polyvinyl halide composition (A) comprising a high molecular weight polyvinyl halide resin, a plasticizer, and a reinforcement material, such as glass fibers, in combination with (B) a composition having adhesion to (A). Preferably (B) comprises a thermoplastic compound selected from the group consisting of PVC, plasticized PVC, styrene derivatives, urethane derivatives, acrylic derivatives, acrylonitrile derivatives, polyester derivatives, and mixtures thereof, with the most preferred composition being an unreinforced, plasticized polyvinyl halide composition. The composition article exhibits good strength, low sag at high use temperatures, and lowered coefficient of thermal expansion for use in contact with metal or polymeric substrates such as panels. The composition having a coefficient of thermal expansion not significantly different than the substrates in contact therewith, provides enhanced permanence of adhesion and sag resistance.
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FIELD OF THE INVENTION
This invention relates to flash-spinning of polymeric, plexifilamentary, film-fibril strands. More particularly, this invention relates to flash-spinning of polymethylpentene.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,081,519 to Blades and White describes a flash-spinning process for producing plexifilamentary film-fibril strands from fiber-forming polymers. A solution of the polymer in a liquid, which is a non-solvent for the polymer at or below its normal boiling point, is extruded at a temperature above the normal boiling point of the liquid and at autogenous or higher pressure into a medium of lower temperature and substantially lower pressure. This flash-spinning causes the liquid to vaporize and thereby cool the exudate which forms a plexifilamentary film-fibril strand of the polymer. Preferred polymers typically include crystalline polyhydrocarbons such as polyethylene and polypropylene.
According to Blades and White, a suitable liquid for flash spinning (a) has a boiling point that is at least 25° C. below the melting point of the polymer; (b) is substantially unreactive with the polymer at the extrusion temperature; (c) should be a solvent for the polymer under the pressure and temperature set forth in the patent (i.e., these extrusion temperatures and pressures are respectively in the ranges of 165 to 225° C. and about 500 to 1500 psia (3447-10342 kPa); (d) should dissolve less than 1% of the polymer at or below its normal boiling point; and (e) should form a solution that will undergo rapid phase separation upon extrusion to form a polymer phase that contains insufficient solvent to plasticize the polymer.
Commercial spunbonded or flash-spun products have been made primarily from polyethylene plexifilamentary film-fibril strands and have typically been produced using trichlorofluoromethane as a spin agent; however, trichlorofluoromethane is an atmospheric ozone depletion chemical, and therefore, alternatives have been under investigation. There have been many other agents used for flash spinning polyethylene to either minimize or eliminate the potential for ozone depletion. Shin, in U.S. Pat. No. 5,032,326 discloses one alternative spin fluid, namely, methylene chloride and a co-spin agent halocarbon having a boiling point between −50° C. and 0° C. Kato et al. in U.S. Pat. No. 5,286,422 discloses an alternative, specifically, a spin fluid of bromochloromethane or 1,2-dichloroethylene and a co-spin agent of, e.g., carbon dioxide, dodecafluoropentane, etc.
As noted above, flashspun products have typically been made from polyethylene, however it is desirable to make flashspun products from other polymers, such as polymethylpentene that have the advantage of a higher melting point than polyethylene.
U.S. Pat. No. 5,250,237 to Shin mentions the use of alcohols with one to four carbons as spin agents for flash spinning polymethylpentene. Also, in a co-pending application assigned to DuPont 09/211,822 filed Dec. 15, 1998, certain azeotropic mixtures are used as spin agents for polymethylpentene. Regardless, a need exists to find additional solvents suited for polymethylpentene, yet also satisfy the need for non-flammability and zero or extremely low ozone depletion potential.
SUMMARY OF THE INVENTION
The present invention is a process for the preparation of plexifilamentary film-fibril strands of synthetic fiber-forming polyolefin which comprises flash-spinning at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure, a spin fluid comprising (a) 5 to 30 wgt. % polymethylpentene, and (b) a spin agent selected from the group consisting of hydrochlorofluorocarbons; hydrocarbons; and chlorinated solvents.
This invention is also a spin fluid comprising (a) 5 to 30 wgt. % polymethylpentene and (b) a spin agent selected from the group consisting of hydrocarbons; hydrochlorofluorocarbons; and chlorinated solvents.
This invention is also directed to plexifilamentary film-fibril strands of fiber-forming polymethylpentene having a tenacity of at least 0.5 grams per denier and more preferably having a tenacity of at least 1 gram per denier. Also included are blends of polymethylpentene with polyethylene and polypropylene.
This invention is also directed to a process for the preparation of microcellular foam fibers from synthetic fiber-forming polyolefin which comprises flash-spinning at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure, a spin fluid comprising (a) at least 40 wgt. % polymethylpentene and (b) a spin agent selected from the group consisting of hydrocarbons; hydrochlorofluorocarbons; and chlorinated solvents.
The invention is further directed to a process for the preparation of discrete plexifilamentary fibers (pulp) from synthetic fiber-forming polyolefins.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, together with the description, serve to explain the principles of the invention, but not to limit the invention.
FIG. 1 is a plot of the cloud-point data for a solution comprised of polymethylpentene in a spin agent of n-pentane.
FIG. 2 is a plot of the cloud-point data for a solution comprised of polymethylpentene in a spin agent of dichlorotrifluoroethane (HCFC-123).
FIG. 3 is a plot of the cloud-point data for a solution comprised of polymethylpentene in a spin agent of HCFC-123 and trichlorodifluoroethane (HCFC-122) as a co-spin agent.
FIG. 4 is a plot of the cloud-point data for a solution comprised of polymethylpentene in a spin agent of dichloropentafluoropropane (HCFC-225).
DETAILED DESCRIPTION OF THE INVENTION
It is known that polymethylpentene has a higher melting point than either polyethylene or polypropylene (235° C. versus 140° C. and 165° C., respectively) and as such can provide a flashspun product usable at higher temperatures. Nylon and polyester also have high melting points but polymethylpentene is more suited to flash spinning. At this time, there is not a suitable agent for flash spinning nylon and the spin agents for polyester are very limited. The flashspun polymethylpentene (PMP) of this invention exhibits very good fibrillation, but it is further noted that PMP does not have the strength of polyethylene (PE). However, the plexifilamentary fibers herein made from PMP have shown strength greater than 0.5 gram per denier which is sufficient for many purposes. Strength greater than one gram per denier can be achieved.
The term “synthetic fiber-forming polyolefin” herein is intended to encompass certain polymers that can be used in the flash-spinning art, e.g., polymethylpentene, polyethylene and polypropylene. A preferred synthetic fiber-forming polyolefin is polymethylpentene. The term “synthetic fiber-forming polyolefin” may also include polymethylpentene blended with either polyethylene or polypropylene. Blends of PMP with both PE and PP can be used. The PE and PP either separately or both together can be present at 10 to 90% of the total weight of the polyolefin.
The term “polymethylpentene” is intended to embrace not only homopolymers of 4-methylpentene-1 but also copolymers where at least 85% of the recurring units are polymerized units of 4-methylpentene-1. The term “polypropylene” is intended to embrace not only homopolymers of propylene but also copolymers where at least 85% of the recurring units are polymerized units of propylene. The term “polyethylene” is intended to embrace not only homopolymers of polyethylene but also copolymers where at least 85% of the recurring units are polymerized units of ethylene.
The preferred process for making plexifilamentary materials employs a spin fluid in which the synthetic fiber-forming polyolefin concentration is in the range of 6 to 22 wgt. %. The range may depend somewhat on whether low density or high density spin agents are used. For example, if a high density spin agent, such as a hydrochlorofluorocarbon were used, the wgt. % of polyolefin would be lower. The term spin fluid as used herein means the solution comprising the fiber-forming polyolefin, the spin agent and any co-spin agent that may be present. Unless noted otherwise, the term wgt. % as used herein refers to the percentage by weight based on the total weight of the spin fluid. The spin agent may be selected from the group consisting of hydrocarbons; hydrochlorofluorocarbons; and chlorinated solvents. Some specific examples of spin agents are cyclopentane, dichlorotrifluoroethane (HCFC-123) and n-pentane.
Co-spin agents can be used to either raise or lower the cloud-point pressure of the spin fluid. To raise the cloud-point pressure, the co-spin agent in the spin fluid must be a “non-solvent” for the polymer or at least a poorer solvent than the primary spin agent. In other words, the solvent power of the co-spin agent of the spin fluid used must be such that if the polymer to be flash-spun were to be dissolved in the co-spin agent alone, typically, the polymer would not dissolve in the co-spin agent, or the resultant solution would have an unacceptably high cloud-point pressure. It is noted that the general term “spin agent” may refer to a primary spin agent when used alone or to the primary spin agent combined with a co-spin agent. Trichlorodifluoroethane (HCFC-122) is an example of a co-spin agent used in the subject invention which lowers the cloud-point pressure.
The term “cloud-point pressure” as used herein, means the pressure at which a single phase liquid solution begins to phase separate into a polymer-rich/spin liquid-rich two-phase liquid/liquid dispersion. However, at temperatures above the critical point, there cannot be any liquid phase present and therefore a single phase, supercritical solution phase separates into a polymer-rich/spin fluid-rich, two-phase gaseous dispersion.
In order to spread the web formed when polymers are flash spun in the commercial operations, the flash spun material is projected against a rotating baffle and then subjected to an electrostatic charge; see, for example, Brethauer et al. U.S. Pat. No. 3,851,023.
Pulp of discontinuous plexifilamentary fibers can be made from PMP alone or from PMP blended with PE and/or PP. The pulp of this invention can be produced by disc refining flash spun plexifilaments as disclosed in U.S. Pat. No. 4,608,089 to Gale & Shin. Alternatively, the pulp can be prepared directly from polymer solutions by flash spinning using a device similar to the one disclosed in U.S. Pat. No. 5,279,776 to Shah.
The pulp made by this invention is comprised of plexifilamentary film-fibrils and can have a three-dimensional network structure. However, the pulp fibers are relatively short in length and have small dimensions in the transverse direction. Their average length is less than about 5 mm and their average diameter is less than about 200 micrometers, preferably less than about 50 micrometers. They typically have relatively high surface area; greater than about 1 square meter per gram when determined by the BET method as further explained below.
Microcellular foams can be obtained by flash-spinning and are usually prepared at relatively high polymer concentrations in the spinning solution, i.e., at least 40 wgt. % synthetic fiber-forming polyolefin. Polymethylpentene is preferred but the synthetic fiber-forming polyolefin may also include polymethylpentene blended with either polyethylene or polypropylene. Blends of PMP with both PE and PP can also be used. Also, relatively low spinning temperatures and pressures that are above the cloud-point pressure can be used. Microcellular foam fibers may be obtained rather than plexifilaments, even at spinning pressures slightly below the cloud-point pressure of the solution. Spin agents used are the same as those noted above for plexifilamentary, film-fibril materials. Nucleating agents, such as fumed silica and kaolin, are usually added to the spin mix to facilitate spin agent flashing and to obtain uniform small size cells.
Microcellular foams can be obtained in a collapsed form or in a fully or partially inflated form. For many polymer/solvent systems, microcellular foams tend to collapse after exiting the spinning orifice as the solvent vapor condenses inside the cells and/or diffuses out of the cells. To obtain low density inflated foams, inflating agents are usually added to the spin liquid. Suitable inflating agents that can be used include low boiling temperature partially halogenated hydrocarbons, such as, hydrochlorofluorocarbons and hydrofluorocarbons; or fully halogenated hydrocarbons, such as chlorofluorocarbons and perfluorocarbons; hydrofluoroethers; inert gases such as carbon dioxide and nitrogen; low boiling temperature hydrocarbon solvents such as butane and isopentane; and other low boiling temperature organic solvents and gases.
Microcellular foam fibers are normally spun from a round cross section spin orifice. However, an annular die similar to the ones used for blown films can be used to make microcellular foam sheets.
EXAMPLES
Test Methods
In the description above and in the non-limiting examples that follow, the following test methods were employed to determine various reported characteristics and properties. ASTM refers to the American Society of Testing Materials, and TAPPI refers to the Technical Association of the Pulp and Paper Industry.
The denier of the strand is determined from the weight of a 15 cm sample length of strand under a predetermined load.
Tenacity, elongation and toughness of the flash-spun strand are determined with an Instron tensile-testing machine. The strands are conditioned and tested at 70° F. (21° C.) and 65% relative humidity. The strands are then twisted to 10 turns per inch and mounted in the jaws of the Instron Tester. A two-inch gauge length is used with an initial elongation rate of 4 inches per minute. The tenacity at break is recorded in grams per denier (gpd). The elongation at break is recorded as a percentage of the two-inch gauge length of the sample. Toughness is a measure of the work required to break the sample divided by the denier of the sample and is recorded in gpd. Modulus corresponds to the slope of the stress/strain curve and is expressed in units of gpd.
The surface area of the plexifilamentary film-fibril strand product is another measure of the degree and fineness of fibrillation of the flash-spun product. Surface area is measured by the BET nitrogen absorption method of S. Brunauer, P. H. Emmett and E. Teller, J. Am. Chem. Soc., V. 60 p 309-319 (1938) and is reported as m 2 /g.
Test Apparatus for Examples 1-23
The apparatus used in the examples is the spinning apparatus described in U.S. Pat. No. 5,147,586. The apparatus consists of two high pressure cylindrical chambers, each equipped with a piston which is adapted to apply pressure to the contents of the chamber. The cylinders have an inside diameter of 1.0 inch (2.54 cm) and each has an internal capacity of 50 cubic centimeters. The cylinders are connected to each other at one end through a {fraction (3/32)} inch (0.23 cm) diameter channel and a mixing chamber containing a series of fine mesh screens that act as a static mixer. Mixing is accomplished by forcing the contents of the vessel back and forth between the two cylinders through the static mixer. A spinneret assembly with a quick-acting means for opening the orifice is attached to the channel through a tee. The spinneret assembly consists of a lead hole of 0.25 inch (0.63 cm) diameter and about 2.0 inch (5.08 cm) length, and a spinneret orifice with a length and a diameter each measuring 30 mils (0.762 mm). The pistons are driven by high pressure water supplied by a hydraulic system.
In the tests reported in Examples 1-23, the apparatus described above was charged with pellets of a polyolefin and a spin agent. High pressure water was used to drive the pistons to generate a mixing pressure of between 1500 and 3000 psig (10,239-20,478 kPa). The polymer and spin agent were next heated to mixing temperature and held at that temperature for a specified period of time during which the pistons were used to alternately establish a differential pressure of about 50 psi (345 kPa) or higher between the two cylinders so as to repeatedly force the polymer and spin agent through the mixing channel from one cylinder to the other to provide mixing and to effect formation of a spin mixture. The spin mixture temperature was then raised to the final spin temperature, and held there for about 15 minutes or longer to equilibrate the temperature, during which time mixing was continued. In order to simulate a pressure letdown chamber, the pressure of the spin mixture was reduced to a desired spinning pressure just prior to spinning. This was accomplished by opening a valve between the spin cell and a much larger tank of high pressure water (“the accumulator”) held at the desired spinning pressure. The spinneret orifice is opened about one to three seconds after the opening of the valve between the spin cell and the accumulator. This period roughly corresponds to the residence time in the letdown chamber of a commercial spinning apparatus. The resultant flash-spun product is collected in a stainless steel open mesh screen basket. The pressure recorded just before the spinneret using a computer during spinning is entered as the spin pressure.
The experimental conditions and the results for Examples 1-16 are given below in Tables 1-3. It is noted that pressures may be expressed as psig which is pounds per square inch gage which is ˜15 psi less than psia (pound per square inch absolute). The unit psi is considered the same as psia. For converting to SI units, 1 psi=6.9 kPa. When an item of data was not measured, it is noted in the tables as nm.
Examples 1-10
In Examples 1-10, samples of TPX DX845 polymethylpentene were obtained from Mitsui Plastics, Inc. (White Plains, N.Y.). Dichlorotrifluoroethane (HCFC-123) was used as the spin agent. The PMP had a melt flow index of 8 g/10 min and a density of 0.835 g/cm 3 and was used at various concentrations.
Weston 619F, a diphosphite thermal stabilizer from GE Specialty Chemicals, was added at 0.1 wgt. % based on the total weight of the spin agent. Acceptable plexifilamentary fibers were obtained with properties as presented in Table 1. It should be noted that the relatively short mixing time shown reflects the mixing after the desired spin temperature has been reached and that mixing was occurring while the solution was being heated to the spin temperature (typically about 30 minutes).
TABLE 1
PMP Plexifilamentary Fibers
Mixing
Spinning
Properties
Tot.
Back
Spinneret,
Accum.
Twist per
Mod
Ten
No.
N.B. Code
wt. %
° C.
Min
psig
mils
psig
° C.
Den
inch
gpd
gpd
E %
1
E91514-92
10
190
1
1700
15 × 15
1000
190
43
24.7
4.24
1.1
46
2
E91514-94
10
220
1
x
15 × 15
1500
220
52
21.7
2.47
1.1
46
3
E91514-96
10
200
1
1610
15 × 15
1200
200
47
23.7
2.28
0.8
52
4
E91514-99
10
220
1
2220
15 × 15
1600
220
49
23.1
1.94
0.8
44
5
E91514-100
10
240
1
2600
15 × 15
2000
240
51
22.1
2.1
0.8
47
6
E91514-103
10
240
1
2600
30 × 30
2000
240
144
13.2
3.46
1.1
54
7
E91514-104
8
220
1
2500
30 × 30
1900
220
166
12.3
1.4
0.5
57
8
E91514-105
10
220
1
2200
30 × 30
1600
220
144
13
2.75
1.2
54
9
E91514-106
8
200
1
2050
30 × 30
1450
200
106
15
3.55
1.1
64
10
E91514-110
8
220
1
2500
15 × 15
1900
220
43
24
1.71
0.8
58
Examples 11-13
In Examples 11-13, samples of PMP as described in Examples 1-10 were used. Various solvents as shown in Table 2 were used as spin agents.
Weston 619F, a diphosphite thermal stabilizer from GE Specialty Chemicals, was added at 0.1 wgt. % based on the total weight of the spin agent. Acceptable plexifilamentary fibers were obtained with properties as presented in Table 2.
TABLE 2
PMP Plexifilamentary Fibers
Polymer
Mixing
Spinning
Properties @ 10 tpi
Tot.
Solvent
Back
Delta
ACCUM.
SPIN
gms
Mod
Ten
No.
N.B. Code
Wt. %
Type
° C.
Min
psig
P
P psig
psig
T ° C.
load
Den
gpd
gpd
E %
11
P11774-151
20
HCFC-225
180-250
20
2000
300
1050
˜950
250
40
379
4.2
1.01
50
12
P11774-152
˜22
80/20
160-250
27
2000
300
1300
1200
251
40
502
3.3
1.04
53
HCFC-123/
HCFC-122
13
P11815-5
22
n-Pentane
125-250
25
2200
200
1325
1225
250
40
180
2.4
1.2
44
Examples 14-15
In Examples 14-15, polymethylpentene as described in Examples 1-10 was blended with ALATHON® high density polyethylene obtained from Lyondell Petrochemical Co., Houston, Tex. The polyethylene had a melt index of 0.75, a number average molecular weight of 27,000 and a molecular weight distribution (MWD) of 4.43. MWD is the ratio of weight average molecular weight to number average molecular weight. The spin agent used was n-pentane. The PMP and PE were blended at various weight percentages of the polyolefin. The total weight percentage of the blended polyolefin in the spin fluid was 20%.
Weston 619F, a diphosphite thermal stabilizer from GE Specialty Chemicals, was added at 0.1 wgt. % based on the total weight of the spin agent.
TABLE 3
Plexifilaments From PMP/HDPE Blends
Polymer
Mixing
Spinning
Properties @ 10 tpi
PP
Solvent
Back
ACCUM.
SPIN
T
gms
Mod
Ten
No.
N.B. Code
Name
%
Type
° C.
Min
psig
ΔP
P psig
psig
° C.
load
Den
gpd
gpd
E %
14
P11547-96
PMP
25
n-Pentane
180
60
2500
300
1400
1300
183
40
322
7.1
2.4
64
PE
75
15
p11547-76
PMP
50
n-Pentane
180
60
2500
300
1800
1800
181
40
678
5.7
1.77
65
Example 16
Microcellular foam was made in this example by mixing and spinning polymethylpentene at selected pressures and temperatures using the indicated spin agents. The spinneret hole measured 30 mil×30 mil (diameter×length). A sample of TPX DX 845 polymethylpentene was mixed in a spin agent of HCFC-123. The polymethylpentene was present at 60 wgt. % of the spin fluid. The additive used was 0.1 wgt. % of Weston 619F thermal stabilizer based on the weight of the spin agent. Mixing was done at 190° C. for 5 min at 1800 psig (12307 kPa). Spinning took place at a 900 psig (6154 kPa) accumulator pressure with the spinning being done at a lower pressure at 190° C. Acceptable microcellular foam was obtained.
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A process for flash spinning polymethylpentene alone or as a blend with polyethylene or polypropylene using various spin agents having essentially zero or very low ozone depletion potential.
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BACKGROUND OF THE PRESENT INVENTION
[0001] The present invention relates to a lock mechanism for use within a window assembly, and in particular to a lock mechanism that prevents accidental damage to the window assembly during operation thereof.
[0002] Window assemblies and lock mechanisms for securing window assemblies, particularly single and double hung window sash assemblies, are used frequently in residential and commercial building structures. These lock mechanisms frequently include a deployable catch member that is operative between an engaged position and a disengaged position. The disengaged position allows a window assembly to be opened. The engaged position prohibits opening of the window assembly because the catch member is inserted into a lock keeper.
[0003] A commonly acknowledged shortcoming in the currently available designs of single and double hung window sash lock mechanisms is that the catch member can be rotated to the locked position when the sash are in an opened position. Specifically, former designs have allowed the catch member to be rotated to the locked position when the sash are in an opened position. When this occurs, the catch member extends outwardly from the associated sash and into the path of the remaining sash thereby causing damage to the remaining sash, lock, lock keeper, etc. when the sash are moved to the closed position.
[0004] Accordingly, a lock mechanism that prevents the catch member from moving into the locked position when the window assembly is open would be useful and an improvement in the art.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a window latch includes a housing member having an interior and a handle operably coupled to the housing member wherein the handle is movable between an unlocked position and a locked position. A catch member is fixed for rotation with the handle and includes a first stop. The catch member rotates between a locked position corresponding to the locked position of the handle, wherein the catch member is adapted to engage a lock keeper thereby preventing movement of a first window with respect to a second window, and an unlocked position, corresponding to the unlocked position of the handle wherein the catch member is adapted to disengage a lock keeper, thereby allowing movement of the first window with respect to the second window. A lever is operably coupled to the housing and includes a second stop. The lever operates between a first position, wherein the second stop abuts the first stop preventing rotation of the catch member from the unlocked position to the locked position, and a second position, wherein the lever allows rotation of the catch member from the unlocked position to the locked position. The second stop is configured to allow rotation of the catch member from the locked position to the unlocked position when the lever is in the first position and when the lever is in the second position.
[0006] In another aspect of the present invention, a window assembly includes a first window including a first window sash and a second window that includes a second window sash substantially parallel with and movable relative to the first window sash. A lock mechanism is fixed to a select one of the first window sash and the second window sash, and a lock receiver is fixed to a select one of the first window sash and the second window sash not fixed to the lock mechanism. The lock mechanism includes a lock member operating between a locked position, wherein the lock member engages the lock receiver preventing movement between the first and second windows, and an unlocked position allowing movement between the first and second windows. A bar member moves between a first position, wherein the bar member engages the lock mechanism preventing the lock mechanism from being moved from the unlocked position to the locked position, and a second position allowing the lock mechanism to be moved from the unlocked to the locked position.
[0007] In yet another aspect of the present invention, a window latch assembly includes a cover member and a handle pivotably coupled to the cover member. A lock member is fixed for rotation with the handle and has a lock portion adapted to protrude beyond a planar extent of the cover into a first position and retract inside the cover into a second position. The lock keeper is also adapted to securely engage a complementary lock keeper. A mechanical finger is movable between a first position allowing the lock portion to be moved from the second position to the first position, and a second position preventing the lock portion from being moved from the second position to the first position.
[0008] The present inventive window latch comprises an uncomplicated design, is quickly and easily assembled during manufacture, is relatively economical to manufacture, is capable of a long operating life, and is well adapted for the proposed use. Specifically, the window latch allows normal operation of a window assembly while preventing accidental damage to the components thereof by an outwardly extended catch or lock member.
[0009] These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front elevational view of a window assembly embodying the present invention;
[0011] FIG. 2 is an enlarged, exploded, top and side perspective view of a window latch;
[0012] FIG. 2A is a top and side perspective view of the window latch in an unlocked position;
[0013] FIG. 2B is a top and side perspective view of the window latch in a locked position;
[0014] FIG. 3 is a side elevational view of the window latch in the locked position;
[0015] FIG. 4 is a front elevational view of the window latch including a raised lever;
[0016] FIG. 5 is a top and opposite side perspective view of the window latch;
[0017] FIG. 6 is a cross-sectional view of the window latch taken at line VI-VI, FIG. 5 ;
[0018] FIG. 7 is a top and opposite side perspective view of the window latch including a raised lever; and
[0019] FIG. 8 is a cross-sectional view of the window latch taken at line VIII-VIII, FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] For purposes of description herein the terms “upper”, “lower”, “right”, “left”, “rear”, “front”, “vertical”, “horizontal” and derivatives thereof shall relate to the invention as oriented in FIG. 2 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0021] The reference numeral 10 ( FIG. 1 ) generally designates a window assembly embodying the present invention, which is designed for use in a building structure (not shown). The window assembly 10 has a window latch 12 ( FIGS. 2 and 3 ) that includes a housing member 14 having an interior 16 and a handle 18 pivotably coupled to the housing member 14 wherein the handle 18 is movable between a locked position 19 ( FIG. 2B ) and an unlocked position 20 ( FIG. 2A ). A catch member 22 is fixedly coupled with the handle 18 and includes a first stop 24 . The catch member 22 rotates between a locked position 19 a corresponding to the locked position 19 of the handle 18 and wherein the catch member 22 is adapted to engage a lock keeper 25 thereby preventing movement of a first window 26 with respect to a second window 28 , and an unlocked position 20 a, corresponding to the unlocked position 20 of the handle 18 and wherein the catch member 22 is adapted to disengage the lock keeper 25 , thereby allowing movement of the first window 26 with respect to the second window 28 . A lever 30 is pivotably coupled to the housing member 14 and includes a second stop 32 . The lever 30 operates between a first position 31 , wherein the second stop 32 abuts the first stop 24 preventing rotation of the catch member 22 from the unlocked position 20 a to the locked position 19 a, and a second position 33 , wherein the lever 30 allows rotation of the catch member 22 from the unlocked position 20 a to the locked position 19 a, and wherein the second stop 32 is configured to allow rotation of the catch member 22 from the locked position 19 a to the unlocked position 20 a when the lever 30 is in the first position 31 and when the lever 30 is in the second position 33 .
[0022] In the illustrated example, the catch member 22 is secured to a top portion 34 of the second window 28 and adapted to engage the lock keeper 25 secured to a bottom portion 36 of the first window 26 . Alternatively, the catch member 22 may be secured to the bottom portion 36 of the first window 26 such that it engages the lock keeper 25 secured to the top portion 34 of the second window 28 .
[0023] As best illustrated in FIGS. 2, 2A , and 2 B, the handle 18 rotates on a top surface 38 of the housing member 14 causing rotation of the catch member 22 into and out of the locked and unlocked positions 19 a, 20 a. Specifically, an aperture 40 extends through a center portion 42 of the catch member 22 and receives a pivot rod 43 therein that is secured to the handle 18 , thereby coupling the handle 18 for rotation with the catch member 22 .
[0024] The catch member 22 includes an indent 44 located adjacent to a retaining flange 46 . The first stop 24 is disposed on an open side 48 of the catch member 22 opposite from the retaining flange 46 . The arcuately shaped retaining flange 46 slopes upwardly between opposite ends 47 , 49 thereof.
[0025] The lever 30 is located within the interior 16 of the housing 14 adjacent to the catch member 22 and pivots about a pivot axis 50 as defined by a pair of pivot bosses 53 . The lever 30 is rotatable between the first position 31 and the second position 33 in a plane perpendicular to a plane in which the handle 18 rotates. When the lever 30 is in the first position, the second stop 32 abuts the first stop 24 . A distal end 52 of the lever 30 is rotated upward into the second position 33 when the window assembly 10 is opened, as further explained below. Rotation of the lever 30 moves the second stop 32 out of interference with the first stop 24 , thereby allowing the handle 18 to rotate the catch member 22 . In the illustrated example, the handle 18 generally turns approximately 180 degrees in the direction of arrow 55 into the locked position 19 and in the direction of arrow 56 in the unlocked position 20 .
[0026] In the event that the lever 30 is moved to the first position 31 when the catch member 22 is in the locked position 19 a, the handle 18 and catch member 22 may be rotated to raise the lever 30 into the second position 33 . As illustrated, a biasing force is exerted on the lever 30 by a spring member 57 forcing the lever 30 towards the first position 31 . Alternatively, the force exerted on the lever 30 may be a gravitational force, or a combination of the gravitational force and the spring force. During rotation of the catch member 22 , the first stop 24 contacts an angled back portion 58 of the second stop 32 of the lever 30 . When a force applied by a user on the handle 18 is greater than the force from the spring member 57 , the angled back portion 58 of the second stop 32 and the entire lever 30 is raised until the first stop 24 clears an abutting face 60 of the second stop 32 . The first stop 24 is no longer in contact with the angled back portion 58 of the second stop 32 once the first stop 24 clears the abutting face 60 of the second stop 32 , thereby allowing the spring member 57 to force the lever 30 back to the first position 31 . Accordingly, the catch member 22 cannot rotate from the unlocked position 20 a to the locked position 19 a because the abutting face 60 of the second stop 32 is in interference with the first stop 24 .
[0027] In operation, the catch member 22 ( FIG. 3 ) rotates out of the housing member 14 to engage the lock keeper 25 . The retaining flange 46 of the catch member 22 secures a complementary receiver 62 in the lock keeper 25 . The handle 18 and the catch member 22 are prevented from rotating further once the retaining flange 46 is fully secured in the lock keeper 25 .
[0028] The catch member 22 of the window latch 12 , as illustrated in FIG. 4 , is in the unlocked position 20 a with the lever 30 in the second position 33 . The catch member 22 is positioned inside the housing member 14 and above a planar extent of a bottom portion 64 of the window latch 12 . The catch member 22 is secured to the pivot rod 43 which is received by a sleeve 66 of the catch member 22 . A collar 68 is disposed around the pivot rod 43 , between the top surface 38 of the housing member 14 and the handle 18 . A frictional washer 69 disposed below the collar 68 creates frictional resistance that impedes movement of the handle 18 out of the unlocked position 20 and out of the locked position 19 . This frictional resistance minimizes the likelihood that the handle 18 will rotate the pivot rod 43 in the sleeve 66 without force applied by a user.
[0029] The catch member 22 of the window latch 12 , as illustrated in FIGS. 5 and 6 , is in the unlocked position 20 a with the lever 30 in the first position 31 . The window latch 12 will generally have this arrangement when the lock keeper 25 is not adjacent to the housing member 14 , i.e., when the window assembly 10 is open. Further, in this position, the first stop 24 is aligned with the second stop 32 and prevents rotation of the handle 18 . The distal end 52 of the lever 30 protrudes beyond a vertical planar extent 70 of the housing member 14 when the lever 30 is in the first position 31 . The lock keeper 25 abuts the distal end 52 of the lever 30 forcing the lever 30 to pivot upward about the pivot axis 50 disposed on the inside portion of the housing member 14 when the window assembly 10 is closed by a user.
[0030] The catch member 22 of the window latch 12 , as illustrated in FIGS. 7 and 8 , is in the unlocked position 20 a with the lever 30 in the second position 33 . The window latch 12 will generally have this arrangement when the lock keeper 25 is adjacent to the window latch 12 , i.e., when the window assembly 10 is closed. In this position, the second stop 32 has been rotated vertically out of interference with the first stop 24 , thereby allowing rotation of the catch member 22 . The distal end 52 of the lever 30 does not protrude beyond the vertical planar extent 70 of the housing member 14 when the lever 30 is in the second position 33 .
[0031] The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.
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A window latch assembly for locking first and second windows together includes a cover member coupled to the first window, and a handle pivotably coupled to the cover member. A lock member is fixedly coupled to the handle and has a lock portion adapted to protrude beyond a planar extent of the cover into a locked position, wherein the lock portion engages a lock keeper coupled to the second window, and an unlocked position, wherein the lock keeper is retracted inside the cover member. A mechanical finger is movable between a first position allowing the lock portion to be moved from the unlocked position to the locked position, and a second position preventing the lock portion from being moved from the unlocked position to the locked position, thereby preventing damage of the first and second windows.
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RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 14/703,857, filed May 4, 2015, by Thomas Eugene Ferg, entitled “Swellable Elastomer Plug and Abandonment Sealing Plugs,” issued Sep. 19, 2017 as U.S. Pat. No. 9,765,591 B2, which claims priority from U.S. Provisional Patent Application No. 61/988,885, filed May 5, 2014 by Thomas Eugene Ferg, entitled “Swellable Elastomer Plug and Abandonment Sealing Plug,” expired, and from U.S. Provisional Patent Application No. 62/002,138, filed May 22, 2014, by Thomas Eugene Ferg, entitled “Swellable Elastomer Well Completion Abandonment Sealing Plugs,” expired.
FIELD OF THE INVENTION
[0002] This invention relates to a method and apparatus for placement of sealing plugs within a wellbore for the purpose of permanent plug and abandonment or temporary suspension. This invention can be used as a stand-alone plug and abandonment cross-sectional barrier or it may be combined with plugs comprised of setting medium (examples; cement, polymers, plastic, Barite or sized aggregate). This invention can be used to plug and abandon a well cemented cased wellbore, as well as perforated, open-hole and screened completion intervals within a wellbore. This invention also relates to the plugging of a wellbore (such as e.g. an oil, gas or water injection well), or for preparing a wellbore to be plugged, e.g. when the wellbore has reached the end of its productive or economic life. The invention also relates to a plugged wellbore.
BACKGROUND OF THE INVENTION
[0003] When an oil or gas well is no longer economical, or if there is a mechanical problem with the well which means that production is no longer possible or that well integrity has been compromised in some way, or for other reasons, the well may be abandoned. It is common practice to plug the well before abandoning it, e.g., to place barriers within the wellbore to prevent seepage of hydrocarbon product or water from the wellbore to the external environment. This can also apply to water injectors, i.e. bores which have been drilled in order to pump water into a reservoir to increase bottom hole pressure or to sweep hydrocarbon fluids to production wells.
[0004] Commonly, in a well with a good primary cement job external to the casing, plugging is accomplished by the placement of balanced cement plugs inside of the casing across from these well cemented intervals as required. The most common plugging medium is an oilfield cement slurry. The slurry can be designed to be gas tight and provide a barrier to upward fluid moment within the wellbore. When set and tested this creates a full cross-sectional barrier extending from inside the casing to outside of the casing and to the rock face.
[0005] Other plugging mediums such as settable plastic, barite and sized aggregate have also been used to place barriers internal to oilfield tubulars within well cemented external annuli intervals.
[0006] Cast iron bridge plugs, cement retainers and packers with a through-bore plug may be used as mechanical bases for placement of settable medium plugs.
[0007] Settable mediums can, by their nature, be very hard and exhibit brittle characteristics when subjected to external lateral force, such as compression or tension caused by subsidence or fault shifting of the strata in contact with the wellbore. If the settable medium is fractured post setting it possesses no mechanism to heal itself and regain cross-sectional integrity.
[0008] For plugging operations using cement, the plugging process often involves pumping a surfactant liquid, known as a “spacer”, down a drill string or work-over string (commonly referred to as the “string”) into the well taking returns up the string-by-casing annulus. The purpose of the spacer is to remove oil residues from the internal surface of the well casing and/or liner making them “water wet” (allowing better adhesion by cement). Commonly, immediately following the spacer, cement is pumped down the string and placed as a balanced plug. The string is then slowly removed from the wet balanced cement plug by pulling the string out of the hole until the bottom end of the pipe is above the cement slurry. The drill string and annulus are then circulated clean. The cement is allowed time to set and then the work string is used to tag (lowered down to contact resistance) and confirm the top of hard cement. Additional cement plugs can then be set with the same procedure or the string may be pulled from the wellbore.
[0009] If the plug is not correctly displaced or properly balanced prior to pulling the placement string above the cement slurry surface, the strength and integrity of the plug may be jeopardized because of cement contamination. The degree to which the cement plug integrity may be compromised can be difficult to assess.
[0010] Cement setting time can be monitored at surface by placing samples of the pumped cement slurry into a testing apparatus that recreates downhole conditions. When it has been determined that the downhole plug has achieved sufficient strength; the plug is pressure tested and tagged with the end of the work string to confirm the top of hard cement.
[0011] Abandonment plugs may also be placed in perforated completion intervals or in sections completed with screens.
[0012] To place a sealing plug inside of casing across from perforated intervals cement is most commonly used. To create an internal seal cement is squeezed through the perforations until the perforations are squeezed off and pressure builds within the tubular. This operation may require repeated squeeze operations before the perforations are squeezed (sealed) off and this repetition is time consuming. Incorporation of particulate material into the cement slurry along with ball sealers may also be required.
[0013] The sealing off of internal intervals with screens may be difficult because of the large open surface area. Cement has been used in conjunction with sized particulate material to seal off flow paths in order to fill the screen with cement and with the intent of retaining the cement inside of the screen. As flow paths are sealed off, the screen is progressively filled with cement plugging off the screen and creating an internal plug.
SUMMARY OF THE DISCLOSURE
[0014] The invention includes a process for plugging a wellbore wherein the process comprises the steps of introducing and installing swellable elastomer plug units into a cased and cemented wellbore, a perforated completion, or a screen completion, for the purpose of creating a cross-sectional barrier which prevents fluid or gas movement upward in a wellbore.
[0015] Swellable elastomers placed on a single rod or tubular are considered to be swellable elastomer plug units.
[0016] When swelling elastomer sealing plug units are attached together or run along with a bridge plug, cement retainer, or packer, the combined components are considered to be a system.
[0017] Swellable elastomer plug units may be linked up at surface and pumped downhole to the desired setting/expansion location.
[0018] Swellable elastomer units may also be pumped downhole singly and then meet up downhole at a desired setting/expansion location.
[0019] These swellable elastomer plug units may be made entirely of a single type of elastomer which is swelling sensitive to only hydrocarbons.
[0020] These swellable elastomer plug units may be made entirely of a single type of elastomer which is swelling sensitive to only water or brine.
[0021] Swellable elastomer plug units may be made to incorporate both hydrocarbon and water/brine swellable elastomers within the same unit.
[0022] Swellable elastomer plug units may be used to create a plug system which incorporate units of both hydrocarbon and water/brine swellable elastomers.
[0023] Swellable elastomers may be cut into circular disks with a central hole for threading onto a steel rod or tubular.
[0024] Swellable elastomers may be wrapped around a rod or tubular in sheet form.
[0025] Swellable elastomers may be applied to a rod or tubular by spray application.
[0026] Swellable elastomer disks, swellable elastomer wraps, or spray applied swellable elastomers with both water and hydrocarbon swelling characteristics, may be incorporated into a single swelling elastomer unit.
[0027] Swellable circular disks can be grouped into intervals with the same swelling characteristics (hydrocarbon or water/brine swelling) or elastomers with different swelling characteristics may be alternated in their placement along the rod/tubular unit.
[0028] Using connections to link swelling elastomer segments together allows for creation of a complete plug system of any desired length or swelling characteristics.
[0029] Swellable elastomer units may be created by use of an injection mold process without a central rod or tubular.
[0030] In certain embodiments, the swellable elastomer plug may be able to bridge or close gaps which can form because of casing deformations caused by rock formation fault shifting, causing collapse compression and tension failure of casing.
[0031] In certain embodiments the swelling elastomers may remain dormant until an activation agent is introduced into the wellbore and contacts the swelling elements.
[0032] The term swelling of the elastomer components is meant to indicate an increase in volume of the material through molecular incorporation of fluid components. However, other swelling mechanisms may be used if desired.
[0033] Swelling of the material to be expanded may occur through contact with an activation agent, such as an organic or inorganic containing fluid.
[0034] Suitable swellable materials for comprising the swelling elastomers may include, but are not limited, to those disclosed in U.S. Pat. Nos. 3,385,367; 7,059,415; and 7,143,832; the entire disclosures of which are incorporated by reference. Some exemplary swellable materials may include, but are not limited to, elastic polymers, such as EPDM rubber, styrene butadiene, natural rubber, ethylene propylene monomer rubber, ethylene-propylene-copolymer rubber, ethylene propylene diene monomer rubber, ethylene propylene-diene terpolymer rubber, ethylene vinyl acetate rubber, hydrogenized acrylonitrile butadiene rubber, acrylonitrile butadiene rubber, isoprene rubber, butyl rubber, halogenated butyl rubber, brominated butyl rubber, chlorinated butyl rubber, chlorinated polyethylene, chloroprene rubber and polynorbornene. In one embodiment, the rubber of the swellable material may also have other materials dissolved in or incorporated within its mixture. The swellable material may also have polyvinyl chloride, methyl methacrylate, acrylonitrile, ethylacetate or other polymers that expand in contact with oil. Units of the swellable elastomers are conveyed into the wellbore by drill pipe, work string, coiled tubing, wireline, braided line, or are hydraulically pumped into position within the wellbore.
[0035] The wellbore environment with respect to hydrocarbon or aqueous fluid will determine the suitability of a specific swellable material.
[0036] Baffle plates securely attached to the central rod or tubular may be used to redirect longitudinal expansion to radial/circumferential expansion.
[0037] The term “wellbore” as used herein shall be taken to mean an oil, gas or water injection well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] A more complete understanding of the present invention and benefits thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings in which:
[0039] FIG. 1 is an example of a swellable elastomer sheet material ( 2 ) being wrapped around a rod core ( 1 );
[0040] FIG. 2 is an example of a swellable elastomer sheet material ( 4 ) being wrapped around a tubular core ( 3 );
[0041] FIG. 3 is an example of swellable elastomer disks ( 6 ) being threaded onto a rod core ( 5 );
[0042] FIG. 4 is an example of swellable elastomer disks ( 8 ) being threaded onto a tubular core ( 7 );
[0043] FIG. 5 is an example of both water/brine swellable elastomer disks ( 10 —disks with lines) and hydrocarbon swelling elastomers disks ( 11 —black disks) being threaded onto a rod core ( 9 );
[0044] FIG. 6 is an example of both water/brine swellable elastomer disks ( 13 —disks with lines) and hydrocarbon swelling elastomers disks ( 14 —black disks) being threaded onto a rod core ( 12 );
[0045] FIG. 7 is a side view of two Sealing Plug Units ( 15 ) and ( 16 ) of one embodiment of the invention with a tubular core ( 19 ) incorporating either water/brine swellable elastomers ( 20 ) or hydrocarbon swellable elastomers ( 21 ) across the entire unit;
[0046] FIG. 8 is a side view of Elastomer Sealing Plug Units ( 24 ) and ( 25 ) of one embodiment of the invention with a tubular core ( 28 ) with alternating water/brine swellable elastomers ( 29 ) and hydrocarbon swelling elastomers ( 30 );
[0047] FIG. 9 is a side view of two Elastomer Sealing Plug Units ( 31 & 32 ) of an embodiment of the invention with a tubular core ( 35 ) with alternating water/brine swellable elastomers ( 37 —light lines with downward left slant) and hydrocarbon swelling elastomers ( 36 —dark lines with downward right slant) wherein the elastomers are confined by baffle plates.;
[0048] FIG. 10 is a side view of an Elastomer Sealing Plug Unit ( 55 ) of one embodiment of the invention with tubular core ( 58 ) with alternating water/brine swellable elastomers ( 60 —light lines with downward left slant) and hydrocarbon swelling elastomers ( 59 —dark lines with downward right slant) in stacked disks threaded onto the tubular core.
[0049] FIG. 11 is an example of four swellable elastomer units ( 64 ) with rod cores placed below a packer, cement retainer or cast iron bridge plug ( 63 ) for running into the wellbore, allowing the unit to be hung off at any location along the wellbore;
[0050] FIG. 12 is an example of four swellable elastomer units ( 65 ) below a side-ported circulating sub ( 66 ) and tubing ( 67 ) placed below a packer, cement retainer, or cast iron bridge plug ( 68 ) for running into the wellbore, allowing the unit to be hung off at any location within the wellbore after a setting medium has been circulated in place;
[0051] FIG. 13 is an example of tubing ( 69 ) run below four swellable elastomer units ( 70 ) that are run below a packer, cement retainer, or cast iron bridge plug ( 71 ). After a settable medium has been pumped to above the height of the hang off device ( 71 ) it can be set sealing off the wellbore and locking all components and the settable medium in place;
[0052] FIG. 14 is an example of a wellbore with a perforated completion interval ( 72 ). The most proximal portion of the perforations (top perforations) is labeled as 73 . The same wellbore is represented by progressive steps labeled as 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 and 82 . Elastomer sealing units 83 , 84 , 85 and 86 are launched separately in progression and pumped downhole in order to seal off the perforations;
[0053] FIG. 15 is an example of a wellbore with a packer ( 87 ) placed downhole as a base for landing out swellable elastomer sealing plug units ( 99 ), ( 100 ), ( 101 ) and ( 102 ) which have been launched individually and pumped downhole to land out on a backpressure ball device ( 98 );
[0054] FIG. 16 is an example of swellable wellbore sealing plug units ( 104 ) run in hole along with a settable packer, cement retainer, or bridge plug ( 103 );
[0055] FIG. 17 is an example of a packer, cement retainer, or bridge plug ( 105 ) run in hole with swellable elastomer sealing plug units with rod cores ( 106 ) followed by a circulating sub ( 107 ) and tubing.
DETAILED DESCRIPTION
[0056] Turning now to the detailed description of the preferred arrangement or arrangements of the present invention, it should be understood that the inventive features and concepts may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow.
[0057] The discussion of any reference herein is not an admission that the reference is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as additional embodiments of the present invention.
[0058] This invention generally relates to a method and apparatus for placement of cross-sectional elastomer sealing plug(s) within a wellbore for the purpose of creating barriers for permanent plug and abandonment or temporary suspension of wellbores.
[0059] The elastomer sealing plug units can be run as a standalone plug and abandonment cross-sectional barrier or they may be combined with cross-sectional cement or other settable medium plugs such as polymers, barite or sized aggregate. This listing of settable mediums is given to provide possible examples; however, there are many others settable mediums which would work in the invention but that are not listed here.
[0060] The swellable elastomers units can be utilized as a primary barrier in wells with a confirmed competent primary external casing cement job across the interval requiring a barrier.
[0061] The swellable elastomer units can be placed across perforations or screen completions in order to seal off the wellbore. They may also be placed in an openhole environment to seal off the wellbore. Swellable elastomers are, by their nature, pliable. Plug units and barrier systems made with swellable elastomers are malleable and should be compressional. When tensional or lateral forces compromise the casing integrity in the area of plug placement, the elastomer will self-heal, maintaining the barrier seal. This invention also relates to the plugging of a wellbore (such as, e.g., an oil, gas or water injection well). The Figures show various nonlimiting examples of swellable elasomter units that may be used in the invention.
[0062] All referenced adhesives are required to be resistant to temperature degradation with time and they must provide bonding of one elastomer layer to the next and/or bonding between the swellable elastomers and a central rod or tubular core if incorporated. Different adhesives may be required to secure the swellable elastomer to a central core rod or tubular or to bond the swellable layers or disks one to another. A volcanizing agent may be used to adhere sellable elastomers one to another. In a process of the invention for permanently plugging a wellbore, the process comprises the following steps: (a) gaining access to the wellbore; (b) running a gaging device into the wellbore to assure passage of all plugging components; (c) running in the wellbore swelling elastomer units; (d) conveying the swelling elastomer units to the planned location within the wellbore; (e) allowing the elastomers to swell; and (f) optionally mixing, pumping, and displacing a settable medium into the wellbore.
[0063] FIG. 1 is an example of swellable elastomer material in sheet form being wound around a solid rod core. Adhesives are applied to the rod core ( 1 ) and the elastomers ( 2 ) as progressive layers are placed around the rod core ( 1 ). The swellable elastomers ( 2 ) may be either water/brine swellable or hydrocarbon swellable.
[0064] FIG. 2 is an example of swellable elastomer material in sheet form being wound around a tubular core. Adhesives are applied to the tubular core ( 3 ) and the elastomer ( 4 ) as progressive layers are placed around the tubular core ( 3 ). The swellable elastomers ( 4 ) may be either water/brine swellable or hydrocarbon swellable.
[0065] FIG. 3 is an example of swellable elastomer disks ( 6 ) being threaded onto a rod core ( 5 ). Adhesives may be used on the rod core ( 5 ) and disks ( 6 ) to hold them in place. The swellable elastomers ( 6 ) may be either water/brine swellable or hydrocarbon swellable.
[0066] FIG. 4 is an example of swellable elastomer disks ( 8 ) being threaded onto a tubular core ( 7 ). Adhesives may be used on the tubular core ( 7 ) surface and disks ( 8 ) in order to hold them in place. The swellable elastomers ( 8 ) may be either water/brine swellable or hydrocarbon swellable.
[0067] FIG. 5 is an example of swellable elastomer disks being threaded onto a rod core ( 9 ). The disks with lines ( 10 ) represent water/brine swellable elastomers and the black disks ( 11 ) represent hydrocarbon swellable elastomers. The disks ( 10 ) and ( 11 ) are shown alternating on the rod core ( 9 ), although other configurations may be used. Adhesives may be used on the rod core ( 9 ) and disks ( 10 ) and ( 11 ) to hold them in place.
[0068] FIG. 6 is an example of swellable elastomer disks being threaded onto a tubular core ( 12 ). The disks with lines ( 13 ) represent water/brine swellable elastomers and the black disks ( 14 ) represent hydrocarbon swellable elastomers. Adhesives may be used on the core ( 12 ) and disks ( 13 ) to hold them in place;
[0069] FIG. 7 is a side view of two swellable elastomer sealing plug units ( 15 ) and ( 16 ) of one embodiment of the invention with a tubular core ( 19 ) incorporating either water/brine swellable elastomers ( 20 ) or hydrocarbon swellable elastomers ( 21 ) across the entire unit. The swellable elastomer is confined by baffle plates ( 22 ) and ( 23 ) which are attached to the central tubular core adjacent and in contact with the swellable elastomer at both ends. These baffle plates ( 22 ) and ( 23 ) confine longitudinal expansion and enhance circumferential expansion. The Sealing Plug Units are fabricated with box ( 17 ) and pin ( 18 ) connections so that the units can be attached to each other for running in hole and to achieve the desired total plug contact length. The box is the female connection and the pin is the male connection;
[0070] FIG. 8 is a side view of two swellable elastomer sealing plug units ( 24 ) and ( 25 ) of one embodiment of the invention with a tubular core ( 28 ) with alternating water/brine swellable elastomers ( 29 —lighter lines with a down left slant) and hydrocarbon swelling elastomers ( 30 —heavier lines with a down right slant). The swellable sealing plug units are fabricated with box ( 26 ) and pin ( 27 ) connections so that the units can be attached to each other for running into the wellbore and to achieve the desired total plug contact length when incorporated into plug systems. The box is the female connection and the pin is the male connection. Capping baffle plates are not incorporated into this embodiment.
[0071] FIG. 9 is a side view of two swellable elastomer sealing plug units ( 31 & 32 ) of an embodiment of the invention with tubular cores ( 35 ) with alternating water/brine swellable elastomers ( 37 —lighter lines with a down slant left) and hydrocarbon swelling elastomers ( 36 —heavier lines with a down slant right). The swellable elastomers of sealing plug 31 are confined by baffle plates ( 38 , 39 , 40 , 41 , 42 & 43 ) and the swellable elastomers of sealing plug 32 are confined by baffle plates ( 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 , 52 , 53 & 54 ) which are attached to the central tubular adjacent and in contact with the swellable elastomer at both ends and in between the alternating elastomer types. These baffle plates confine longitudinal expansion and enhance circumferential expansion. The swellable elastomer sealing plug units are fabricated with female ( 33 ) and male ( 34 ) connections so that the units can be attached to each other for running into the wellbore and to achieve the desired total plug contact length when incorporated into plug systems.
[0072] FIG. 10 is a side view of a swellable elastomer sealing plug unit ( 55 ) of one embodiment of the invention with tubular core ( 58 ) with alternating water/brine swellable elastomers ( 60 —lighter lines with a down left slant) and hydrocarbon swelling elastomers ( 59 —heavier lines with a down right slant) in stacked disks threaded onto the tubular core ( 58 ). Constraining baffle plates ( 61 ) and ( 62 ) are attached to the tubular core ( 58 ) to cap the ends of the elastomer units to assist in keeping the elastomer disks in place and also to confine longitudinal expansion and enhance circumferential expansion. The sealing plug unit is fabricated with box ( 56 ) and pin ( 57 ) connections so that the units can be attached to each other for running into the wellbore and to achieve the desired total plug contact length when incorporated into plug systems. The box is the female connection ( 56 ) and the pin is the male connection ( 57 );
[0073] FIG. 11 is an example of four swellable elastomer sealing plug units ( 64 ) run in hole with a packer, cement retainer, or cast iron bridge plug ( 63 ) to allow the units to be “hung off” at any location within the wellbore.
[0074] FIG. 12 is an example an elastomer plugging system consisting of four swellable elastomer sealing plug units ( 65 ) below a circulating sub ( 66 ) and tubing ( 67 ) all placed below a packer, cement retainer, or cast iron bridge plug ( 68 ) for running into the wellbore, allowing the unit to be hung off at any location within the wellbore. A circulating sub is a joint of drill pipe or work string tubular with a side port (hole) to allow circulation of fluid from the inside of the string to outside or vice versa. A settable medium can be pumped in place and then the hang off device ( 68 ) set.
[0075] FIG. 13 is one example of a swellable elastomer sealing plug unit and settable medium plugging system. For this embodiment tubulars ( 69 ) are run in the hole open ended below swellable elastomer units ( 70 ) placed below a packer or cement retainer ( 71 ). A spacer is then pumped followed by a settable medium and when the designed column of settable medium has been balanced the packer or retainer is set. The running string is then pulled above the top of the settable medium, the hole circulated clean, and the medium is allowed time to set. After setting, the running string is slacked off until the top of the firm settable medium is determined. The running string is then pulled.
[0076] FIG. 14 is an example of a perforated wellbore section ( 72 ) with the most proximal perforations (top perforations) labeled as 73 . The same wellbore is represented by progressive steps labeled at the top of the drawing as 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 and 82 . In wellbore representation 74 , the elastomer sealing unit ( 83 ) has been launched downhole from surface and has progressed until it is located just above the top of perforations. In wellbore representation 75 , as pumping continues, the top of the sealing unit ( 83 ) clears the top of the perforations, the pressure moving the unit forward leaks off at the perforations and forward movement of the elastomer sealing unit ceases. In wellbore representation 76 the second elastomer sealing unit ( 84 ) has been launched and pumped down the wellbore until just above the elastomer sealing unit ( 83 ). Pumping is continued and in wellbore representation 77 , the two elastomer sealing units ( 84 & 85 ) have connected and are jointly being pushed forward within the wellbore until, in wellbore representation 78 , the top of elastomer sealing unit 84 clears the top of the perforations and the pressure moving the units forward leaks off at the perforations and forward moment of the elastomer sealing units ceases. In wellbore representation 79 the third elastomer sealing unit ( 85 ) has been launched and pumped down the wellbore until just above the elastomer sealing unit ( 84 ). Pumping continues and in wellbore representation 80 the three elastomer sealing units ( 83 , 84 & 85 ) have connected and are jointly being pushed forward within the wellbore until the top of unit 85 clears the top of the perforations, the pressure moving the units forward leaks off and forward moment of the elastomer sealing units ceases. In wellbore representation 81 the forth elastomer sealing unit ( 86 ) has been launched and pumped down the wellbore until just above the elastomer sealing unit 85 . In wellbore representation 82 the four elastomer sealing units ( 83 , 84 , 85 & 86 ) are connected and are jointly being pushed forward within the wellbore until the top of unit 86 clears the top of the perforations, the pressure moving the units forward leaks off and forward moment of the elastomer sealing units ceases. The sealing plugs can now be left to expand and seal the wellbore across perforations where they are located. Now cement spacer can be pumped downhole followed by a lead wiper plug cement and a tail wiper plug. The forward progress of the wiper plugs and cement will cease when the lead wiper plug lands out on the last elastomer sealing plug unit ( 86 ) sealing off the perforations. The wellbore is now sealed with elastomer sealing plugs across the perforations and a cement plug across from the well cemented casing annulus above the completion.
[0077] FIG. 15 provides progressive time shots of the same wellbore are denoted by 88 , 89 , 90 , 91 , 92 , 93 , 94 , 95 and 96 . In this example a packer ( 87 ) is located downhole which is used as a base for landing a backpressure ball device ( 97 ) followed by swellable elastomer plug units ( 99 ), ( 100 ), ( 101 ) and ( 102 ) which are pumped downhole in succession. The plug external diameters have tolerances which allow fluid to bypass or flow around them until they have had time to swell and seal off the wellbore.
[0078] FIG. 16 is an example of swellable elastomer sealing plug units ( 104 ) with rod cores run in hole together above a packer, cement retainer, or bridge plug ( 103 ). When the sealing plug units are at the desired location within the wellbore, the packer, cement retainer, or bridge plug is set and elastomer sealing plugs are left to swell and seal the wellbore. A setting medium may then be pumped downhole to set-up on top of the entire elastomer sealing plug system.
[0079] FIG. 17 is an example of swellable elastomer sealing plug units ( 106 ) with rod cores run in hole together above a packer, cement retainer, or bridge plug ( 105 ) along with a circulating sub ( 107 ) and tubing ( 108 ). When the sealing plug units are at the desired location within the packer, the cement retainer, or bridge plug is set and the elastomer sealing plugs are left to swell and seal the wellbore. A settable medium can now be pumped downhole and out through the circulating sub, with a side port, until the medium is balanced. The running string can then be released leaving the tubing ( 108 ) in place. The hole is then circulated clean and the running string pulled from the wellbore.
[0080] In wells with a mono-bore completion, completion intervals can be sealed off by pumping swellable elastomer sealing units downhole using a lubricator to launch them at the wellbore surface. The swelling elastomer sealing units are conveyed downhole much like a pipeline pig being pumped along a pipeline. Each progressive unit meets up and latches to the previous units at the top of the completion interval moving all units forward together.
[0081] Swellable elastomer plugs allow for selectively plugging off production intervals below the top of the swelling elastomer sealing system.
[0082] A swellable elastomer plugging unit system can be used to seal off open-hole intervals.
[0083] Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventor that variations and equivalents of the invention are within the scope of the claims while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents. No limitations are intended to the details of construction or design herein shown, other than as described in the claims below. While products and methods are described in terms of “comprising,” “containing,” “having,” or “including” various components or steps, the products and methods can also “consist essentially of” or “consist of” the various components and steps. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined herein.
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A process for plugging a wellbore, e.g., an oil or gas well, which comprises installing swelling elastomer sealing units across an interval of casing which is properly in the annulus space between the outside of the casing and the rock face. The swellable elastomer sealing units can also be used to seal off perforated casing, production screen and open hole completions. The plug and abandonment system is comprised of swelling elastomer units that are connected together to achieve a desired sealing contact length. These connected units may be hung off below or placed above a packer, cement retainer, cast iron bridge plug or setting slips. Both the tubular form of the plugging unit and the rod form of the plugging unit can be used in conjunction with conventional settable medium (cementing, barite or sized aggregate) plug setting operations. The elastomers incorporated are designed to swell with the current wellbore fluid and/or any possible future wellbore fluid. The swelling elastomers create sufficient expansion force to effectively seal off the wellbore internal to the casing, liner, screen or open-hole interval.
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This application is a divisional application of prior application Ser. No. 10/726,960 filed Dec. 3, 2003, now abandoned, which is a continuation of U.S. patent application Ser. No. 09/523,817, filed Mar. 13, 2000, now U.S. Pat. No. 6,746,425, which is a continuation-in-part of U.S. patent application Ser. No. 08/873,413 filed Jun. 12, 1997 now abandoned, which claims benefit of U.S. provisional application No. 60/019,931 filed Jun. 14, 1996, the entire disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
This invention relates to the field of balloons that are useful in angioplasty and other medical uses.
BACKGROUND OF THE INVENTION
Catheters having inflatable balloon attachments have been used for reaching small areas of the body for medical treatments, such as in coronary angioplasty and the like. Balloons are exposed to large amounts of pressure. Additionally, the profile of balloons must be small in order to be introduced into blood vessels and other small areas of the body. Therefore, materials with high strength relative to film thickness are chosen. An example of these materials is PET (polyethylene terephthalate), which is useful for providing a non-compliant, high-pressure device. Unfortunately, PET and other materials with high strength-to-film thickness ratios tend to be scratch- and puncture-sensitive. Polymers that tend to be less sensitive, such as polyethylene, nylon, and urethane are compliant and, at the same film thickness as the non-compliant PET, do not provide the strength required to withstand the pressure used for transit in a blood vessel and expansion to open an occluded vessel. Non-compliance, or the ability not to expand beyond a predetermined size on pressure and to maintain substantially a profile, is a desired characteristic for balloons so as not to rupture or dissect the vessel as the balloon expands. Further difficulties often arise in guiding a balloon catheter into a desired location in a patient due to the friction between the apparatus and the vessel through which the apparatus passes. The result of this friction is failure of the balloon due to abrasion and puncture during handling and use and also from over-inflation.
SUMMARY OF THE INVENTION
The present invention is directed to a non-compliant medical balloon suitable for angioplasty and other medical procedures and which integrally includes very thin inelastic fibers having high tensile strength, and methods for manufacturing the balloon. The fiber reinforced balloons of the present invention meet the requirements of medical balloons by providing superior burst strength; superior abrasion-, cut- and puncture-resistance; and superior structural integrity.
More particularly, the invention is directed to a fiber-reinforced medical balloon having a long axis, wherein the balloon comprises an inner polymeric wall capable of sustaining pressure when inflated or expanded and a fiber/polymeric matrix outer wall surrounding and reinforcing the inner polymeric wall. The fiber/polymeric matrix outer wall is formed from at least two layers of fibers and a polymer layer. The fibers of the first fiber layer are substantially equal in length to the length of the long axis of the balloon and run along the length of the long axis. But “substantially equal in length” is meant that the fiber is at least 75% as long as the length of the long axis of the balloon, and preferably is at least 90% as long. The fiber of the second fiber layer runs radially around the circumference of the long axis of the balloon substantially over the entire length of the long axis. By “substantially over the entire length” is meant that the fiber runs along at least the center 75% of the length of the long axis of the balloon, and preferably runs along at least 90% of the length. The fiber of the second fiber layer is substantially perpendicular to the fibers of the first fiber layer. By “substantially perpendicular to” is meant that the fiber of the second fiber layer can be up to about 10 degrees from the perpendicular.
The invention is further directed to processes for manufacturing a non-compliant medical balloon. In one embodiment, a thin layer of a polymeric solution is applied onto a mandrel, the mandrel having the shape of a medical balloon and being removable from the finished product. High-strength inelastic fibers are applied to the thin layer of polymer with a first fiber layer having fibers running substantially along the length of the long axis of the balloon and a second fiber layer having fiber running radially around the circumference of the long axis substantially over the entire length of the long axis. The fibers are then coated with a thin layer of a polymeric solution to form a fiber/polymeric matrix. The polymers are cured and the mandrel is removed to give the fiber-reinforced medical balloon.
In another embodiment of the invention, a polymer balloon is inflated and is maintained in its inflated state, keeping the shape of the balloon. High-strength inelastic fibers are applied to the surface of the balloon, with a first fiber layer having fibers running substantially along the length of the long axis of the balloon and a second fiber layer having fiber running radially around the circumference of the long axis substantially over the entire length of the long axis. The fibers are then coated with a thin layer of a polymeric solution to form a fiber/polymeric matrix. The fiber polymeric matrix is cured to give the fiber-reinforced medical balloon, which can then be deflated for convenience, until use.
In a presently preferred embodiment, a thin coating of an adhesive is applied to the inflated polymer balloon or to the polymer-coated mandrel prior to applying the inelastic fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an inflated standard medical balloon, which is used in this invention as the base of the final composite fiber-reinforced balloon.
FIG. 2 illustrates an inflated standard medical balloon, which is used in this invention as the base of the final composite fiber-reinforced balloon.
FIG. 3 illustrates the positioning of the second layer of fiber over the first fiber layer. The fiber is wound radially around the long axis substantially over the entire length of the long axis of the balloon, each wrap being substantially equally spaced from the others. The fiber runs substantially perpendicular to the fibers of the first fiber layer.
FIG. 4 illustrates the positioning of the third layer of fiber over the second fiber layer, in accordance with another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.
A medical balloon in accordance with the present invention in one embodiment begins with an inflated polymeric balloon 2 , as shown in FIG. 1 , to which there is applied by hand or mechanically, inelastic fiber or filament 4 , as shown in FIG. 2 . This is sometimes referred to as the “primary wind.” To assist in placement and retention of the fibers, there can be applied an adhesive to either the inflated balloon surface or to the fiber. The purpose of this first application of fiber is to prevent longitudinal extension (growth) of the completed balloon.
An alternate method of applying the longitudinal fibers involves first creating a fabric of longitudinal fibers by pulling taut multiple parallel fibers on a flat plate and coating with a polymeric solution to create a fabric. The fabric is then cut into a pattern such that it can be wrapped around the base balloon or mandrel.
Next, a second application of inelastic fiber 6 is applied to the circumference of the balloon, as shown in FIG. 3 . This is sometimes referred to as the “hoop wind.” The purpose of the hoop wind is to prevent or minimize distension of the completed balloon diameter during high inflation pressure.
After the hoop wind is completed, the exterior of the fiber-wound inflated balloon is coated with a polymeric solution and cured to form a composite, con-compliant fiber-reinforced medical balloon. The outer polymeric coating of the fiber/polymeric matrix secures and bonds the fibers to the underlying inflated balloon so that movement of the fibers is restricted during deflation of the composite balloon and subsequent inflation and deflation during use of the balloon. The polymeric solution can be applied several times, if desired. The polymeric solution can use the same polymer as or a polymer different from the polymer of the inflated polymeric balloon 2 . The polymers should be compatible so that separation of the composite balloon is prevented or minimized.
In a second method of making a medical balloon of the present invention, a removable mandrel having the shape that is identical to the shape of the inside of the desired balloon is used. A shape such as shown in FIG. 1 is suitable. The mandrel can be made of collapsible metal or polymeric bladder, foams, waxes, low-melting metal alloys, and the like. The mandrel is first coated with a layer of a polymer, which is then cured. This forms the inner polymeric wall of the balloon. Next, repeating the steps as described above, the primary wind the hoop wind are placed over the inner polymer wall, followed by a coating with a polymeric solution and curing thereof to form a fiber/polymeric matrix outer wall. Finally, the mandrel is removed, by methods known in the art such as by mechanical action, by solvent, or by temperature change, to give the composite medical balloon of the invention.
In view of the high strength of the balloons of the present invention, it is possible to make balloons having a wall thickness less than conventional or prior art balloons without sacrifice of burst strength, abrasion resistance, or puncture resistance. The balloon wall thickness can be less than the thickness given in the examples hereinbelow.
In addition, the fiber-reinforced balloons of the present invention are non-complaint. That is, they are characterized by minimal axial stretch and minimal radial distention and by the ability not to expand beyond a predetermined size on pressure and to maintain substantially a profile.
Polymers and copolymers that can be used for the base balloon and/or the covering layer of the fiber/polymeric matrix include the conventional polymers and copolymers used in medical balloon construction, such as, but not limited to, polyethylene, polyethylene terephthalate (PET), polycaprolactam, polyesters, polyethers, polyamides, polyurethanes, polyimides, ABS copolymers, polyester/polyether block copolymers, ionomer resins, liquid crystal polymers, and rigid rod polymers.
The high-strength fibers are chosen to be inelastic. By “inelastic,” as used herein and in the appended claims, is meant that the fibers have very minimal elasticity or stretch. Zero elasticity or stretch is probably unobtainable taking into account the sensitivity of modern precision test and measurement instruments, affordable costs and other factors. Therefore, the term “inelastic” should be understood to mean fibers that are generally classified as inelastic but which, nevertheless, may have a detectable, but minimal elasticity or stretch. High strength inelastic fibers useful in the present invention include but are not limited to, Kevlar, Vectran, Spectra, Dacron, Dyneema, Terlon (PBT), Zylon (PBO), Polyimide (PIM), ultra high molecular weight polyethylene, and the like. In a presently preferred embodiment, the fibers are ribbon-like; that is, they have a flattened to a rectangular shape. The fibers of the first fiber layer may be the same as or different from the fiber of the second fiber layer.
The most advantageous density of the fiber wind is determinable through routine experimentation by one of ordinary skill in the art given the examples and guidelines herein. With respect to the longitudinally-placed fibers (along the long axis of the balloon) of the first fiber layer, generally about 15 to 30 fibers having a fiber thickness of about 0.005 to 0.001 inch and placed equidistant from one another will provide adequate strength for a standard-sized medical balloon. With respect to the fiber of the hoop wind, or second fiber layer, fiber having a thickness of about 0.0005 to 0.001 inch and a wind density within the range of about 50 to 80 wraps per inch is generally adequate. The fiber of the second fiber layer is preferably continuous and is, for a standard-sized medical balloon, about 75-100 inches long.
The longitudinally placed fibers should be generally parallel to or substantially parallel to the long axis of the balloon for maximum longitudinal stability (non-stretch) of the balloon. The fibers of the hoop wind should be perpendicular to or substantially perpendicular to the fibers placed longitudinally for maximum radial stability (non-stretch) of the balloon. This distributes the force on the balloon surface equally and creates “pixels” of equal shape and size. In the case where the fibers of the hoop wind are at a small acute angle (e.g. about 10 degrees or more) to the longitudinal fibers, two hoop winds (in opposite directions) can be used for minimizing radial distension. FIG. 4 depicts a balloon having a second hoop wind 12 .
EXAMPLES
The following examples are provided to illustrate the practice of the present invention, and are intended neither to define nor to limit the scope of the invention in any manner.
Example 1
An angioplasty balloon, as shown in FIG. 1 , having a wall thickness of 0.0008 inch is inflated to about 100 psi, and the two open ends of the balloon are closed off. The inflation pressure maintains the shape (geometry) of the balloon in an inflated profile during the construction of the composite balloon. The balloon is a blow-molded balloon of highly oriented polyethylene terephthalate (PET). to the inflated balloon is applied a very thin coat of 3M-75 adhesive to hold the fibers sufficiently to prevent them from slipping out of position after placement on the balloon.
Kevlar® fibers are placed, by hand, along the length of the balloon as shown in FIG. 2 to provide the primary wind. Each of the fibers is substantially equal in length to the length of the long axis of the balloon. Twenty-four fibers are used, substantially equally spaced from each other. The fiber used for the primary wind has a thickness of 0.0006 inch.
Next, a hoop wind of Kevlar® fiber is applied radially around the circumference of and over substantially the entire length of the long axis of the balloon, as shown in FIG. 3 . The fiber has a thickness of 0.0006 inch and is applied at a wind density of 60 wraps per inch.
The fiber-wound based PET balloon is then coated with a 10% solution of Texin® 5265 polyurethane in dimethylacetamide (DMA) and allowed to cure at room temperature. Five additional coating of the polurethane solution are applied in about 6-hour increments, after which the pressure in the balloon is released. The resulting composite fiber-reinforced balloon is non-compliant and exhibits superior burst strength and abrasion and puncture resistance.
3M-75 is a tacky adhesive available from the 3M Company, Minneapolis, Minn. Kevlar® is a high strength, inelastic fiber available from the DuPont Company, Wilmington Del. Texin® 5265 is a polyurethane polymer available from Miles, Inc., Pittsburgh, Pa.
Example 2
The procedure of Example 1 was repeated with the exception that Vectran® fiber, having a thickness of 0.005 inch is used in placed of the Kevlar® fiber. The resulting composite balloon is axially and radially non-compliant at very high working pressures. The balloon has very high tensile strength and abrasion and puncture resistance.
Vectran® is a high strength fiber available from Hoechst-Celanese, Charlotte, N.C.
Example 3
A mandrel in the shape of a balloon as shown in FIG. 1 is made of a water-soluble wax. The wax mandrel is coated with a very thin layer (0.0002 inch) of Texin® 5265 polyurethane. After curing, adhesive and Vectran® fibers are applied, following the procedure of Example 1. Next, several coats of Texin® 5265 polyurethane as applied in Example 1. The wax is then exhausted by dissolving in hot water to give a non-compliant, very high strength, abrasion-resistant, composite fiber-reinforced balloon.
Example 4
The procedure of Example 3 is repeated using high strength Spectra® fiber in place of Vectran® fiber. Spectra® fiber is available from Allied Signal, Inc. Morristown, N.J.
Example 5
The procedure of Example 1 is repeated using Ultra High Molecular Weight Polyethylene (Spectra 2000) fiber, which has been flattened on a roll mill. To the flattened fiber is applied a thin coat of a solution of 1-MP Tecoflex® adhesive in a 60-40 solution of methylene chloride and methylethylketone. The fiber is applied to the balloon as in Example 1 using 30 longitudinal fibers, each substantially equal in length to the length of the long axis of the balloon, and a hoop wind of 54 wraps per inch. The fibers are then coated with the Tecoflex® solution.
Tecoflex® is supplied by Thermedics Inc., Woburn, Mass.
Example 6
A balloon-shaped solid mandrel made of a low melting temperature metal alloy is coated with a thin layer of Texin® 5265/DMA solution (10%). Vectran® fibers are applied as in Example 1, followed by coating with Texin®/DMA. The metal mandrel is melted out using hot water. A very high strength, abrasion-resistant, composite balloon is obtained, which is non-compliant.
Example 7
Following the procedures of Example 6, a mandrel is coated with a very thin layer of PIM polyimide (2,2-dimethylbenzidine) in solution in cyclopentanone. Polyimide fibers are applied, and the composite balloon is then completed with additional applications of the PIM solution. The mandrel is removed to give a high strength, puncture-resistant balloon having an extremely cohesive fiber/matrix composite wall that is resistant to delamination.
Example 8
A balloon is constructed as in Example 7, except that the longitudinal fibers are replaced by a longitudinally oriented thin film made of polyimide LARC-IA film (available from IMITEC, Schenectady, N.Y.). The film is cut into a mandrel-shaped pattern and applied to the mandrel, over which the polyimide hoop fibers and the PIM solution are applied.
Although the illustrative embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A non-compliant medical balloon, where the non-compliant medical balloon may be changed from a deflated state to an inflated state by increasing pressure within the balloon, is made with a first fiber layer, a second fiber layer over said first fiber layer such that the fibers of the first fiber layer and the fibers of the second fiber layer form an angle and a binding layer coating the first fiber layer and said second fiber layer. The interior surface area of the non-compliant medical balloon remains unchanged when the balloon changes from a deflated state to an inflated state.
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BACKGROUND
Often a user expects a certain quality of service from his data storage system and sets targets for this performance. A user generally chooses a storage system with static performance ratings showing that the storage system has the capability to meet performance targets. But a user may have little information about the quality of service of individual storage devices and/or storage systems within his data storage system. The user may also have little information about the present quality of service of individual storage devices as it compares to past performance or the static performance ratings.
In addition, the increased use of virtualization software makes the quality of service of individual storage devices and/or storage systems increasingly difficult to ascertain. In a virtualized storage system, the host application is presented with logical units of storage capacity that may be made up of one or more storage elements or portions thereof. Where virtualization is used, users are therefore insulated from knowledge of which storage elements they are using. Nonetheless, with or without virtualization, the quality of service provided by individual storage devices and/or storage systems affects the quality of service experienced by the user.
Known monitoring tools, such as performance monitors and application software optimizers, measure on-line system performance over a relatively long-term basis—typically hours, days, weeks, or months. These tools are thus able to identify system trends by comparing the system's measured performance to its past performance in a comparable performance period. Known monitoring tools rely on existing host traffic to measure system performance. Accordingly, it may be difficult to use the information available from known tools to determine the available capacity of a system for future use. Similarly, with known monitoring tools, performance data may be unavailable if the system has been idle. Although these tools can be used to monitor a system, they typically include no feedback mechanism that would enable a monitored system to be automatically adjusted.
The lack of information about the quality of service presently available from individual storage devices and/or storage systems can be detrimental to the optimal use of a user's storage system. Sometimes users may have prioritized tasks, but lack information that enables them to determine how a low priority task may affect higher priority tasks. For example, a user may schedule a back-up task to occur when trends indicate there will be available capacity to run the back-up task without affecting the quality of service for higher priority tasks. Similarly, a user may set a parameter such that a movement of data during a migration task runs at a low speed to avoid affecting the quality of service for higher priority tasks. Making these decisions based on trends or on static performance ratings may unnecessarily reduce the network's efficiency.
SUMMARY OF EXEMPLARY EMBODIMENTS
The inventor of the present invention recognized that a method for proactively characterizing the dynamic quality of service available from a storage element within a computer system could enable a user to increase the use of the storage element while maintaining an acceptable quality of service. The inventor recognized that present quality of service measurements may be preferable to trend analysis or static performance ratings of data storage elements when determining the impact of a future task to be performed using a storage element. The inventor recognized that such a method could enable a user to optimize the quality of service of a virtual storage system and could also be useful in a computer system without a virtualization system.
Methods and systems are disclosed that relate to characterizing the dynamic performance quality of service available from one of a plurality of storage elements in a storage system. One embodiment consistent with principles of the invention is a method that includes initiating a known input/output (I/O) request to a storage element within the storage system. The time the first storage element takes to respond to the known I/O request is measured and a measure of the dynamic performance quality of service available from the first storage element is reported.
Another embodiment consistent with principles of the invention is a method for characterizing a dynamic performance quality of service available from one of a plurality of storage elements in a virtualization system. The virtual storage system presents storage capacity of the plurality of storage elements to a host application as at least one logical unit. The method includes identifying a first storage element within the virtualization system. The method also includes initiating a known I/O request to a first storage element within the storage system, measuring a time the first storage element takes to respond to the known I/O request, and reporting a measure of the dynamic performance quality of service available from the first storage element.
Another embodiment consistent with principles of the invention is a system for characterizing the dynamic performance quality of service available from a plurality of storage elements within a virtual storage system. The system includes a memory and a processor coupled to the memory. The processor is also coupled, via a network, to a host and the plurality of storage elements. The memory stores metadata related to the first storage element. The processor is configured to manage the first storage element using the metadata and to present a storage capacity associated with the first storage element to a host application as at least a portion of a logical unit. The processor is also configured to implement a method for characterizing the dynamic performance quality of service available from the first storage element. The method includes initiating a known I/O request to the first storage element, measuring a time the first storage element takes to respond to the known I/O request, and reporting a measure of the dynamic performance quality of service available from the first storage element.
Additional embodiments consistent with principles of the invention are set forth in the detailed description which follows or may be learned by practice of methods or use of systems or articles of manufacture disclosed herein. It is understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 illustrates an exemplary computer system including a virtualization system in the host consistent with features and principles of the present invention;
FIG. 2 illustrates another exemplary computer system including a virtual storage system in the data storage array consistent with features and principles of the present invention;
FIG. 3 illustrates another exemplary computer system including a virtual storage system consistent with features and principles of the present invention;
FIG. 4 illustrates an exemplary method for proactively characterizing a dynamic performance quality of service available from a storage element in a storage system; and
FIG. 5 illustrates a relationship, for a storage element, between a time to service an I/O request and types of I/O requests of various sizes.
DETAILED DESCRIPTION
The inventor of the present invention recognized that using existing I/O to gather performance trend information and the knowing the static performance ratings of a storage system may not be sufficient to gauge the performance available for future operations when a storage element is in use. Accordingly, the inventor devised a method for proactively characterizing the dynamic performance quality of service available from one of a plurality of storage elements.
In addition, the inventor of the present invention recognized that, while the use of a virtual layer in a computer system offers advantages, it also presents challenges to a user trying to manage his computer system to achieve or maintain a specific quality of service. In particular, virtualization hinders a user's ability to ascertain the quality of service available from individual storage elements in a virtual storage system. The inventor further recognized that information derived from this method can be used to make adjustments in the storage system and I/O requests to the storage system to maintain a specific target dynamic performance quality of service. Additionally, the inventor recognized that information derived from this method can be used to increase the usage of a storage system while maintaining a specific quality of service.
Dynamic performance quality of service, as used herein, may differ from the static quality of service identified in the specifications of a storage element. Examples of dynamic performance quality of service measures include I/O per second throughput and megabyte per second bandwidth for a given I/O type (I/O read or write and I/O size).
Reference is now made in detail to illustrative embodiments of the invention, examples of which are shown in the accompanying drawings. First, three computer systems including a virtualization system in which the invention may be implemented are described. Then, an implementation of the invention is described in detail. Although each of the exemplary illustrated computer systems include a virtualization system, the invention may be implemented in a computer system that does not include a virtualization system.
FIG. 1 illustrates an exemplary computer system 100 including a virtualization system 115 . Computer system 100 includes at least one host 110 connected via a network 150 to at least one storage array. Host 110 can be a personal computer or a server. Network 150 enables communications between host 110 and each of the storage arrays 120 - 1 through 120 - n . A storage element is any physical storage device such as a disk drive.
In FIG. 1 , host 110 includes an operating system (OS) 113 , an optional virtualization system 115 , and at least one host bus adapter 117 . The at least one host bus adapter 117 controls communication between host 110 and other components on network 150 . The host bus adapter 117 , for example, may be implemented as a Small Computer Systems Interface standard (SCSI) driver to interact with other SCSI drivers where network 150 includes a SCSI bus. Alternatively, network 150 can be implemented as a Fibre channel fabric. The available storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n service the I/O requests of applications running on host 110 via network 150 .
If FIG. 1 did not include virtualization system 115 anywhere in computer system 100 —storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n would be directly available to any host application running on OS 113 . Accordingly, without a virtualization system, storage elements storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n are directly presented to any host application running on OS 113 as logical units.
In FIG. 1 , however, virtualization system 115 on host 110 handles communication between the at least one host bus adapter 117 and any host application running on OS 113 . When virtualization is implemented in host 110 or elsewhere in computer system 100 , the virtualization system creates a layer of abstraction between the functionality of the available storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n and any host application running on OS 113 . The virtualization system may create a layer of abstraction between at least one logical unit and the available storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n by aggregating, striping, and/or mapping the storage capacity of storage elements. Virtualization system 115 , for example, presents the storage capacity of storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n to any host applications running on to OS 113 as at least one logical unit. The VERITAS virtualization system, available from Symantec Corporation of Cupertino, Calif., is an example of a virtualization system that can be implemented on a host. A logical unit presented to a host application may be made up of at least a portion of one or more available storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n , which may be from any storage array 120 - 1 through 120 - n . Storage elements storage elements 129 - 1 , . . . , 129 - n and 139 - 1 , . . . , 139 - n are the back end of the storage system where there is virtualization.
FIG. 2 illustrates another exemplary computer system 200 . Like computer system 100 , computer system 200 includes at least one host 210 connected via a network 250 to storage. Like storage array 120 , storage array 220 contains one or more storage elements 229 . Like network 150 , network 250 enables communications between host 210 and storage. Unlike computer system 100 , computer system 200 includes a virtualization system 224 in a storage array 220 . Accordingly, storage elements 229 service the requests of applications running on host 210 via storage array 220 . Storage array 220 in FIG. 2 could be, for example, a CLARIION, a FAStT, a TagmaStore, or a SYMMETRIX data storage system. Both CLARIION and SYMMETRIX data storage systems are available from EMC Corporation of Hopkinton, Mass. The FAStT and TagmaStore data storage systems are respectively available from IBM and HDS.
FIG. 2 also illustrates an exemplary storage array 220 in detail. Storage array 220 includes a plurality of storage elements 229 - 1 to 229 - n , at least one storage bus 227 , an at least one disk controller 222 . Each disk controller 222 controls communication between storage array 220 and other components outside the storage array 220 . Each disk controller 222 typically controls access to a plurality of storage elements 229 . The disk controller 222 may be implemented as a SCSI driver to interact with other SCSI drivers where network 250 includes a SCSI bus. Alternatively, network 250 can be implemented as a fibre channel fabric. Disk controller 222 includes a processor 225 , memory 223 , and virtualization system 224 . Virtualization system 224 presents logical units, made up of storage capacity from storage elements 229 - 1 to 229 - n , to host 210 via disk controller 222 and network 250 .
FIG. 3 illustrates a third exemplary computer system 300 including a virtualization system 330 implemented in hardware that acts as an intermediary between host 310 and storage. FIG. 3 includes at least one host 310 connected via a network 350 and a virtual storage system 330 to at least one storage element 339 . In particular, FIG. 3 includes one host 310 and a plurality of storage elements 329 - 1 , 329 - 2 , . . . , 329 - n , which can be storage elements connected via network 350 to virtual storage system 330 . The inclusion of virtualization system 330 between network 350 and storage devices 320 may enable centralized and/or simplified management of data on storage elements 329 - 1 , 329 - 2 , . . . , 329 - n . Other than virtualization system 330 , each of the other elements of FIG. 3 may be the same as or similar to those illustrated in and described with respect to FIG. 1 and/or FIG. 2 .
Unlike FIG. 3 , the storage devices associated with a virtualization system in the network layer may be grouped together within an array. When a computer system is reconfigured to add a virtualization system in the network layer, such as virtualization system 330 , an existing storage element or array can be imported into the virtual storage system and the storage element or array is then considered “encapsulated” by the virtual storage system.
In computer system 300 , virtualization system 330 includes an intelligent multi-protocol switch (IMPS) 332 including memory 334 for storing metadata related to storage element 320 and any other data volume incorporated into computer system 300 . Memory 334 can be any device for storing data, such as a disk array. Virtualization system 330 also includes a controller 326 including at least one processor 335 . Processor 335 can be any device capable of processing information, such as a microprocessor or a digital signal processor. Controller 326 is configured to manage the storage elements 329 - 1 , 329 - 2 , . . . , 329 - n encapsulated by virtual storage system 330 using the metadata in memory 334 and IMPS 332 .
Virtual storage system 330 can be, for example, the INVISTA application running on an IMPS, such as one of Cisco's MDS 9000 family of switches. EMC Corporation of Hopkinton, Mass. offers the INVISTA application. Virtual storage system 330 can be, for another example, a “Fabric_X Instance” such as described in U.S. patent application Ser. No. 10/810,988, entitled “System and Method for Managing Storage Networks and Providing Virtualization of Resources in Such a Network,” filed on Mar. 26, 2004, the description of which is hereby incorporated by reference.
Although virtualization system 330 has no physical disk geometry, it presents geometry information to host 310 . This feature enables virtualization system 330 to appear as one or more storage elements 329 to host 310 . Together the virtualization system 330 and the encapsulated storage elements 329 can be considered a storage system in computer system 300 . Virtualization system 330 presents logical units of storage capacity, made up of storage elements 329 or portions thereof, to the operating system and applications running on host 310 . Storage elements 329 encapsulated by virtual storage system 330 are the back end of the storage system 330 .
FIG. 4 illustrates a method 400 for characterizing a dynamic performance quality of service available from a storage element in a computer system. Method 400 can be implemented, for example, in virtualization system 115 in computer system 100 , virtualization system 224 in computer system 200 , or virtualization system 330 of computer system 300 . Method 400 can also be implemented a computer system without a virtual layer or a virtualization system. Method 400 includes three basic stages. In stage 420 , a known I/O request to the target storage element is initiated. In stage 430 , the time for the target storage element to respond to the known I/O request is measured. In stage 450 , a measure of the quality of service available from the target storage element is reported.
When method 400 is used to characterize the dynamic performance quality of service available from a storage element in a computer system featuring a virtualization system, it may further include stage 410 . In optional stage 410 , a target storage element of interest is identified. The target storage element may differ each time method 400 is practiced. For example, where there are three storage elements in the storage system, stage 400 may target each of the three storage elements on a round robin basis. Such a scheme may be implemented to detect over or under utilized storage elements and flag them for possible data migration or other efficiency improvement initiatives. Alternatively, storage elements may be targeted on a demand basis. For example, if a user is wants to perform a task that would put a high demand on a particular storage element, he may first request a report of the quality of service available from that storage element. The user may thereby specify parameters for the task that are appropriate in view of the available quality of service. Still alternatively, storage elements may be targeted on a more specific basis. For example, low-performing storage elements may be targeted less frequently to minimize the increased load on these storage elements.
The size of the I/O request initiated in stage 420 can be selected for its known relationship to the measure of the quality of service available from the target storage element. Alternatively, the size of the initiated I/O requests can be selected to achieve the best estimation of quality of service for the next I/O request to be performed in the computer system. For example, before a data migration task is performed, a large I/O size may be selected for initiation in stage 420 . Alternatively, for an application accessing small portions of memory frequently, a small I/O size may be selected for initiation in stage 420 .
In stage 450 , the reported measure of the quality of service available from the target storage element need not be the measured time for the target storage element to respond to the known I/O request. In optional stage 440 , a measure of the quality of service available from the target storage element is calculated using the measured time and an estimation algorithm. Estimation algorithms can be developed by bench testing a storage element to ascertain a relationship between the time to respond to a known I/O request and a measure of a quality of service available from the storage element. Alternatively, the same relationship can be dynamically estimated from the series of previous sample I/O measurements.
FIG. 5 illustrates exemplary bench testing results from which estimation algorithms have been developed. FIG. 5 illustrates service times for a range of sizes of three different types of I/O requests with one outstanding I/O request per storage element (N=1). The I/O request sizes 510 on the horizontal axis of FIG. 5 range from 0 to 64 blocks where each block is 512 bytes. The service times 520 on the vertical axis of FIG. 5 range from 0 to 300 ms. Three exemplary curves 530 , 540 , 550 in FIG. 5 illustrate a mathematical fit to data for uncached reads, cached reads, and uncached writes respectively. Curve 530 illustrates a relationship between the size of an uncached read request and a service time, which can also be represented by the equation, where the curve fit measure R 2 =1.0:
y=8.188 e0.0308x
Curve 540 illustrates a relationship between the size of a cached read request and a service time, which can also be represented by the equation, where the curve fit measure R 2 =1.0:
y=2.3369 e0.0069x
Curve 550 illustrates a relationship between the size of an uncached request and a service time, which can also be represented by the equation, where the curve fit measure R 2 =0.9995:
y=27.887 e0.0363x
The data that is the basis for each of the curves 530 , 540 , 550 illustrated in FIG. 5 was generated using various block sizes on an array with 240 storage elements, with an average of one outstanding I/Os per storage element. Data, such as that illustrated in FIG. 5 , can be measured on an idle system. Alternatively, data can be collected from systems under varied conditions to create estimation algorithms.
Using a known relationship between the size of an I/O request and a service time with a known number of outstanding I/O requests, a service time for a smaller known I/O request can be used to predict the service time for a larger I/O request. For example, if exemplary curve 530 illustrates the relationship, the time to service a 16 block I/O request (approximately 50 ms) can be used to estimate the time to service a 32 block I/O request (approximately 50 ms). Thus, the time to respond to a smaller known I/O request can be measured in stage 430 , and the measured time can be used to estimate the quality of service for a larger I/O request. The estimate may then be reported in stage 450 .
In some embodiments of stage 440 , the measure of the quality of service available from the target storage element is calculated from a plurality of measured times for the target storage element to respond to known I/O requests. In some such embodiments, a number of different sized known I/O requests can be used to calculate the quality of service available from a target storage element. In optional stage 470 of method 400 , a second known I/O request is initiated. Stage 440 can use more than one measured response time to determine the quality of service available from the target storage element. For example, in one optional stage 440 , a measure of the quality of service available from the target storage element is calculated using both measured times for the target storage element to respond to known I/O requests as input to an estimation algorithm. Additionally, stage 440 can use the last several measured response times for the target storage element. In that case, the number of measured response times used as input to the algorithm remains constant and each use of the algorithm includes the most recent measured response times for the target storage element as input. Moreover, a set of known I/O requests required to calculate quality of service for a single storage element can include I/O requests of different sizes. Finally, the set of known I/O requests required to calculate quality of service may differ for different storage elements.
In optional stage 460 , a feedback mechanism is used to ensure the storage system maintains a desired level of service. Stage 470 can include comparing the calculated quality of service measure for the target storage element to a predetermined quality of service measure. The predetermined quality of service measure may be specified for the entire storage system or for one or more storage elements within the storage system. If the calculated value exceeds the predetermined value, the load on the target storage element can be adjusted to improve its available quality of service. Such load adjustment can include, for example, reducing the speed at which a plurality of low-priority I/O requests directed to the target storage element are executed or suspending these requests to achieve the predetermined quality of service for higher priority I/O requests. Alternatively, a load adjustment may include data migration, where data is moved from one storage element to another to maintain the desired quality of service level. The calculated quality of service measure may also be used to determine the speed at which this data is migrated to another storage element or the size of each portion of data to be moved.
The equations illustrated in FIG. 5 can be used as estimation algorithms to determine the reserve capacity of a target storage element. Results, such as those exemplified in FIG. 5 , can be used in conjunction with the measured response time from stage 430 to find the I/Os per second reserve capacity of a storage element that is currently in use. Once determined, the reserve capacity reveals the additional use a storage element can handle while maintaining the target dynamic performance quality of service.
For example, in optional stage 460 , virtualization system 115 could use algorithm and data illustrated in FIG. 5 to estimate the available capacity and adjust the load of I/O requests to that storage element to take advantage of all of the available capacity. Using computer system 100 , a user may be interested in doing 8 KB uncached reads for a particular application running on OS 113 . In this example, virtualization system 115 can initiate an 8 KB uncached read request in stage 420 . In stage 430 , the measured time may be the same as the service time for an 8 KB uncached read request in FIG. 5 —0.010 seconds (10 ms). This measured time suggests that the storage element may have available capacity. Consequently, virtualization system 115 may check the average number of outstanding I/O requests (N) for the target storage element. If that number is less than 1.0 (N<1.0), virtualization system 115 can use Little's Law to calculate the available capacity. Little's Law, N=X*(R+Z), describes the relationship between the average number of outstanding I/O requests—N, the throughput—X, the service time—R, and the queue or think time—Z. Applying Little's Law to the data provided with respect to FIG. 5 (N=1.0, R=0.010 seconds, Z=0 seconds), the storage element's throughput capacity can be calculated as one hundred 8 kB I/O requests per second (X=N/(R+Z)=1.0/(0.01+0.0)=100). Then, applying Little's Law to the current storage element data (N=0.5, R=0.010 seconds, Z=0 seconds), the storage element's current throughput can be calculated as fifty 8 kB I/O requests per second (X=N/(R+Z)=0.5/(0.01+0.0)=50). The available capacity is the throughput capacity (data from FIG. 5 ) less the current throughput. Thus, in this example, the storage element has fifty 8 kB I/O requests per second in available storage capacity (100−50=50). Accordingly, in stage 460 , virtualization system 115 may therefore enable a task to direct up to fifty 8 kB I/O requests per second to the target storage element without adversely affecting the quality of service provided by that storage element.
Similarly, if the calculated value falls below some margin of the predetermined value, the load on the target storage element can be adjusted to take advantage of the available capacity. The user can specify the relevant margin as part of his load balancing policy. Such load adjustment can include, for example, increasing the speed at which a plurality of low-priority I/O requests directed to the target storage element are executed. The present invention enables the load on a target storage device to be adjusted dynamically as the quality of service available from the target storage device changes.
In method 400 , the initiation of a known I/O request to a target storage element can be triggered in a variety of ways. For example, a timer can trigger the initiation of an I/O request. Where there are a plurality of storage elements, there can be one timer for all of the storage elements. This frequency at which such a timer triggers the initiation of an I/O request can be adjusted based on the number of storage elements being sampled. Alternatively, where there are a plurality of storage elements, there can be a separate timer for each storage element. The frequency at which a timer triggers the initiation of an I/O can be selected by a user to prevent a noticeable impact on the quality of service available from one or more of the target storage elements. A higher frequency of I/O requests provides more information to the user, but also increases the traffic to the target storage element potentially decreasing the quality of service available from the target storage device. Similarly, a lower frequency of I/O requests provides less information to the user and less potential impact on the quality of service available from the target storage element. A user can choose different sampling frequencies for different storage elements. In one embodiment, I/O requests are initiated once every period where the period ranges between a half second to five seconds.
For another example, the initiation of an I/O request can be triggered on demand. A user may want to information to determine appropriate parameters for a high volume task such as a storage system backup. Accordingly, a user may request a measure of the quality of service available from one or more target storage devices. Thus, a user may trigger the initiation of one or more I/O requests.
The embodiments and aspects of the invention set forth above are only exemplary and explanatory. They are not restrictive of the invention as claimed. Other embodiments consistent with features and principles are included in the scope of the present invention. As the following sample claims reflect, inventive aspects may lie in fewer than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this description, with each claim standing on its own as a separate embodiment of the invention.
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Disclosed methods and systems relate to characterizing a dynamic performance quality of service available from a storage element within a storage system. An exemplary method includes initiating a known I/O request to the storage element; measuring a time the storage element takes to respond to the known I/O request; and reporting a measure of the quality of service available from the storage element. One implementation of the method further includes using the time measurement and an estimation algorithm to calculate the quality of service and adjusting the load on the storage element based on the quality of service.
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FIELD OF THE INVENTION
The invention relates to building structures, and more particularly to trim members for protecting, covering and decorating the area from the base of the roof to the upper portion of the outer wall of a building structure, such as a home or office or other commercial building, where the trim members are manufactured by pultrusion.
BACKGROUND OF THE INVENTION
In the United States, most residential or light weight-building systems employ wood or metal rafters, which extend from six to twenty-four inches beyond the outer wall. The outer wall is typically constructed of masonry or wood construction. Typically, the rafters and the sub-fascia (a member that connects the rafter ends together) support roof decking which forms the base of the roof. Shingles or other roofing materials cover the roof decking. Typically, the entire area from the lower edge of the roof decking to the upper portion of the outer wall of the building structure is covered with a cornice assembly, usually made of wood or wood covered with aluminum or vinyl. Aluminum or vinyl is a preferred material because of the high maintenance of wood trim pieces, which require repainting every few years (but in fact, vinyl cannot be painted at all). A fascia, usually the upper trim member of the cornice assembly, typically covers the sub-fascia or the outer portion of the rafter ends. This fascia protects the sub-fascia or rafter ends from the elements, and provides a decorative cover. The soffit, another trim member of the cornice, typically extends horizontally between the bottom inside edge of the fascia to the upper portion of the outer wall. The third trim member of the cornice assembly, known as the frieze, is a decorative member that starts at the soffit and runs down the outside surface of the top of the outer wall. The frieze is usually made of the same material as the fascia and soffit.
One problem associated with decorative and protective cornice assemblies is the labor required to install the several component parts, such as the fascia, the soffit, the frieze, and decorative moldings associated therewith. A second problem occurs when wood is used, which may rot and which requires regular repainting. A third problem is denting of aluminum products, and a fourth problem is expanding and contracting of aluminum and vinyl. Numerous fastening means, such as nails, staples, and the like must be used to attach the component parts together and/or to the building. This practice adds significant time and expense to the construction of a conventional building structure.
In addition, a problem associated with aluminum or vinyl cornice assemblies is the shearing of the fasteners used to fasten the cornice assembly or the enlarging of the holes created for fastening the assembly to the building structure. This shearing/enlarging problem is due to the relatively large amount of expansion and contraction due to temperature or moisture variations, which also causes buckling of the aluminum or vinyl material. As a result, the cornice assembly may become detached fi-om the building structure or may appear warped.
In the past, a cornice assembly has had to be fabricated in place. Each portion of the cornice assembly is attached to the building individually. When a wood backing is used in conjunction with vinyl or aluminum assembly, yet another aspect of the assembly must be attached individually. This process is time-consuming, labor-intensive, and difficult to attain professional looking results.
A known method of manufacturing articles which have a lineal profile and a constant cross-section is called pultrusion. Pultrusion is the opposite of extrusion. It is a continuous pulling process in which rovings or strands of fibers are impregnated with resin and are then pulled through a heated die which cures the resin while also providing the cross-sectional shape to the piece. The cured piece is cut to length as it comes off the line. See, for example, “Pultrusion for Engineers” (Trevor F. Starr ed., CRC Press, 2000), which is hereby incorporated by reference. Pultruded material can be colored during manufacture, but unlike vinyl, also has surface that can accept and permanently retain paint.
Therefore, pultrusion is desirable to provide an improved method for the manufacture of the cornice assembly (or other trim members used in home construction), to protect the interface between the roof decking and the upper portion of the outer wall of a building structure. Pultrusion would provide a cornice assembly that minimizes structural instability by eliminating expansion and contraction of the cornice assembly and minimizes the use of fasteners while providing a less labor-intensive fabrication process. In addition, a pultruded cornice assembly is desirable to reduce production and labor costs, including the elimination of the need to paint the trim after assembly—although painting remains an option if color change is desired.
SUMMARY OF THE INVENTION
The present invention includes improved methods for fabricating cornice assemblies and other trim members used in house construction. The cornice assemblies and trim members are fabricated through a process of pultrusion. Improved cornice assemblies are disclosed, which include at least a fascia, a soffit and a frieze with crown molding, all of which may be integrated into a unitary structure. The improved cornice assemblies may be constructed from one, two or more trim members. Also disclosed is a method of trimming a building structure using the cornice assemblies and trim members made by pultrusion. The dies utilized in the pultrusion of the cornice assemblies and trim members are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a cornice assembly made of a unitary construction which includes a facia, a soffit, a crown, a frieze and a gutter.
FIG. 2 is a cross-section of a cornice assembly made of two trim members.
FIG. 3 is a pultrusion die with a channel for a unitary construction cornice assembly with a facia, a soffit, a crown, a frieze and a gutter.
FIG. 4 is a pultrusion die for a trim member including a soffit and a crown.
FIG. 5 is a pultrusion die for a trim member including a facia and a gutter.
FIG. 6 is a pultrusion die for a trim member including a frieze.
FIG. 7 is a cross-section of a cornice assembly made of three trim members.
FIG. 8 is a cross-section of a cornice assembly made of two trim members.
FIG. 9 is a cross-section of a trim member including a facia, a soffit and a gutter and a longitudinal section of the soffit including an area of vent holes.
FIG. 10 is a cross-section of a trim member including a facia and a soffit without gutter.
FIG. 11 is a cross-section of a trim member including a crown and a frieze where the frieze includes a slotted opening to receive wood, metal or vinyl siding.
FIG. 12 is a cross-section of a trim member including a crown and a frieze where the frieze includes a slotted opening to receive brick veneer.
FIG. 13A is a cross-section of a outside edge cap trim member.
FIG. 13B is a cross section of an inside edge cap.
FIG. 14 is a cross-section of a belt board trim member.
FIG. 15 is a cross-section of a rake trim member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a cornice assembly 10 according to the invention is shown. The cornice assembly 10 includes portions a facia 12 , a soffit 14 , a crown 16 , and a frieze 18 . Optionally, the cornice assembly may also include a gutter 20 in which case the facia 12 forms the back side of the gutter 20 .
A significant advantage may be gained through a unitary constriction (formed as one piece) of the cornice assembly 10 in terms of the amount of labor needed to install the cornice assembly 10 . With a unitary construction, effort need only be spent on attaching the cornice assembly 10 to the building structure, while effort spent on fabricating the cornice assembly 10 is completely eliminated.
The cornice assembly 10 may be used in with walls made of any suitable outer sheathing building material known in the art, such as plywood, fiber board, celotex, OSB (oriented strand board) and the like.
In a second embodiment, as best seen in FIG. 2 , the cornice assembly 22 may be made of two or more trim members which are connected together to form the overall cornice assembly 22 . For example, one trim member may comprise the gutter 20 , the facia 12 and the soffit 14 , while another trim member includes the crown 16 and the frieze 18 . In this embodiment, the trim members are preferably constructed such that they may be press fit together. However, any suitable means of connecting the trim members to form the cornice assembly 22 may be used, including adhesives, bolts, nails or screws. By using press fit connections, the effort of fabricating the cornice assembly 22 on the job site is reduced as compared to traditional cornice assemblies. First, trim members capable of being press fit can be connected without the use of tools. Second, because press fitting connections are separate from the means for attaching the cornice assembly 22 to the building structure, the cornice assembly 22 can be fabricated at ground level as opposed to during attachment to the building structure. This saves both on the effort needed to fabricate the cornice assembly 22 and to attach the cornice assembly 22 to the building structure.
The cornice assemblies and trim members of the present invention are preferably manufactured through the process of pultrusion. Pultrusion is an economical technique which is especially suited for the manufacture of cornice assemblies and other trim members because they have uniform cross-sections and also benefit from the high strength to weight ratio provided by pultrusion.
Of importance to the pultrusion process is the die through which the resin impregnated reinforcements are pulled. Die include multiple metal blocks, which, when assembled, has a through-hole or channel in the shape of the desired cross-section of the trim member. FIG. 3 shows a die 24 with a channel 25 which would be used to manufacture an entire cornice assembly in a unitary construction. As can be seen, a total of ten different blocks 26 - 44 make up the die 24 for the unitary construction of the cornice assembly. The various blocks of the die 24 are held together with bolts, screws or other suitable fasteners 46 . FIG. 4 shows a die 48 which is used to manufacture a portion of a cornice assembly including a soffit 14 and a crown 16 . The soffit/crown trim member made with die 48 would be connected to a trim member including a gutter 20 and a facia 12 made with die 50 , shown in FIG. 5 , and to a trim member including a frieze 18 made with die 52 , shown in FIG. 6 . Together the trim members created by these die 48 , 50 and 52 would fit together to form a cornice assembly 54 , shown in FIG. 7 .
Selection of the particular resin and reinforcements that may be used in the pultrusion of cornice assemblies and trim members are well within the design capability of those skilled in the art. Exemplary reinforcements include continuous strands of fiberglass, aramid fibers, and graphite. In addition, chopped strand, continuous strand or swirl mats may also be used as reinforcements. A useful reinforcement is glass fiber because it is economically priced as compared to other fibers, such as carbon fibers, and has a high strength to weight ratio. Exemplary resin include polyurethane, polyesters, vinyl esters, epoxy resins, acrylic and phenolic resins.
One or more stiffening ribs may be attached to the building structure side of the cornice assemblies and trim members. In FIG. 8 , stiffening rib 55 included in a two piece cornice assembly made of a trim member with a gutter 20 , a facia 12 and a soffit 14 and a trim member with a crown 16 and a frieze 18 . These stiffening ribs may be pultruded from the same die as the cornice assemblies or trim members. The stiffening ribs provide extra support for the cornice assemblies and trim members against forces applied there against. This bracing prevents damage which may result from the placement of ladders against the cornice assemblies and trim members, particularly placement of ladders at the frieze 18 . Furthermore, nailers 57 , 61 , which form a nailing surface for nailing the cornice assembly or trim member to the building structure.
The available cross-sections for trim members is unlimited. Exemplary cross-sections, in addition to the ones previously shown with regard to the die 48 - 52 , include a trim member 56 which includes a gutter 20 , a facia 12 and a soffit 14 shown in FIG. 9 , a trim member 58 which includes a facia 12 and a soffit 14 shown in FIG. 10 , a trim member 60 which includes a crown 16 and a frieze 18 (adapted for use with exterior sheet siding) shown in FIG. 11 . shown in FIG. 12 . The friezes shown in FIGS. 8 and 11 show a relatively narrow channel 63 for accepting exterior sheet siding (such as aluminum, vinyl, wood, or the like). The frieze shown in FIG. 12 has a relatively wide channel 65 designed to accept brick or stone veneering. The trim members 56 - 62 may be mixed and matched to achieve the desired cornice assembly.
Other trim members which may be pultruded include caps for covering vertical edges, as shown in FIG. 13A , which are used to cover an outside edge cap where two pieces of siding come together. Belt boards as shown in FIG. 14 , which are used to transition from one siding material 71 to another FIG. 13B shows an inside edge cap. One trim member which may be pultruded is a rake, which is used along the gable side of the intersection between the siding material 71 and the roof deck 73 , as seen in FIG. 15 .
One or more vent holes may be made in the soffit allow circulation of air and escape of moisture. These vent holes may be made shortly after the time of fabrication of the pultruded member or at the job site, as dictated by the needs of the installer. Vent holes 64 in the soffit 14 , are shown in a longitudinal view of the soffit portion 14 of trim member 56 in FIG. 9 .
Preferably, the method of attaching the trim members to each other are press fit connections 59 , as best seen in FIG. 11 , because such fasteners are easily constructed during the pultrusion process. However, because of the thermal stability of pultruded members, any fastening means may be used without concern about the expansion and contraction due to variations in temperature or moisture. Cornice assemblies and trim member manufactured via pultrusion expand and contract less than 1/26 th of that of steel over a given temperature range. Thus, fasteners will not be sheared by pultruded cornice assemblies and trim members.
Various fastening slots are needed in aluminum and vinyl siding trim members to facilitate expansion and contraction that occurs after installation around the fastening nail after installation. However, such fastening slots are not necessary with pultruded members because, as discussed above, the pultruded cornice assemblies and trim members of the present invention do not expand or contract due to changes in temperature or moisture. Thus, when fastening pultruded cornice assemblies to building structures, the step of having to form slots can be eliminated. Also, trim members made from aluminum or vinyl and more difficult to install than pultruded members because they cannot be firmly nailed to the sheathing but must be loosely nailed so that they literally “hang” from the mounting nails by way of the slots. Pultruded members can be nailed firm just like wood can be nailed to other wood.
Because the pultruded cornice assemblies and trim members of the present invention have superior rigidity and strength to weight ratios, a significantly fewer fasteners are needed to attach the cornice assemblies and trim members to building structures.
In combination with the pultruded cornice assemblies of the present invention and other trim members, a variety of butt joint caps, corner caps, and end caps may be used to complete the trimming of a building structure. Butt joint caps are used to bridge the area where two linear sections of a cornice assembly or trim member come together.
Corner caps are used to bridge the area where two linear section of a cornice assembly or trim members come together at a corner. Both inside and outside corners are needed. While not suitable for manufacturing by pultrusion, butt joint, end, and corner caps may cost effectively be manufactured by other conventional methods such as foam injection, plastic injection, urethane casting, and the like. Caps are preferably attached with two-sided tape.
End caps are used to close off the ends of cornice assemblies and trim members to prevent dirt and water from penetrating behind the cornice assembly and potentially damaging the building structure.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.
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The present invention is an improved method of making cornice assemblies and other trim members utilizing the process of pultrusion. The cornice assemblies and the other trim members made by the method of the present invention exhibit superior strength to weight ratios, low expansion and contraction due to changes in temperature and humidity, as well being less labor intensive to install.
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CROSS-REFERENCE TO THE RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 054,313 filed on May 26, 1987, and now abandoned.
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a method of securing a catheter body to a human skin for a long period of time.
(b) Description of the Prior Art
An intravenous catheter (to be referred to hereinafter as an IVH catheter) is widely used for high calorie fluid therapy. Other various catheters have been also used for long-term indwelling in human body (e.g., in a vein).
A distal portion of the IVH catheter or the like is inserted into a vein by using, for example, the hollow needle method or the cut-down method. The part of the catheter outside of the body needs to be secured in place, to avoid being accidently moved. When such a catheter is indwelled in the body, a sepsis may occur as a complication. It is said that the cause of the sepsis is bacteria entering the body from the outside of the catheter, and that the rate of occurrence of the sepsis increases when the catheter is not secured firmly to the body.
Conventional methods of securing the catheter are: securing the part of the catheter outside of the body by using surgical tape; forming a subcutaneous tunnel and inserting the catheter with a Dacron cuff thereinto; and securing in place by suturing, with a ligature, the portion of the catheter outside of the body in the skin. In the method using the surgical tape, the catheter can still be easily moved, and therefore this method is not reliable. In the method of forming the subcutaneous tunnel, the catheter can be secured firmly in place. However, this operation is too complicated to be widely employed. Since a catheter of this type, e.g., an IVH catheter is normally indwelled for one or two weeks, the method of suturing the catheter in the skin by means of a ligature is widely employed as an easy-to-perform and reliable method.
However, using this method, the catheter may be broken at the portion tied by the ligature, or the cavity of the catheter may become so narrowed that a transfusion liquid cannot be supplied into the catheter at a predetermined flow rate.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the conventional problems described above and to provide a method of securing a catheter body to a human skin in such a manner that the catheter body will not be broken at a portion tied by a ligature, and a cavity thereof not be narrowed, and hence a transfusion liquid can be reliably supplied into the catheter, at a predetermined flow rate, and also provide a catheter-securing member which allows the catheter to be easily and firmly secured to the skin.
More specifically, according to the present invention, a securing member is provided which allows the catheter to be firmly secured to the surface of the skin, and which is constituted by a cylindrical body having a hollow portion into which the catheter body is slidably inserted in its axial direction, the cylindrical body having a slit formed to extend along the axial direction of the cylindrical body, and the slit reaching the hollow portion. Furthermore, according to the present invention, there is provided a method of securing a catheter body to a surface portion of human skin, which comprises;
preparing a cylindrical body having a hollow portion into which said catheter body is slidably inserted in an axial direction of said cylindrical body, said cylindrical body having a slit formed to extend along the axial direction of said cylindrical body, and said slit reaching said hollow portion;
piercing a middle portion of a ligature through a surface portion of human skin and tieing the middle portion of the ligature over the surface portion of human skin, extending a pair of free end portions of said ligature out of the skin for fastening said cylindrical body;
securing said cylindrical body with said pair of free end portions of the ligature by winding said ligature around said cylindrical body and fastening said ligature, thereby securing the catheter body to a surface portion of human skin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a state wherein the catheter-securing member mounted on the catheter body is secured on a surface portion of human skin;
FIG. 2 is a sectional view as taken along the line II--II of FIG. 1;
FIG. 3 is a perspective view of a catheter-securing member according to the present invention; and
FIGS. 4 and 5 are respectively perspective views showing other modifications of the catheter-securing member according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described, with reference to an embodiment shown in the accompanying drawings.
FIG. 1 is a perspective view of catheter-securing member 1 mounted on a catheter body 5 and secured to human skin B with a strip of ligature 10 according to the present invention. The catheter-securing member 1 comprises a cylindrical body 3 having hollow portion 2 into which a catheter body is slidably inserted in an axial direction thereof. Slit 4, reaching hollow portion 2, is formed from one end to the other end of catheter-securing member 1, along the axial direction thereof.
The catheter-securing member 1 is also provided as shown in FIG. 3 with an annular groove 6, which is circumferentially formed to traverse an axial direction of cylindrical body 3, and is preferably formed in a direction perpendicular to the axial direction thereof.
Annular groove 6 need not necessarily be formed around the center circumferential surface of member 1, but may be formed on a portion thereof, so long as it can prevent the ligature from being moved. Annular groove 6 may be formed in a V-shaped, a V-shape, or any other shape.
Catheter-securing member 1 is preferably made of a flexible synthetic resin material, and more preferably made of a material having a high elasticity. Examples of such a material are a soft vinyl chloride resin, rubber (e.g., silicone rubber and latex rubber), polypropylene, polyethylene, and polyurethane. The length of member 1 is not limited, but is preferably 3 to 30 mm, and more preferably 5 to 15 mm, to ensure secure tying of a ligature on member 1, and ease of handling.
Slit 4 may extend along the axial direction of the catheter body, or it may extend parallel, at an oblique angle, or spirally in relative to the axial direction of the catheter body, and preferably be arranged parallel to the axis of the catheter body. Slit 4 may be formed by simply cutting member 1. Member 1 is fitted on the catheter body, and this cut portion serves as slit 4. Slit 4 may have a predetermined width. If member 1 is fitted on the catheter body and the width of slit 4 is not more than 1/5 or preferably not more than 1/10 the overall circumferential length of member 1, the cavity of the catheter body will not be narrowed upon tying by the ligature.
The inner diameter of hollow portion 2 is slightly larger than the outer diameter of the catheter body, so that the catheter body can be moved therewithin. The difference in diameter between them may be determined such that when the catheter-securing member is tied with the ligature, to be fixed to the skin, it is brought into tight contact with and is firmly secured to the catheter body. The inner diameter of hollow portion 2 may alternatively be equal to or slightly smaller than the outer diameter of the catheter body. In this case, the catheter body can be rendered movable by enlarging slit 4.
Catheter body 5 is a tube whose distal and proximal ends are open, and is made of a soft resin. Examples of the soft resin which can be used are silicone rubber, a soft vinyl chloride resin, and a polyurethane elastomer.
In the conventional IVH catheter, a catheter body having an inner diameter of 0.5 to 1.7 mm and an outer diameter of 0.9 to 2.1 mm is used.
A catheter is fixed to the skin by using catheter-securing member 1 tied with a ligature as follows. In the first step, a single or a plurality of catheter-securing members 1 are indwelled, as is shown in FIG. 1, by inserting a predetermined portion of catheter body 5 into hollow portion 2. The position of catheter body 5 is shifted and adjusted within hollow portion 2, so as to determine the portion thereof to be tied with the ligature.
Then, ligature 10 is pierced into skin A, followed by temporarily fastening ligature 10 on skin A. Further, the ligature on skin A is wound about the catheter-securing member such that the ligature extends within annular groove 6 of the catheter-securing member. Under this condition, the free end portions of the ligature are tied to each other so as to fix catheter-securing member 1 and, thus, to fix catheter 5 to skin A via catheter-securing member 1.
FIG. 4, which illustrates a modification of catheter-securing member 1, shows that at least two ribs, 7a and 7b, may be circumferentially formed in place of annular groove 6, to extend along a portion of the outer surface of member 1, such that a groove is formed between the ribs.
FIG. 5, which illustrates another modification of catheter-securing member 1, shows that flat portion 8 is preferably formed at a portion of the outer surface of member 1, such that it extends along the axial direction thereof. A contact area of member 1 to the skin of human body is increased by forming flat portion 8, thereby allowing member 1 to be easily and firmly secured to the skin.
In the case of the modification shown in FIG. 5, in place of annular groove 6, a pair of notches 9 for preventing the ligature from being moved are formed at portions of both the edges of flat portion 8.
The same reference numerals in FIGS. 4 and 5 denote the same parts as in FIG. 3, and a description thereof will be omitted.
When a catheter-securing member according to the present invention is used for securing a catheter, for example in the case of an IVH catheter, a distal end of catheter body 5 is inserted into a vein, by means of the hollow needle method, and member 1 is shifted to a position where it can be secured to a portion of skin. The catheter is then secured in place, by means of ligature tied at a portion of member 1. Then, a high-calorie transfusion liquid is allowed to flow from a proximal end of catheter 5.
The catheter-securing member according to the present invention serves as a member for securing the catheter body to the skin. Since the catheter-securing member has an insertion portion for the catheter body, and can be moved along the axial direction thereof, the catheter body can be easily and firmly secured to any desired portion of the skin without being bent at a ligature portion or the cavity thereof being narrowed.
The catheter-securing member according to the present invention is not limited to the IVH catheter-securing member, but can be applied to any catheter which is indwelled in a body for a relatively long period of time.
Next, examples and a comparative example according to the present invention will be described.
EXAMPLE 1
A catheter composed of a soft vinyl chloride resin was constructed, having an outer diameter of 1.5 mm, an inner diameter of 0.8 mm, and having open distal and proximal ends. A catheter-securing member was made of a soft vinyl chloride resin was constructed in the form of a cylindrical tube having an inner diameter of 1.4 mm, an outer diameter of 3.0 mm, and a length of 6.0 mm, and having a slit in its axial direction. A catheter body was inserted into the catheter-securing member, so as to form the catheter according to the present invention. It should be noted that the above catheter-securing member could be easily moved in its axial direction.
The above-described catheter was tied as shown in FIGS. 1 and 2 to a rubber plate having a thickness of 6 mm, by using a No. 3 ligature at a portion of the catheter-securing member.
As a result, the catheter body could be easily and firmly secured to the rubber plate by means of the securing member. Furthermore, the catheter body was not bent and a cavity thereof was not narrowed upon fastening of the ligature around the catheter, nor did the catheter break off when it was pulled hard.
EXAMPLE 2
In this example, a catheter was arranged in the same manner as described in Example 1, except that an annular groove (a V-shaped groove having a depth of 0.5 mm) was circumferentially formed in a direction perpendicular to the axis of the catheter-securing member.
As was the case in Example 1, the catheter-securing member could be easily moved along the longitudinal axis of the catheter body.
The catheter was tied to a rubber plate having a thickness of 6 mm, by using the No. 3 ligature in the same manner as in Example 1, such that the ligature was fitted into the annular groove of the catheter-securing member.
As a result, the catheter body could be easily and firmly secured to the rubber plate, by the fixing member. Furthermore, the catheter body was not bent and the cavity thereof was not narrowed upon fastening of the ligature around the catheter, nor did the catheter break off when it was pulled hard. The ligature was not shifted when only the fixing member was pulled.
EXAMPLE 3
A catheter made of a soft vinyl chloride resin was constructed, having an inner diameter of 1.4 mm, a length of 6.0 mm, and an outer diameter of 3.0 mm at a thin wall portion. A flat portion having a length of 6.0 mm in the axial direction of the catheter-securing member and a length of 4.0 mm in a direction perpendicular to the axial direction thereof was formed on the securing member. A number of 0.8 mm deep notches were formed midway along the flat portion, at positions symmetrical about the axis of the securing member.
A catheter body as shown in Example 1 was used in this example. As was the case in Example 1, the catheter-securing member could be easily moved along the longitudinal axis of the catheter body.
The catheter was tied to the rubber plate having a thickness of 6 mm, by using the No. 3 ligature in the same manner as in Example 1, such that the ligature was fitted into the annular groove of the catheter-securing member. As a result, the catheter body could be easily and firmly secured to the rubber plate, by means of the securing member. Furthermore, the catheter body was not bent and the cavity thereof was not narrowed upon fastening of the ligature around the catheter. The catheter did not break off when it was pulled hard, nor did the ligature shift when only the catheter-securing member was pulled. It should be noted that in this example, the catheter-securing member was secured to the rubber plate more firmly than in the above examples.
COMPARATIVE EXAMPLE
In this example, a catheter made of a soft vinyl chloride resin was constructed, having an outer diameter of 1.5 mm and an inner diameter of 0.8 mm, and having open distal and proximal ends. The catheter was tied to the rubber plate having a thickness of 6 mm, by using the No. 3 ligature in the same manner as in Examples 1 to 3.
As a result, the cavity of the catheter was narrowed and the catheter body was bent at the ligature portion when it was sutured somewhat tightly. In addition, the catheter broke at the ligature portion when it was pulled hard.
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A method of firmly securing a catheter body to a surface portion of human skin, without causing the catheter body to be bent or reducing the diameter of the inner passage of the catheter body. This method employs a catheter-securing member which comprises a cylindrical body for allowing the catheter body to be slidably inserted therein, and a slit is provided along the axial direction of the cylindrical body. In this method a ligature is first pierced through a surface portion of human skin and tied over the surface of human skin, leaving a pair of free end portions extending out of the skin, and then the cylindrical body is secured with the free end portions of the ligature by winding the ligature around the cylindrical body and fastening them.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for the centralised control of the opening points of a motor vehicle. It is intended for controlling the door locks, the trunk and other protected-access devices, such as the petrol flap, the glove box, etc.
2. Description of the Related Art
The control of the locking or unlocking of these various opening points or accesses is centralised, that is to say it can be controlled by the actuation of the key in the lock of one of the front doors or of the boot, by remote control or by an anti-attack button.
The door locks have two locking states, namely a first "secure" state, in which the door is locked, and a second "super secure" state which corresponds to a locking mode in which the lock is unpickable and can be only electrically unlocked.
In systems with a centralised control, the action of the key in the lock of one of the front doors generates electrical signals which are transmitted to a central control unit which sends a "secure" or "desecure" command to all the opening points or protected accesses.
This central control unit can also receive a "secure", or "desecure" signal transmitted by a remote command made from outside the vehicle or by an anti-attack button.
Moreover, in motor vehicles there is generally an alarm device warning the driver that one of the protected accesses is improperly closed and visually designating the access which is improperly closed. The indication of improper closure is provided by a contactor which is most often located in the lock and is called an O.D.C. or open-door contactor.
As a result of this, to perform all these functions it is necessary to connect a large number of conductors to each protected access; this number can rise to eight for a front door having a "super secure" system. Now the operation of electrically wiring of a motor-vehicle opening point is difficult and remains expensive.
The object of the invention is, therefore, to provide a device for the centralised control of the opening points of a motor vehicle, which makes it possible to considerably reduce the number of conductors necessary for the connection between the opening points and the central control unit.
SUMMARY OF THE INVENTION
The subject of the invention is a device for the centralised control of the opening points of a motor vehicle, in which the opening points have a double- or triple-effect electrical actuator comprising at least one electric motor, and some opening points have a mechanically controled device with a lock key sending commands to a central control unit which also receives commands coming particularly from the ignition key and/or from a remote control set and/or from an anti-attack button, characterised in that the central control unit is connected to each of the opening points by means of a single line with three conductors used sometimes for power transfer and sometimes for information transfer, in that in each opening point the actuator is connected permanently between two or three conductors of the said line, and in that the central control unit comprises means for selectively applying to each of the said conductors the voltages necessary for the execution of a sequence.
According to another characteristic of the invention, in the opening points having a mechanical control with a lock key, a series of passive electronic voltage-level setting components is connected between two conductors contactlessly in the position of rest.
Any "secure" or "desecure" command by the key defines a position of the said key which closes the circuit by means of one or more of the abovementioned components and the two conductors, one biased at the positive voltage of the source by means of a resistor and the other connected to earth. The central unit comprises a detector of the level of voltage tapped at the terminal of the resistor adjacent to the components; this detector supplies control signals to the means for applying to the three conductors the polarities corresponding to the request.
The invention will be better understood from the following description given purely by way of example and made with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of the invention;
FIG. 2 is a diagram of the circuit located in a front opening point;
FIG. 3 is a block diagram of the central control unit;
FIGS. 4 and 5 are detailed diagrams of the central control unit;
FIG. 6 is a graph explaining FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a general block diagram of a device according to the invention which comprises essentially a central control unit 1 intended for controlling the "desecuring", "securing" or "super securing" of opening points, such as front doors 2, rear doors 3 and a tailgate 4. The central control unit can receive commands sent by the mechanism of the ignition key 5, a remote-control receiver 6 or an anti-attack button.
The two front doors 2 are equipped with a key lock 7 which is fitted with electrical contacts supplying electrical signals to the central control unit 1 for the purpose of "desecuring", "securing" or "super securing" the opening points.
The structure of the various elements of this diagram is such that the connection between the central unit 1 and the various opening points is made simply by means of a line 8 with three conductors 31, 32, 33 which forms a kind of bus junction between the central control unit 1 and the opening points, each of these being connected in parallel to the line 8.
FIG. 2 is an electrical diagram of the circuit contained in an opening point, such as a front door. This circuit essentially comprises three conductors 11, 12, 13, each connected to one of the conductors of the line 8 (control by key can take place, for example, between 11 and 12).
Each opening point comprises a triple-effect electrical actuator, for example two direct-current motors M1 and M2; the motor M1 controls the "securing" or "desecuring" of the opening point, and the motor M2 controls the "super securing" or "desecuring" of the lock. In the "super secure" position, the door cannot be opened by using the mechanical control elements of the door, namely a lever or pusher, but only by an electrical control provided by the insertion of a coded key into the lock 7 or by a remote command received by the detector 6.
According to the invention, for each actuator, the motors M1 and M2 are connected permanently between the three conductors 11, 12 and 13. In the example illustrated, the motor M1 is connected between the conductor 13 and the conductor 12. The second motor M2 is likewise connected between the conductors 13 and 12. On this conductor 12, a diode D1 separates the terminals of the motors M1 and M2, and the cathode of D1 is connected to M2. Moreover, the terminal of M2 joined to the conductor 12 is extended on the conductor 11 by a diode D2, the cathode of which is connected to this conductor 11. The control takes place between the conductors 11 and 12. From the conductor 11 an assembly of three electronic components is connected, in the illustrated example Zener diodes 14 connected in series. From the anodes of these Zener diodes, three terminals are defined for a switch.
The other conductor 12 is connected to the common terminal of a three-position switch 15 by means of a diode 16, the cathode of which is connected to the conductor 12. The function of the diode 16 is to prevent a power current from passing through the Zener diodes if a key request occurs during a power transfer for "super securing". This three-position switch consists, in fact, of the coded key inserted into the lock 7; the three possible positions of the lock key 15 correspond to the three abovementioned states of "desecure", "secure" and "super secure". This switch closes a circuit via one or more Zener diodes according to the particular request.
Finally, a resonant circuit consisting of a coil 17 and of a capacitor 18 is connected between the two conductors 11 and 12, with the interposition of a contact 19 which corresponds to the open-door contactor O.D.C. and which is closed when the door is open or improperly closed.
The electrical circuit integrated in the other opening points, such as the rear doors or the tail gate, does not include the elements 14 to 16 corresponding to the key lock 7.
FIG. 3 illustrates the circuit of the central control unit in simplified form. The line 8 is connected to three inputs 21, 22 and 23 which correspond respectively to the conductors 11, 12 and 13 of each of the opening points. Each of these inputs is connected to the contact of a control relay, B1, B2 and B3 respectively, these being shown in the state of rest. The coils of the relays B1, B2 and B3 are controlled by a microprocessor 20, as will be described in detail later. In the state of rest corresponding to the vehicle left unattended, the terminal 23 corresponding to the conductor 33 of the line 8 and the terminal 22 corresponding to the conductor 32 of the line 8 are connected to the negative terminal 24 of the vehicle's supply battery. When the relays B2 and B3 are energised into the working position, the terminals 22 and 23 are connected to the positive terminal 25 of the vehicle battery.
When the relay B1 is energised, the terminal 21 corresponding to the conductor 31 of the line 8 is connected to the negative terminal 24 of the battery. In the position of rest, the terminal 21 is connected to a measuring detector 26 which supplies information to the microprocessor 20. This terminal 21 is biased at the positive voltage by a resistor 10 which is connected to the conductor 21 by means of the break contact 27 of the relay B1 and the make contact of a switch 30' controlled by the actuation of the ignition key.
Moreover, when the vehicle is being used, with the ignition key inserted, the break contact 27 of the relay B1 can also be connected to an alternating-current generator 28 either by means of trap circuits connected in series or by means of a resistor, in which case the string of trap circuits can be connected in parallel between 12 and 13 or omitted. Each of these trap circuits is tuned to the resonant frequency of the resonant circuit 17, 18 of one of the opening points. An alarm device, such as an indicator lamp 29, is connected in parallel to each of the resonant circuits. This indicator lamp can consist, for example, of a light-emitting diode.
The putting into operation of the generator 28 is controlled by a signal occurring as a result of the closing of a contact 30 which is closed by the ignition key of the vehicle and which corresponds to the circuit 5 of FIG. 1.
The microprocessor 20 also receives from the contact 30 information on the insertion of the ignition key of the vehicle. It also receives information by means of an anti-attack contact 34 which can be closed by the user when he is in the vehicle. Finally, the microprocessor 20 receives a "secure", "super secure" or "desecure" command provided by means of a contact 35 associated with the remote-control detector 6.
FIG. 4 is a detailed diagram representing the detector circuit 26. The signal coming from the measuring conductor 31 is sent to three operational amplifiers 41, 42 and 43 which, in addition, each receive a nominal value matched to the voltages of the Zener diodes 14.
In the example illustrated, these reference signals are respectively equal to 2, 4 and 6 volts. The signal supplied by the first operational amplifier 41 is sent to an AND gate 44 with three inputs, the other two inputs of which receive a positive voltage corresponding to the logical state 1. The output of the logical AND gate 44 is sent to a monostable multivibrator 45, the output of which supplies a first command signal.
The output of the second operational amplifier is sent to a logic AND circuit 46 with three inputs; the second input of this circuit receives the output signal from the operational amplifier 43 and the third input of this circuit receives the inverted output signal from the comparator 41, the inversion being carried out by an inverting gate 47. The output of this logic AND circuit 46 controls a second monostable multivibrator 48, the output of which likewise supplies a command signal.
The output of the operational amplifier 43 is sent to a logical AND circuit 49 with three inputs, the other two inputs of which receive respectively the inverted output signal from the operational amplifier 41 and the inverted output signal from the operational amplifier 42 by means of an inverting gate 51. The output of the logical AND circuit 49 controls a third monostable multivibrator 52, the output of which likewise supplies a command signal.
FIG. 5 is a diagram showing the generator 28 in detail. It consists essentially of four multivibrators 61, 62, 63 and 64 which are connected in series so as to constitute a ring counter; FIG. 6 is a timing diagram respectively representing clock signals sent to each of the multivibrators and their output Q.
The output signal Q of each of the multivibrators controls a transistor 65 which forms a switch arranged between the direct-voltage source and the feed wire of each periodic-signal generator 71, 72, 73 and 74. The output of each of these generators is sent to the conductor 36 of FIG. 3 upstream of the trap circuits.
The frequencies of the signals supplied by the generators 71 to 74 correspond respectively to the resonant frequencies of each of the resonant-circuit assemblies 17, 18 of the gate circuit and corresponding trap circuit assembly of the central control unit.
The device which has just been described operates as follows. When the door key is inserted into the lock 7, this key can assume the three positions of the switch 15. The voltage of the Zener diodes 14 is selected so as to be slightly below the triggering threshold of the comparators 41 to 43; thus, if a Zener diode voltage slightly below 2 volts is selected, the triggering of the comparators 41, 42 and 43 will be obtained when only one of the Zener diodes 14 is connected by the switch 15, the triggering of the comparators 42 and 43 when two diodes are connected and the triggering of the comparator 43 when the three Zener diodes 14 are connected by the switch 15.
In the absence of a request by the key in the lock 7, the voltage read off by the detector 26 is the battery voltage which is sent from the terminal 25 via the resistor 10.
Since this voltage is higher than the maximum threshold of 6 V, none of the comparators 41 to 43 changes from the logical value "0" to the logical value "1". No command is sent to the coils of the relays B1, B2 and B3. If the key is inserted into the lock 7 and is actuated in the "desecuring" direction, the contact corresponds to the connecting of the three Zener diodes 14 in series and only the comparator 43 supplies a logical "1" at its output, thereby unblocking the logical AND gate 49 which changes to 1 and activates the multivibrator 52 which provides a command for activating the coil of the relay B2. The effect of this is to apply the positive supply voltage to the conductor 32 of the bundle 8 and consequently to the control line 12. The motor M1 and the motor M2 by means of the diode D1 are thus fed in the "desecuring" direction in each of the doors controlled by the central control unit.
If the door key is actuated in the "securing" direction, there are two positions, the first corresponding to the normal "securing" of the doors and the second to "super securing". These two positions can be two successive positions of the key or the second position can correspond to keeping the key in the "securing" position for a given time.
If the door key is actuated in order to obtain "securing", the position corresponding to two diodes 14 in series is obtained and the two comparators 42 and 43 change to the logical state "1"; the inverter 51 blocks the AND gate 49 and only the gate 46 changes to the logical state "1", thereby activating the multivibrator 48 which controls the supply to the coil of the relay B3. The result of this is that the motor M1 is fed in the opposite direction to the "desecuring" direction. The motor M2 is not actuated because its two terminals are connected to the same positive supply potential and D1 opposes the passage of current towards 32.
Finally, if the key changes to the "super secure" position, only the first Zener diode 14 is connected to the measuring circuit and the comparators 41, 42 and 43 change to the logical state "1". The output of the comparator 41 blocks the gates 46 and 49 by means of the inverting circuits 47 and 51. The result of this is that only the gate 44 is unblocked, thereby actuating the multivibrator 45 which controls the supply to the coil of the relays B1 and B3. In this case, the positive voltage is applied to the conductor 13, the other conductors being connected to the negative terminal; the motor M1 is actuated in the "securing" direction and the motor M2 is likewise actuated in the "securing" direction, the combination constituting the "super secure" facility.
The diodes D1 and D2 make it possible to isolate or select M2 according to the polarities applied to the three conductors, this allowing it to be put at rest in the event of a request for simply "securing" when M1 alone is activated.
Should there be two simultaneous key requests, the lowest Zener diode voltage has priority, thus determining priority in the event of two simultaneous different key requests. In the example given, the "super secure" request corresponding to the lowest Zener diode voltage has priority over the other commands. The same is true of the "secure" command which has priority over a "desecure" command. This is a choice which can be changed as desired. This and protections on the monostable multivibrators prevent the transmission of two different simultaneous commands.
The Zener diodes 14 can be replaced by other electronic components dividing a voltage applied to the terminals of the two conductors. It would be possible, for example, to use three resistors of different values connected in parallel between the conductor 11 and the movable contact of the switch 15, each resistor forming a voltage divider bridge with the resistor 10, the free ends of the resistors forming three contact studs of the switch.
The microprocessor 20 can also be controlled by the remote control represented diagrammatically by the contact 35 which supplies "desecuring" or "securing" information to the microprocessor 20.
The device according to the invention also comprises an anti-attack device represented diagrammatically by the contact 34 which is actuated by the occupant of the vehicle when he is inside this and which likewise transmits "securing" command information to the microprocessor 20.
The microprocessor 20 also receives information relating to the ignition key of the vehicle (contact 30). The information provided as a result of the actuation of the ignition key of the vehicle allows the actuation of the anti-attack device and inhibits the remote control. Furthermore, the actuation of the ignition key of the vehicle commands the monitoring procedure of the door contacts by activating the generator 28 which therefore operates only when the ignition key is in the active position. This position cancels the positive direct voltage applied to the control conductor 21 which is thus subjected to the periodic signals supplied by the generator 28.
Should a door "securing" or "desecuring" command be transmitted during this monitoring as a result of the actuation of the anti-attack device, the monitoring is interrupted for a brief moment by the microprocessor 20 for the purpose of execute the command.
The monitoring of the state of closure of the doors is carried out by using two conductors only, namely the conductors 31-32.
As can be seen by referring to FIGS. 5 and 6, the generator supplies a train of pulses of different frequencies which correspond respectively to the resonant frequencies of the resonant-circuit/trap-circuit pairs of the central control unit and of each door.
If one of the door contacts 19 is closed, the current circulates via the two conductors 11 and 12, there is a drop of impedance of the resonant circuit to the resonant frequency of the door in question, and the result of this is that the voltage at the terminals of the corresponding trap circuit of the central control unit assumes a higher value, thereby actuating the alarm consisting, for example, of the indicator lamp 29 which flashes at the cyclic frequency of the generator 28.
According to another embodiment of the invention, the generator 28 supplies a complex voltage comprising a plurality of equal voltages, the frequencies of which correspond to the frequencies of the resonant circuits. In this case, a summing circuit can be used to send all the frequencies along the conductor 11. In this case, the four signal generators are supplied continuously and the ring counter is no longer used.
It can be seen that, when the vehicle is at a standstill (no ignition contact made), a positive voltage is applied to the control conductor 11, 21, 31 and that, even if a door is improperly closed, with a contact 19 closed, no current will circulate in the two control conductors 11 and 12 because the capacitor of the resonant circuit of the improperly closed door forms a direct-current switch.
According to another embodiment of the invention, a single-frequency generator is provided in the central control unit only, and in each door the series resonant circuit is replaced by a vibrator operating at the frequency supplied by the generator of the central control unit.
This embodiment makes it possible to limit the space required on the dashboard by numerous indicator lamps. However, a single indicator lamp constituting a permanent alarm can be provided, whilst the operation of the vibrator is delayed and the sound signal ceases after a particular time.
To prevent current consumption when ignition contact is not made and a positive direct voltage is sent along the first control conductor 11, a capacitor can be arranged in series with each of the vibrators. Since the indicator of an improperly closed door is in the door itself, the attention of the occupants is gained much more quickly, above all where rear doors are concerned.
According to another embodiment of the invention the trap circuits are omitted and the generator 28 permanently sends periodic wave trains of different frequencies cyclically. These signals pass through a resistor arranged in series with the generator 28 in the central unit. Together with the impedance of the resonant circuits, this resistor performs the function of a voltage divider bridge: the amplitude of each of the signals passing through it is seen at its terminal adjacent to the conductor 21. In the absence of an improperly closed door, the amplitude of the signal at the abovementioned terminal is that of the signal transmitted by the generator 28. From the moment when a door contact 19 closes, this amplitude falls in the manner of a voltage divider bridge for the signal to the resonant frequency of the improperly closed door. An alarm is triggered as soon as this variation in voltage amplitude is detected. Since any signal at a given frequency is transmitted periodically for a 1/4 period as a result of the supply of the system by the ring counter (see FIG. 5), in the event of a voltage drop it is known exactly which door is involved since a door is sensitive to its natural frequency and not to the other frequencies transmitted for the other doors during the remaining 3/4 of the period. The period is divided into as many portions as there are doors to be monitored (4 here in the example given).
According to another embodiment of the invention, it is also possible to arrange the series of trap circuits in parallel between the two conductors 21 and 22 in the central unit, that is to say between the output 36 of the generator connected to the conductor 21 and the negative polarity of the battery connected to the conductor 22. The generator 28 permanently sends the periodic wave trains at the various frequencies cyclically via a resistor. When its natural frequency is received, each trap circuit has a high impedance. As soon as the door contact 19 of the corresponding resonant circuit is closed, the impedance at the terminals of the said trap circuit falls, and the same is true of the voltage at its terminals. An alarm is triggered as soon as this voltage drop is detected.
It can be seen that the invention, using only three junction conductors forming a bus between the central control unit and each of the opening points, makes it possible to control in a centralised manner the opening, "securing" and even "super securing" of the doors and to send from each of the doors the necessary commands provided by the door key.
Another advantage of the invention is that only passive elements are accommodated in the doors, this being important from the point of view of cost and reliability.
Moreover, two of these conductors are sufficient to carry out the monitoring of the state of closure of all the opening points, with the improperly closed door being indicated each time.
The invention also applies to opening points comprising a double-effect actuator, such as opening points without "super securing" (luggage boot, petrol flap etc.). In this case, if the actuator is a reversible motor, it will be connected permanently between two conductors.
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The invention relates to a device for the centrallized control of the opening points of a motor vehicle, in which the opening points have electrical actuators, including two locking states, and comprising at least one electric motor, and some opening points have a mechanically controlled device with a lock key sending commands to a central control unit which also receives commands coming particularly from the ignition key and/or from a remote-control set and from an anti-attack button. The device according to the invention is characterized in that the central control unit is connected to each of the opening points by a single line (8) with three conductors (31, 32, 33) which will be used sometimes for power transfer and sometimes for information transfer, in that in each opening point the actuator is connected permanently between the three conductors of the said line (8), and in that the central control unit selectively applies to each of the said conductors (31, 32, 33) the voltages necessary for the execution of a sequence.
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CLAIM OF PRIORITY FROM COPENDING PROVISIONAL PATENT APPLICATION
[0001] This patent application claims priority under 35 U.S.C. §119(e) from Provisional Patent Application No. 60/610,730, filed Sep. 16, 2004, the disclosure of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The presently preferred embodiments of this invention relate generally to wireless communications systems and methods and, more specifically, relate to over-the-air (OTA) device management procedures for delivering information to a mobile device such as, but not limited to, a cellular telephone.
BACKGROUND
[0003] As the functionality of mobile devices grows at an increasing rate, configuring and maintaining the services and features on the mobile devices becomes a complex and time-consuming task. For instance, enabling Wireless Application Protocol (WAP), CDMA, and data connectivity requires the configuration of multiple settings. Even with the limited features that are currently available, some users do not know how to configure their mobile devices.
[0004] Another use case is OTA provisioning and management of new services to mobile devices. Advanced mobile services such as browsing, multimedia messaging, mobile e-mail and calendar synchronization require accurate mobile device settings. The process of remotely managing device settings and applications is referred to as Device Management.
[0005] OTA management is defined in the 3GPP2 OTASP/OTAPA, OMA (Open Mobile Alliance) Device Management (OMA DM), and 3GPP2 IOTA-DM standards (IOTA-DM stands for “IP based over-the-air device management”).
[0006] There are also currently non-Internet Protocol-based techniques for remotely managing mobile devices. For example, the IS-683 standard (TIA/EIA-683-C, Over-the-Air Service Provisioning of Mobile Stations in Spread Spectrum Systems, March, 2003) defines a protocol that employs air-interface signaling for remotely managing mobile stations. Another example of the use of non-IP protocols includes the use of proprietary Short Message Service (SMS) based protocols.
[0007] Device Management is intended to aid the widespread adoption of mobile services, as it provides a mechanism for users to easily subscribe to new services. For network operators this enables a fast and easy way to introduce new services and manage provisioned services, by dynamically adjusting to changes and ensuring a certain level of quality of service.
[0008] In June 2003 the OMA released the OMA Device Management (OMA DM) version 1.1.2 standard based on SyncML DM (Synchronization markup language device management). Reference in this regard may be had to: OMA SyncML HTTP Binding, Version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML OBEX Binding, version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML Device Management Protocol, version 1.1.2, OMA, Jun. 12, 2003. http://www.openmobilealliance.org/release_program/enabler_releases.html; OMA SyncML Representation Protocol, Device Management usage, version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML Device Management Bootstrap, version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML DM DDF DTD (SyncML_dm_ddf v111 — 20021002.dtd), version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML Device Management Tree and Descriptions, version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML Device Management Notification Initiated Session, version 1.1.2, OMA, Jun. 12, 2003; OMA SyncML Device Management Security, version 1.1.2, OMA, Jun. 12, 2003; and OMA SyncML WSP Binding, version 1.1.1, OMA, Jun. 12, 2003.
[0009] OMA DM provides an integrated and extensible framework for the OTA management needs of 3G mobile devices and beyond. The standard includes the OMA DM protocol specification, which is based on the SyncML DM protocol. The protocol is optimized for OTA management, wherein a basic consideration is related to the resource and bandwidth limitations of mobile devices.
[0010] OMA DM, as a mechanism, is very versatile and can be used to manage different types of data objects. Some of the data objects are simple numeric or textual parameters, while others are binary in nature. Numeric objects may include connectivity parameters, such as access point addresses and proxy configurations. Binary objects may include security keys, blocks of data or software modules.
[0011] The protocol leverages the WAP 2.0 bootstrap for initial provisioning, and the set of DM protocol specifications for continuous management after the initial provisioning.
[0012] Currently, there is no unified way of managing mobile services over-the-air. What is needed, but was not available prior to this invention, is an integrated method for network service providers to manage mobile devices and services using a single mechanism. The currently available different standards for OTA management, such as OMA DM, IOTA-HCM, IS-683, proprietary OTA, OTA Teleservices, and so forth, do not fulfill this need in a satisfactory manner.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0013] The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of this invention.
[0014] Disclosed is a method, a system and a computer program executable by a data processor or data processors to accommodate a non-IP OTA protocol using an end-to-end IP protocol. The method includes receiving a message from a non-IP entity; using markup language for message and content representation, where in a markup language message non-IP protocol content is identified using a ‘Meta’ element, where the Meta element describes the content type as ‘non-IP protocol name’, and sending the markup language message. The step of using the markup language preferably includes encapsulating received content in the markup language message and using the Meta element to enable a receiver of the markup language message to extract the content. The message received from the non-IP entity may be, as a non-limiting example, an IS-683 message.
[0015] An aspect of this invention is a network node operable to accommodate a non-IP OTA protocol using an end-to-end IP protocol. The network node includes a receiver to receive a message that contains non-IP protocol content and a processor operable with a markup language, such as XML, for message and content representation to encapsulate in an XML message the non-IP protocol content that is identified to a potential receiver of the XML message as such using an XML ‘Meta’ element. The Meta element describes the Meta content type as ‘non-IP protocol name’. The network node further includes a transmitter to transmit the XML message containing the non-IP protocol content towards a recipient, and via a wireless network.
[0016] A further aspect of this invention is a mobile station having a non-IP client and a receiver to receive a markup language message that contains a non-IP protocol content message using an end-to-end IP protocol. The mobile station further includes a processor operable with the markup language for message and content representation to extract the non-IP based content message from the received message in response to a presence of a ‘Meta’ element that describes the Meta content type as ‘non-IP protocol name’.
[0017] A still further aspect of this invention is a network node operable to accommodate a non-IP Over-the-Air (OTA) protocol using an end-to-end IP protocol. The network node comprises receiver means for receiving a message that contains non-IP protocol content, where the receiver means is coupled to data processor means operable with a markup language, such as Extensible Markup Language (XML), for message and content representation for encapsulating in an XML message the non-IP protocol content that is identified to a potential receiver of the XML message as such using an XML ‘Meta’ element. The Meta element describes the Meta content type as ‘non-IP protocol name’. The network node further includes transmitter means coupled to the data processor means for transmitting the XML message containing the non-IP protocol content towards a recipient, and via a wireless network.
[0018] A still further aspect of this invention provides a method for accommodating a non-IP Over-the-Air (OTA) protocol using an end-to-end IP protocol, and includes a step for receiving a message from a non-IP entity; a step for using markup language for message and content representation, where in a message non-IP protocol content is identified using an ‘Meta’ element, where the Meta element describes the content type as ‘non-IP protocol name’; and a step for sending the message with the “Meta” element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The foregoing and other aspects of the presently preferred embodiments of this invention are made more evident in the following Detailed Description of the Preferred Embodiments, when read in conjunction with the attached Drawing Figures, wherein:
[0020] FIG. 1 is simplified block diagram of a CDMA-based DM network architecture;
[0021] FIG. 2 shows an end-to-end architecture for IOTA-DM;
[0022] FIG. 3 shows message flow for accommodating an exemplary non_IP DM message, in this non-limiting case an IS-683 DM message; and
[0023] FIG. 4 shows a representation of an end-to-end message format in accordance with the example of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] By way of introduction, the embodiments of this invention can be used to integrate different OTA protocols, resulting in a unified method for managing mobile devices and services. More specifically, the embodiments of this invention enable the handling of non-Internet Protocol (non-IP) management protocols using an IP-based protocol.
[0025] The embodiments of this invention enable the use of an IP-based protocol to achieve an integrated approach for OTA management in different networks and with heterogeneous mobile devices in such networks. The use of the preferred embodiments of this invention ensures that wireless service providers have at their disposal a unified mechanism to manage the mobile devices and services offered in their network(s) or service domain.
[0026] The preferred embodiments of this invention use a special Meta type, as well as a specific way of using the DM protocol, to achieve backward compatibility with non-IP protocols used in legacy systems. This enables the markup language-based (i.e., the XML-based) DM protocol to be used in different networks for managing mobile devices of varying features.
[0027] The use of the preferred embodiments of this invention may result in cost savings through the re-use of existing components of legacy mobile systems.
[0028] The use of the preferred embodiments of this invention also provides an integrated method for service providers to manage mobile services offered in a service domain, and aids in integrating legacy features, as well as third generation (3G) features and future generation features.
[0029] The preferred embodiments of this invention can be implemented in mobile devices. Existing software components can be reused to develop an integrated entity in the mobile device to support legacy features. New features for 3G and future generations can then be integrated. Thus, the preferred embodiments of this invention support both legacy features and new features, offering an integrated mechanism to accommodate both. For CDMA mobile devices, the OTASP/OTAPA components can be reused.
[0030] To place the embodiments of this invention in a proper technological context, reference is made to FIG. 1 for showing a network architecture for DM in an exemplary CDMA network. Though only the CDMA interface is shown, the OMA DM specifications support as well DM over local access technologies, such as low power RF (e.g., Bluetooth™) and infrared (e.g., IrDA). Reference is also made to FIG. 2 for showing the end-to-end architecture for IOTA-DM, and includes a mobile station (MS) 1 , such as a cellular telephone, also referred to as a mobile equipment (ME), and a DM server 2 coupled to the MS 1 via a wireless network 22 , such as a cellular (e.g., a CDMA) wireless network.
[0031] In general, the various embodiments of the MS 1 can include, but are not limited to, cellular telephones, personal digital assistants (PDAs) having wireless communication capabilities, portable computers having wireless communication capabilities, image capture devices such as digital cameras having wireless communication capabilities, gaming devices having wireless communication capabilities, music storage and playback appliances having wireless communication capabilities, Internet appliances permitting wireless Internet access and browsing, as well as portable units or terminals that incorporate combinations of such functions. Non-portable devices are also within the scope of these teachings.
[0032] In these figures the MS 1 is assumed to include a DM Client 10 that processes the DM messages and commands, performs authorization, and handles access to a DM management tree. Management Objects 12 include parameters, software objects, configuration data blocks and so forth that are associated with applications and services. Management Objects 12 are organized as logically related groups (or subtrees) in a hierarchical tree. The MS 1 is also assumed to include Applications 14 .
[0033] The DM Server 2 is an entity in the network for managing the services and applications in the MS 1 . The DM Server 2 issues DM commands and correctly interprets responses from the DM client 10 . The DM Server 2 includes a DM database 2 A in which are stored Device Description Framework (DDF) 16 documents. The DDF 16 document is, in the preferred but non-limiting embodiments of this invention, an XML document (Extensible Markup Language (XML) 1.0 (Second Edition), W3C Recommendation, Version 6-October-2000, World Wide Web Consortium) which describes the properties of management objects in the device.
[0034] The OMA DM Protocol (OMA SyncML Device Management Protocol, version 1.1.2, OMA, Jun. 12, 2003) defines a management framework and a set of messages exchanged between the MS 1 and the network entity referred to as the DM server 2 .
[0035] Also shown for completeness in FIG. 1 are various networks (N/W), including by example an ANSI-41 network 30 and an Internet Protocol (IP) network 32 . Coupled to the ANSI-41 network 30 is a messaging center (MC) 34 , a home location register (HLR) 36 , an over-the-air function (OATF) 38 and a mobile switching center/visitor location register pair (MSC/VLR) 40 . The MC 34 is coupled to the DM server 2 , while the MSC/VLR 40 is coupled to a base station controller/packet control function (BSC/PCF) 42 , as is a packet data support node (PDSN) 44 that is associated with the IP network 32 . Also associated with the IP network 32 are various Authentication, Authorization and Accounting (AAA) functions 46 , 48 , and a home agent (HA) 50 . The HA 50 couples the IP network 32 to the DM server 2 . Above the DM server 2 are shown a plurality of exemplary management functions 60 , including Configuration Management 60 A, Service Management 60 B, CDMA OTA Service Provisioning (OTASP) and OTA Parameter Administration (OTAPA) Management 60 C, Enterprise Management 60 D and Software Management 60 E functions.
[0036] Also shown in FIG. 2 , interposed between MS 1 and wireless network 22 , and between the DM server 2 and the wireless network 22 , is a suitable Hyper Text Transfer Protocol (HTTP), Object Exchange Protocol (OBEX) and Short Message Service (SMS) interface 70 A and 70 B, respectively.
[0037] An aspect of this invention relates to the handling of non-IP management protocols using IP-based protocols. In a non-limiting example the non-IP management protocols are described in the content of IS-683 messages (IS-683 is a TIA/EIA and 3GPP protocol for OTA provisioning and OTA parameter administration in the in cdma2000 systems, also known as C.S0016 in 3GPP).
[0038] FIG. 3 shows the message flow between at least one non-IP client 20 , the DM client 10 , the wireless network 22 (e.g., a CDMA network or a Bluetooth™ network), an IP-based server 24 and at least one non-IP network entity 26 , when handling a typical IS-683 message.
[0039] Discussing now more specifically the handling of non-IP management protocols using IP based protocols, it is noted that current IP-based management protocols do not support backwards compatibility with a wide range of non-IP protocols. However, an integrated framework requires handling of non-IP protocols as well as IP protocols.
[0040] In accordance with an aspect of this invention, non-IP OTA protocols may be handled using an end-to-end IP protocol that uses XML for message and content representation. In an XML message, the non-IP protocol content is identified using a ‘Meta’ element of XML.
[0041] An embodiment of a method in accordance with this invention is shown in FIG. 3 , where the Meta element describes the content type as ‘non-IP protocol name’. For example, if the XML protocol used is one based on SyncML, and the non-IP protocol is IS-683, the content type may be expressed as ‘syncml-dm:cdma-is683’. For a proprietary protocol, such as one known as, but not limited to, the protocol: Nokia-Ericsson OTA (see for example: http://www.forum.nokis.com/main/1,6566,1 — 47 — 50,00.html), it may be ‘syncml-dm:nokia-ota’.
[0042] The process shown in FIG. 3 , which may also be viewed as a logic flow diagram, is as follows.
[0043] Step A. An IP-based server 24 intercepts a non-IP protocol message, such as an IS-683 Request Message, and encapsulates the non-IP protocol message in an XML message using a ‘Meta’ element as described above.
[0044] Step B. The XML message having the encapsulated non-IP message is sent as a DM message to the DM client 10 via the wireless network 22 .
[0045] Step C. The XML-capable DM client 10 receives the DM message and identifies the Meta type as a non-IP message content and extracts the Meta content. The content encoding may be specified in the ‘Meta’ element using a format element.
[0046] Step D. The XML-capable DM client 10 invokes a non-IP client 20 in the MS 1 and passes the Meta content to the non-IP client 20 in the non-IP protocol format. It should be noted that in a typical case the MS 1 may contain multiple ones of the non-IP clients 20 , and in this case the DM client 10 will determine the identity of the destination non-IP client 20 from the received message and route the Meta data to the correct destination non-IP client. Note also that there may also typically be multiple non-IP network entities 26 that send messages (IS-683 and other types of messages) that are intercepted and processed by IP-based server 24 , as described above.
[0047] Step E. The non-IP client 20 processes the message containing the Meta content and may send a response. The response sequence then follows the same sequence as in Steps A, B, C and D. That is, at Step F the DM client 10 encapsulates the non-IP response in a XML message using the ‘Meta’ element as described above. In Step G the DM message is sent to the IP-based server 24 , which extracts the Meta content (Step H) and formats and sends a suitable IS-683 response message back to the non-IP network entity 26 (Step I).
[0048] In Step C above, and when using SyncML DM for XML representation, the non-IP client 20 can be invoked by specifying an ‘Exec’ command in the XML message and specifying the target of the Exec command as a node in the management tree for the non-IP protocol.
[0049] If the non-IP protocol is 3GPP2 IS-683, the node name may specify IS-683. For example the Uniform Resource Indicator (URI) of the node may be ‘./root/ . . . cdma/is-683’.
[0050] FIG. 4 is a representation of an exemplary end-to-end message in accordance with the method and system described above.
[0051] The various method steps of FIG. 3 can be implemented by suitably programmable data processors located at the nodes of interest in FIG. 3 , such as in the MS 1 , the IP-based server 24 and the DM client 20 .
[0052] It can be realized that in embodiments of this invention a message received from the non-IP entity 26 can comprises an IS-683 message, and can include different versions of the IS-683 protocol.
[0053] It can be realized that in embodiments of this invention the XML message may include additional information for the processing of Meta content, such as a URI and/or “commands”, such as one or more commands to invoke a process in the receiver of the XML message to handle the Meta content, where the Meta data may be base 64 (b64) encoded, or encoded in another format, as specified by a ‘Format’ element.
[0054] It can also be realized that in embodiments of this invention the message received from the non-IP entity 26 can comprise, as an example, a Nokia-Ericsson OTA message (see above).
[0055] Further, the XML message may comprise a SyncML DM, or OMA DM message, and the XML protocol may comprise a 3GPP2 IOTA-DM message.
[0056] It can be appreciated that the use of the embodiments of this invention can provide significant cost savings through the re-use of software components. For each network there are typically thousands of devices, and instead of re-writing the code for existing functions, developers may instead focus on advanced services and functions, and the carriers may then provision these advanced functions and services to the mobile users using a common integrated provisioning mechanism, as described herein.
[0057] The foregoing description has provided by way of exemplary and non-limiting examples a full and informative description of the best method and apparatus presently contemplated by the inventors for carrying out the invention. However, various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings and the appended claims. As but some examples, the use of other similar or equivalent message formats, content representations and the like may be attempted by those skilled in the art.
[0058] However, all such and similar modifications of the teachings of this invention will still fall within the scope of the embodiments of this invention.
[0059] Furthermore, some of the features of the preferred embodiments of this invention may be used to advantage without the corresponding use of other features. As such, the foregoing description should be considered as merely illustrative of the principles, teachings and embodiments of this invention, and not in limitation thereof.
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Disclosed herein is a method, a system, a network node and a computer program executable by a data processor or data processors to accommodate a non-IP OTA protocol using an end-to-end IP protocol. The method includes receiving a message from a non-IP entity; using a markup language, such as XML, for message and content representation, where in an XML message non-IP protocol content is identified using an XML ‘Meta’ element, where the Meta element describes the content type as ‘non-IP protocol name’ and sending the XML message. The step of using XML preferably includes encapsulating received content in an XML message and using the XML Meta element to enable a receiver of the XML message to extract the content. The message received from the non-IP entity may be an IS-683 message.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent application Ser. No. 61/348,154, which was filed on May 25, 2010.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to sensors for fast and easy deployment in electroencephalogram acquisition and monitoring applications, including consciousness and seizure monitoring. The present invention further relates to electrodes for measuring biopotentials. The present invention further relates to groups or sets of sensors having individual features which facilitate their fast and correct placement and use and/or hinder or preclude their incorrect placement and use, without requiring extensive preparation of a patient's skin.
(2) Description of Related Art
Consciousness monitoring encompasses the field that uses measurements of biopotentials or other biological signals to gauge the level of consciousness or alertness of a subject or patient, especially in applications such as anesthesia monitoring or testing for seizure or other brain dysfunction or injury. Consciousness monitoring is frequently based on electroencephalographic (EEG) measurements.
In a typical diagnostic or monitoring study, a set of electrodes will be applied to the subject or patient. Proper design of electrodes and their placement is often critical to the reliability, accuracy, and/or repeatability of biopotential measurements and their analysis by the sophisticated monitoring equipment into which their signals are fed; variations in electrode placement or improper electrode placement or improper electrode spacing may mar the study if the analysis equipment is dependent upon proper placement, and may even unnecessarily endanger the patient in the event that a cardiac defibrillation shock is applied to the patient during consciousness monitoring. Traditionally, sets of electrodes are used in which all of the electrodes are essentially identical to each other in appearance. The similarity in some cases can result in electrode confusion on the part of the physician or technician applying the electrodes. Common mistakes in electrode placement include a mix-up between left-side and right-side electrode placement on the patient, a mix-up between signal and ground electrodes on the patient, incorrect placement of the electrodes on the patient in relation to the optimal or desired placement sites, placement of electrodes too near to each other or too far from each other, or placement of the electrodes in wrong or sub-optimal orientations with respect to each other. Extreme cases of misplacement result in entirely different electrode placement montages being used, but even minor misplacement can have a significant impact on the study or test results since the artifact processing, feature estimation, and suppression detection methods of test equipment or study methods can be sensitive to electrode placement. For example, too-short interelectrode distance can result in very small amplitude signals resembling suppression observed in some patients. Manufacturers of consciousness monitoring equipment have introduced specific sensors to address the problem of improper electrode placement and facilitate proper signal acquisition. Previous disclosures in this field of art include U.S. Pat. Nos. 6,032,064 to Devlin et. al., 6,301,493 B1 to Marro et al., 6,950,698 B2 to Sarkela et al., and U.S. Patent Application Publication No. 2004/0193068 A1 to Burton et al., all of which are herein incorporated by reference.
However, the need still exists for novel systems and methods which better facilitate fast and accurate electrode placement and use and/or hinder or preclude their incorrect placement and use. It is envisioned that once seizure detectors are as common appliances in workplaces and schools as are emergency cardiac defibrillators today, it will be critical for persons of no special training to perform fast and accurate electrode placement. It is therefore an object of the present invention to provide a novel electrode kit for easy and fast deployment in electroencephalogram acquisition and monitoring applications.
BRIEF SUMMARY OF THE INVENTION
In some embodiments, the present invention is an electrode for consciousness monitoring. Preferably, the electrode has a front, a back, and bottom, top, left, and right sides.
Preferably, each electrode is constructed of at least two separate structures: a physiological recording electrode and insulating region or adhesive collar. The electrode preferably comprises these two structures, but is constructed in a single unit which is able to be removed from the packaging and deployed onto a subject's skin. The physiological recording electrode can be of any type currently known in the art or later developed which is capable of conducting and recording physiological signals from a subject. The physiological recording electrode preferably comprises an upper surface and a lower surface. The upper surface is preferably that which is intended to face away from the subject when applied to said subject, and preferably will comprise an electrode connector (described herein). The lower surface is preferably that face of the physiological electrode which, when applied to a subject or patient, comes in contact with the subject's skin and receives and conducts the physiological signal from the subject to the monitoring equipment. The lower surface may optionally further comprise at least one surface feature which serves to either penetrate the subject's stratum corneum or to otherwise reduce electrode impedance and increase the quality of the physiological signal by bypassing factors that inhibit signal recording, such as the stratum corneum and the subject's hair. The physiological recording electrode is described in greater detail below.
The insulating region or adhesive collar may be of any insulating material known in the art, but preferably is a material that is pliant and comfortable to wear, such as polyester foam. This insulating region or adhesive collar preferably comprises two surfaces: an outer surface and an adhesive surface. The outer surface is that face of the insulating region or adhesive collar which, when placed on a subject's skin, faces outward and is capable of being viewed by the wearer, a user, or some other clinician. The adhesive surface is the face of the insulating region or adhesive collar which, when place on a subject's skin, comes in contact with the skin and cannot be seen. Preferably, at least part of the adhesive surface of the electrode is adhesive or sticky for application to skin. Again, the adhesive or method of sticking the electrode can be of any type known in the art such as acrylic adhesive. Preferably, the adhesive is capable of sticking to the skin for long periods of time (on the order of 1-24 hours) without losing adhesion and can be removed without undue pain to the wearer.
Preferably, the electrode has a colored label on the electrode front or on the outer surface of the insulating region or adhesive collar, allowing easy identification to prevent misplacement. The label may be printed directly onto the outer surface of the insulating region or adhesive collar material or may be printed onto a separate thin sheet and applied to the outer surface of the insulating region or adhesive material with an adhesive by any means known in the art. The label may also be stamped, etched, marked, engraved, burned, or affixed to the outer surface of the insulating region or adhesive collar material by any other means known in the art. The insulating region or adhesive collar material may also be manufactured in such a way as to have the label embossed in the surface of the outer surface of the insulating region or adhesive collar material.
Preferably, the electrode has a tab. Preferably the tab is upward-pointing in relation to the electrode's intended placement orientation. Preferably, the back of the tab is not adhesive or sticky, allowing the tab to be used as a handle in the application and removal of the electrode. The tab must be of sufficient size to be easily grasped between a typical human forefinger and thumb, i.e., no less than 0.2 inches in either its width or height dimensions. Preferably the tab is roughly triangular in shape, optionally with a rounded top, and measures 0.510 inches wide at its base and 0.218 inches tall. Preferably the tab is made out of the same material as, and is one with, the insulating region or adhesive collar material of the electrode (e.g., foam).
Preferably, the electrode label has one or more alignment indicators. The alignment indicators preferably correspond to a direction or an alignment in which the electrode is preferred to be oriented when applied to the subject or patient. The alignment indicators may be dots, lines, arrows, crosses, daggers, or any other symbols or configuration of markings, etchings, or stampings which can show both position and orientation. Preferably, the alignment indicator is an arrow. Preferably, it is of sufficiently bold and outstanding character as to be readily visible. The alignment indicator must not be just a negligibly thin hatch mark or seam. Preferably, the stalk of the arrow is more than one millimeter in width and more than 5 millimeters in length, the head of the arrow is more than five millimeters wide at its base, and the arrow is of a solid color that contrasts with the rest of the label color. Also, preferably, the electrode has on one or more of its sides a jut, and the electrode label has at the position of the jut and pointing in the direction of the jut a corresponding alignment indicator (e.g., arrow). In some embodiments, preferably, the electrode and its label have only one such jut and corresponding alignment indicator. Also preferably, the electrode has both a handling tab (as described above) and exactly one jut and corresponding alignment indicator such that the angle between the tab and the jut distinguish the electrode as unique among several such electrodes in a set, each having a different angle between tab and jut. For example, one electrode may have a 90° (clockwise) angle between tab and jut, whereas another has a 180° (clockwise) angle between tab and jut, whereas a third might have a 270° (clockwise) angle between tab and jut, helping to distinguish the three electrodes and diminish the chance of confusion between electrodes with regards to their placement on a patient in an electrode montage. Preferably, the arrow or other alignment indicator is applied to a patient such that it points at some distinctive feature, such as down at the bridge of the nose from the middle of the forehead, or to the corner of the eye from the temple.
The electrode may be a physiological electrode of any type known in the art. In some embodiments, the electrode is preferably a pre-gelled electrode having a spongy well of electrically conductive gel. In other embodiments, the electrode is preferably a dry electrode having surface features capable of penetrating the stratum corneum of the skin, for example of the type described in U.S. Pat. No. 7,286,864 B1 to Schmidt et al. or any of its related applications, all of which are herein incorporated by reference. In other embodiments the electrode may be a combined gel/penetrator electrode.
The electrode should have a connector for connecting to an electrode lead. In some embodiments the connector is preferably a standard electrode snap connector. The standard electrode snap connector consists of a single round conductive button, usually metal, with a diameter of approximately 3.9 millimeters at its widest point and approximately 3.73 millimeters at its thinned midsection, which comes approximately 2.7 millimeters down from the button top. Having a standard snap connector permits the use of standard leads at low cost. In other embodiments the connector is a snap connector that is larger or smaller or different in shape than a standard electrode snap connector. Having a snap connector that varies in size or shape from a standard connector enforces the use of a non-standard lead known to have superior performance characteristics such as better shielding for lower noise, or various other proprietary improvements. Furthermore, having a snap connector that varies in size or shape from a standard connector enforces the use of the electrode as electrodes with a standard connector will not mate with the non-standard electrode lead, which precludes the use of other electrodes that may yield suboptimal signal quality. Also, using snap connectors of different sizes and/or shapes for each electrode in the electrode kit helps further uniquely differentiate among the electrodes and prevent wrong connections. Standard connectors are round in shape, but if a different-shaped connector would be desired, it could be triangular, square, rectangular, pentagonal, hexagonal, octagonal, or shaped like stars of 3, 4, 5, 6, 7, or 8 points.
In some embodiments, two of the above-described electrodes are conjoined by their mutual foam insulating region or adhesive collar. In such an embodiment, the planar distance between the conductive regions of the two electrodes is enforced by the continuous insulating region or adhesive collar between the two conductive regions. This continuous insulating region or adhesive collar forms a kind of insulating bridge between the two electrodes. Preferably, this distance is at least the minimum effective distance for preventing electrical conduction between the two electrodes during cardiac defibrillation. The known and preferred minimum effective distance is 17 millimeters. “Planar distance” as referred to in this specification means the linear distance as measured when the electrodes lie flat in a plane, and not, for example, when they are folded up upon each other.
In some embodiments, the present invention comprises a set of electrodes for biosignals measurement for consciousness monitoring. Each electrode in the set may have any or all of the features described above. Preferably, the set comprises at least four electrodes, including a first electrode for the patient's right temple, a second electrode for the patient's left temple, a reference electrode, and a ground electrode. Each electrode has a front, a back, and bottom, top, left, and right sides. Each electrode back has a conductive region surrounded by an insulating region or adhesive collar.
As described previously, preferably, at least part of the back of each electrode is adhesive or sticky for application to skin.
Preferably, each electrode has a label on the electrode front, each label being visually distinct from the labels of the other electrodes, and the labels having the characteristics previously described in this disclosure. The feature providing the visual distinction may be color, pattern, reflectivity, or any other visually distinguishable feature or combination of features, but preferably it is color, and so preferably each electrode label has a unique color. The unique color label on each electrode helps the user to identify the desired location and position for each given electrode. Any set of colors may be selected for the electrode, but for example, preferably, the right temple electrode label is orange in color, the reference electrode label is beige in color, the ground electrode label is gray in color, and the left temple electrode label is yellow in color. The difference in colors helps prevent confusion of the electrodes during placement, and further assists in proper and faster electrode placement with the use of an easy-to-use electrode placement map having a color legend. The electrode placement map and legend is preferably provided with the packaging of the electrodes. Furthermore, each electrode lead should preferably echo the color of the corresponding electrode it mates with in order to facilitate easy and correct connection.
Preferably, all of the electrodes in the set are provided on a single sheet of thin plastic, styrene, or similar material, and each electrode easily peels off. Further preferably, the electrodes are positioned or ordered on the plastic or styrene sheet in roughly the same arrangement they are intended to be applied to the patient, for example, with the right temple electrode on the left of the sheet, and the bridged reference and ground electrodes in the middle of the sheet, and the left temple electrode on the right of the sheet, providing for a helpful spatial correspondence between original packaging placement and eventual placement of the electrodes on the patient.
Preferably at least three of the at least four electrodes each have an upward-pointing pointed tab at the electrode top of the type described previously, the back of the tab not being adhesive or sticky, each tab having sufficient size to be grasped between a human forefinger and thumb. If two or more electrodes are joined by one or more insulating bridges, as with the reference and ground electrodes in some embodiments, the two or more electrodes may share only one handling tab.
One or more of the electrodes in the set also preferably have the orientation juts and alignment indicators as described previously. For example, preferably, in the set, the right temple electrode has on its right side a rightward-pointing jut, and the right temple electrode label has at the position of the rightward-pointing jut and pointing in the direction of the rightward-pointing jut a corresponding rightward-pointing alignment arrow. Also preferably, in the set, the left temple electrode has on its left side a leftward-pointing jut, and the left temple electrode label has at the position of the leftward-pointing jut and pointing in the direction of the leftward-pointing jut a corresponding leftward-pointing alignment arrow. Also preferably, in the set, the reference electrode has on its bottom side a downward-pointing jut, and the reference electrode label having at the position of the downward-pointing jut and pointing in the direction of the downward-pointing jut a corresponding downward-pointing alignment arrow. If two or more electrodes are joined by one or more insulating bridges, as with the reference and ground electrodes in some embodiments, the two or more electrodes may share only one orientation jut and/or alignment arrow.
Also preferably in the set of electrodes, the reference and ground electrodes are conjoined by the insulating bridge described above. In such a case, the planar distance between the conductive regions of the reference electrode and the ground electrode is enforced by a continuous insulating region or adhesive collar between the two conductive regions, and said distance is at least the minimum effective distance for preventing electrical conduction between the two electrodes during cardiac defibrillation.
In some embodiments, preferably, each electrode has an independent connector for connecting to an electrode lead, and further preferably, at least one connector is a standard electrode snap connector. Having independent connectors, and having all of the connectors be snap connectors, enforces or conduces the application of pressure to the electrode after its application to the patient during the attachment of snap electrode leads, sealing the electrode to the skin surface, applying the gel and/or pressuring in the electrode penetrators, if any, to provide for good signal conductance and improved signal quality, as well of good adhesion of the electrode to the skin for longer-term use. In some embodiments, one or more of the connectors is not a standard electrode snap connector. It may be a snap connector of slightly larger or small size or different shape than standard to provide for the advantages described above.
This application also discloses a method of using the electrode set described above comprising the steps of peeling the right temple electrode from a backing and applying the right temple electrode to the right temple of a patient such that the alignment arrow on the right temple electrode label aligns with the eye line of the patient and points to the right side of the patient's right eye; peeling the left temple electrode from a backing and applying the left temple electrode to the left temple of the patient such that the alignment arrow on the left temple electrode label aligns with the eye line of the patient and points to the left side of the patient's left eye; peeling the reference and ground electrodes from a backing and applying the reference electrode to the middle forehead of the patient approximately 1.5 inches above the patient's eye line such that the alignment arrow on the reference electrode label aligns with the midline of the patient and points downward toward the patient's nose, and applying the ground electrode tot he left forehead of the patient at the distance from the reference electrode enforced by continuous insulating region or adhesive collar between the two conductive regions of the reference electrode and ground electrode; applying electrode leads to the individual electrodes; and using biopotentials measured by the electrodes to monitor the consciousness of the patient. The distance of “approximately 1.5 inches” can be measured as the combined width of the index, middle and ring fingers as measured at the fingertips, as indicated in FIG. 6 , though for those with wider fingers, two fingers may suffice. It will be appreciated that the first three steps of applying the electrodes may be performed in any order with respect to each other.
One embodiment of the present invention is set of electroencephalographic monitoring electrodes comprising at least four electrodes, including a first electrode for the patient's right temple, a second electrode for the patient's left temple, a reference electrode, and a ground electrode, each electrode having a front, a back, and bottom, top, left, and right sides, each electrode back having a conductive region surrounded by an insulating region, at least part of the back of each electrode being adhesive or sticky for application to skin, each electrode having a label on the electrode front, each label being visually distinct from the labels of the other electrodes, at least three of the at least four electrodes each having an upward-pointing pointed tab at the electrode top, the back of the tab not being adhesive or sticky, each tab having sufficient size to be grasped between a human forefinger and thumb, the right temple electrode having on its right side a rightward-pointing jut, and the right temple electrode label having at the position of the rightward-pointing jut and pointing in the direction of the rightward-pointing jut a corresponding rightward-pointing alignment arrow, the left temple electrode having on its left side a leftward-pointing jut, and the left temple electrode label having at the position of the leftward-pointing jut and pointing in the direction of the leftward-pointing jut a corresponding leftward-pointing alignment arrow, the reference electrode having on its bottom side a downward-pointing jut, and the reference electrode label having at the position of the downward-pointing jut and pointing in the direction of the downward-pointing jut a corresponding downward-pointing alignment arrow, wherein the planar distance between the conductive regions of the reference-electrode and the ground electrode is enforced by a continuous insulating region between the two conductive regions, and said distance is at least the minimum effective distance for preventing electrical conduction between the two electrodes during cardiac defibrillation.
Another embodiment of the present invention is a method of using a set of electroencephalographic monitoring electrodes comprising the steps of before or after either of the following two steps, peeling a right temple electrode from a backing and applying the right temple electrode to a patient having a forehead, a right temple, a left temple, an eyeline, and a right and left eye, such that an alignment arrow on a label on the right temple electrode aligns with the eye line of the patient and points to the right side of the patient's right eye, after or before the preceding step or the following step, peeling a left temple electrode from a backing and applying the left temple electrode to the left temple of the patient such than an alignment arrow on a label on the left temple electrode aligns with the eye line of the patient and points to the left side of the patient's left eye, after or before either of the preceding two steps, peeling a reference and a ground electrode from a backing and applying the reference electrode to the middle forehead of the patient approximately 1.5 inches above the patient's eye line such that an alignment arrow on a label on the reference electrode aligns with a midline of the patient and points downward toward the patient's nose, and applying the ground electrode to the left forehead of the patient at the distance from the reference electrode enforced by a continuous insulating region between two conductive regions of the reference electrode and ground electrode, applying electrode leads to the individual electrodes, and using biopotentials measured by the electrodes to monitor the electroencephalogram of the patient.
Another embodiment of the present invention is an electrode for electroencephalographic monitoring, the electrode having a front, a back, and bottom, top, left, and right sides, the electrode back having a conductive region surrounded by a foam insulating region, at least part of the back of the electrode being adhesive or sticky for application to skin, the electrode having a colored label on the electrode front, the electrode having an upward-pointing pointed tab at the electrode top, the back of the tab not being adhesive or sticky, the tab having sufficient size to be grasped between a human forefinger and thumb, the electrode having on one of the sides a jut, and the electrode label having at the position of the jut and pointing in the direction of the jut a corresponding alignment arrow.
Still another embodiment of the present invention is an electrode for monitoring physiological signals that can be deployed quickly and easily comprising a physiological recording electrode comprising an upper surface and a lower surface, an adhesive collar comprising an outer surface and an adhesive surface, and an electrode label, wherein the label comprises an alignment indicator corresponding to a direction in which the electrode is to be oriented when placed on a subject.
Yet another embodiment of the present invention is a set of electrodes for monitoring physiological signals that can be deployed quickly and easily comprising at least four electrodes, each comprising a physiological recording electrode and an adhesive collar comprising an outer surface and an adhesive surface, wherein each physiological recording electrode comprises an upper surface with a connector and a lower surface, wherein each electrode has a label on the outer surface of the adhesive collar, the labels containing an alignment indicator corresponding to a direction in which each electrode assembly is to be oriented on a subject.
Still another embodiment of the present invention is a set of electrodes for monitoring physiological signals that can be deployed quickly and easily comprising at least four electrodes, each comprising a physiological recording electrode and an adhesive collar comprising a outer surface and an adhesive surface, wherein each physiological recording electrode comprises an upper surface with an independent connector and a lower surface, wherein each electrode has a label on the outer surface of the adhesive collar, the labels containing an alignment indicator corresponding to a direction in which each electrode assembly is to be oriented on a subject, wherein the connector on the upper surface of each physiological recording electrode has a distinct and unique shape in relation to the other electrodes connectors contained in the set.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . Perspective view of an electrode set of the present invention from the bottom.
FIG. 2 . Plan view of combined printing and cutting templates of the electrode set of the present invention from the front, with the backing sheet indicated by a dashed line.
FIG. 3 . Plan view of the label printing template of the electrode set of the present invention from the front.
FIG. 4 . Plan view of the foam cutting template of the electrode set of the present invention from the front.
FIG. 5 . Perspective view of an electrode set of the present invention from the back.
FIG. 6 . Placement diagram for the electrode set of the present invention.
FIG. 7 . Cross-sectional view of the epidermis layer and an illustration of the insertion of the penetrator(s) of the dry electrode used in some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention is illustrated and described. Four thin prepared electrodes come as a package as shown in FIG. 1 . The right temple electrode 1 comes placed on the left side of a thin plastic, or similar material, backing sheet 5 , and the left temple electrode 2 comes placed on the right side of the backing sheet. The reference electrode 3 and ground electrode 4 are conjoined by an insulating bridge 6 . Each electrode has its own independent connector 7 . As illustrated, the connectors are standard-size metal button or snap connectors, but as previously described, the connectors can be of any type or form factor known in the art. The right temple electrode, reference electrode and left temple electrode each have upward-pointing handling tabs 8 on their top sides. The handling tab is one and the same material as the foam insulating body structure 9 of the electrode with the exception that the handling tab is not backed with an adhesive like the rest of the electrode insulating body structure. This allows the tab to be bent frontward and grasped between the forefinger and thumb to more easily peel the electrode from the backing sheet 5 or to peel it off the subject when done. The insulating body structure is foam having a thickness of 1/16 inch in the illustrated embodiment, but in variations can be made of other insulating, pliant material and can be any practicable thickness. Each electrode also has a printed label 10 . In the illustrated embodiment, the labels are printed stickers that each have an adhesive backing and are applied to the foam insulating body structure, but as described previously, the labels can take a variety of other forms and be manufactured and/or applied in any other ways known in the art. The insulating body structure of the left temple, right temple, and reference electrodes also have orientation juts 11 which are simply protrusions out from the rounded bodies of the electrodes. As with the handling tabs, the orientation juts are one and the same material as the foam insulating body structure 9 . On each label, at the location and in the orientation of the jut beneath it, a bold arrow 12 is printed as a readily visible guide for correct electrode placement. Preferably, the electrodes are also conveniently packaged with an electrode skin prep pad (not shown), e.g., a very mildly abrasive paper or thin cloth pad saturated with rubbing alcohol or similar, which can be used to clean and prepare the electrode sites on the surface of the skin prior to application of the electrodes.
The tabs and juts may be better seen in the plan view of FIG. 2 , which combines the printing and cutting templates used in the manufacture of the electrode set of the present invention. The fronts of the electrodes are shown, and the backing sheet 5 , which is not actually part of the printing or cutting templates, as indicated by a dashed line.
FIG. 3 is a plan view of the label printing template used in the manufacture of the labels for the electrode set of the present invention. Different hatching patterns indicate the different colors used in the templates. The right temple electrode label is orange (preferably, Pantone color Orange 021 C), the left temple electrode label is yellow (preferably, Pantone 101 C), the reference electrode label is beige (preferably, Pantone 713 C) and the ground electrode is gray (preferably, Pantone Cool Gray 9 C). Cut-out holes are provided in the middle of each label for the electrode connectors. These holes are round and 0.440 inches in diameter. Excepting juts and flat tops and bottoms, the labels are round with widths of 1.100 inches. The labels are manufactured with center-to-center distances of 1.500 inches. The right temple electrode label is marked with a numeral 1, the left temple electrode label is marked with a numeral 2, the reference electrode label is marked with a letter R and the ground electrode label is marked with a letter G to assist in each recognition and proper designation and placement of electrodes. The labels may also have other markings indicating the manufacturer, brand or trade name, model number, serial number, expiration date, patient protection status, etc. The labels are backed with a permanent adhesive and are applied to the foam of the electrode body after printing.
FIG. 4 is a plan view of the foam cutting template used in the manufacture of the insulating body structures for the electrode set of the present invention. The handling tabs are 0.510 inches in width at the base, except for the handling tab of the reference electrode, which is 0.528 inches in width at the base, and are 0.218 inches in height. These dimensions are ample enough to allow the handling tabs to be easily grasped by the thumb and forefinger in order to peel the tabs off and manipulate the electrodes for placement. With the exception of the tabs and juts, the insulating body structures are 1.404 inches in height. The right and left temple electrodes are 1.336 inches wide and the conjoined reference and ground electrodes are 2.687 inches wide. Any electrically insulating, plaint material may be used for the insulating body structures, so long as it is biocompatible according to existing standards for surface electrodes in contact with the skin for 16 hours maximum application. The adhesive applied to the back of the foam is of an aggressive tackiness. The foam is 1/16 inches in width. The foam is white in color. It will be appreciated that these details may vary and still be within the spirit of the present invention.
FIG. 5 illustrates a perspective view of an electrode set of the present invention from the back. The electrodes 1 2 3 4 , rendered in dashed lines, are visible through the transparent or translucent backing sheet and the conductive regions of the electrodes comprising the gel-filled wells or reservoirs 13 surrounding the electrode proper 14 are visible. The round gel-filled wells 13 , measuring about 0.64 inches in radius and having a depth nearly equal to the thickness of the insulating body structures, are filled with a light, thin sponge material saturated with a conductive gel. The electrode proper 14 , visible in FIG. 5 as the black disc at the center of each well 13 , is made of stainless steel or similar conductive metal or other conductive material. In the manufacture of the electrodes, the button connector 7 can be mated and crimped to the electrode proper 14 with the thinned top of the insulating body structures sandwiched in between, sealing the top of the well 13 and forming the electrode as unit having a gelled inside and a dry outside.
Once assembled and placed on the backing sheet, the electrodes can be packaged in a sealed paper pouch for distribution and can be stored on a shelf for some definite period of time if of the gelled type or an indefinite period of time if of the dry electrode type. Preferably, the gelled electrodes have a shelf life of at least a year without suffering a reduction in gel conductivity that would significantly impact sensor performance. More preferably, the shelf life is at least 2 years. Even more preferably, the shelf life is at least 5 years. An extended shelf life permits the electrode kit to be stored with a shelf-mounted emergency seizure detector for years and still work reliably when needed.
FIG. 6 shows the placement diagram for the electrode set of the present invention, intended to be shown on the packaging of the electrodes. Reference to the diagram facilitates fast and correct placement of the electrodes. As shown, the alignment arrows of the temple electrodes should align with the patient's eye line and the alignment arrow of the reference electrode should align with the patient's midline. The reference and ground electrodes should be placed on the forehead roughly 1.5 inches above the eye line. The placement diagram indicates a helpful guide for instantly and easily measuring the appropriate distance. The juts on the temple electrodes further help enforce appropriate distances in electrode placement. Because the reference and ground electrodes are conjoined by an insulation bridge, they help proof the setup against damage to the diagnostic equipment or patient injury from cardiac defibrillator impulses while also assuring accurate placement of the ground in relation to the reference. The color-coded electrodes reduce the chances that left and right electrodes are inadvertently mixed up by the physician or technician doing the electrode placement, or more importantly, the person of no special training in an emergency scenario and using a emergency seizure monitoring kit.
FIG. 7 is a schematic illustrating the insertion of the penetrator(s) of the dry electrode used in some embodiments of the present invention into the epidermis. The penetrator(s) 16 are used to push through the high impedance upper layer or stratum corneum of the epidermis to reduce the contact impedance of the dry physiological electrode. Preferably, the penetrator(s) 16 also “lock” the electrode into the chosen skin region and thus reduce motion artifacts. The penetrator(s) 16 are further used for physiological sensing in the lower layers of the epidermis. The lower layers of the epidermis include the other layers below the stratum corneum of the epidermis. Physiological sensing generally is the sensing of electric potentials. The penetrator(s) 16 are used transmit the electric potential from the lower layers of the skin, particularly the epidermis and more particularly the stratum germinativum layer of the epidermis. The electric potential then can be measured by conventional measuring devices.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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Electrodes for use in electroencephalographic recording, including consciousness and seizure monitoring applications, have novel features that speed, facilitate or enforce proper placement of the electrodes, including aligning tabs and arrowed aligning juts, color coding, and an insulating bridge between reference and ground electrodes which ensures a safe application distance between the conductive regions of the two electrodes in the event of cardiac defibrillation. A method of using a set of four such electrodes is also disclosed.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of mathematical interpolators. More specifically, the present invention relates to the use of mathematical interpolators in conjunction with computer memories.
BACKGROUND OF THE INVENTION
A computer memory often contains a table of continuous and/or cyclic data. Such data tables are typically used to provide mathematical functions, such as trigonometric and logarithmic functions. A typical such table may contain sine and/or cosine data for a fast Fourier transform function.
In order to realize a desired degree of accuracy, such tables tend to be large. Large tables require extensive use of computer memory. This increases the on-chip real estate and power consumption, thereby increasing the overall cost of the tables.
Some method is often used to reduce the overall size of the table and of the computer memory in which it is contained. The approach most often taken is that of using a smaller table in conjunction with an interpolator to approximate inter-tabular values.
One problem of conventional table-plus-interpolator schemes is that two sequential data-value accesses need be performed in order to obtain data values above and below the desired value. The interpolator then may interpolate the “correct” value between these two values.
Since the accessing computer must perform two accesses, such double-access schemes are non-transparent. That is, the computer is obliged to recognize the special nature of the table-plus-interpolator circuitry. This recognition is usually made in software.
The replacement of a large table with a smaller table plus an interpolator typically cannot be accomplished without an alteration of the software in order to accomplish the two sequential memory accesses. This inhibits the use of software intended for use with a single large table, thereby limiting the use of table-plus-interpolator schemes.
SUMMARY OF THE INVENTION
Accordingly, an advantage of the present invention is provided by a transparent data access and interpolation apparatus and method therefor.
Another advantage of the present invention is provided by a data access apparatus and method that are transparent to the accessing processor.
Another advantage of the present invention is provided by a data access apparatus and method that are usable with pre-existing software.
Another advantage of the present invention is provided by a data access apparatus and method that obtain two values for interpolation in a single access.
Another advantage of the present invention is provided by a data access and interpolation apparatus that significantly reduces on-chip memory area.
Another advantage of the present invention is provided by a data access and interpolation method that reduces power consumption during access.
The above and other advantages of the present invention are carried out in one form by a method of accessing and interpolating data, wherein the method incorporates producing first and second address portions, generating a plurality of data values of a function, storing a first half of the data values in a first table, storing a second half of the data values in a second table, accessing one of the data values in each of the first and second tables substantially simultaneously in response to said the address portion, and determining an output data value greater than or equal to one of the accessed data values in response to the second address portion.
The above and other advantages of the present invention are carried out in another form by an apparatus for accessing and interpolating data within a set of data values, the apparatus incorporating a first memory circuit containing a first table having a first half of the set of data values and configured to output a first table data value in response to a first address portion, a second memory circuit containing a second table having a second half of the set of data values and configured to output a second table data value in response to said first address portion, a routing circuit coupled to the first and second memories and configured to output a first-indexed data value and a second-indexed data value in response to the first and second table data values, and an interpolation circuit coupled to the routing circuit and configured to produce an output data value that combines the first-indexed data value and the second-indexed data value in response to a second address portion.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
FIG. 1 shows a schematic block diagram depicting a data access and interpolation apparatus in accordance with a preferred embodiment of the present invention;
FIG. 2 shows a flowchart depicting a process for accessing and interpolating data using the apparatus of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 3 shows an exemplary table having an integral-power-of-two number of data values to be emulated by the apparatus of FIG. 1 using the process of FIG. 2 in accordance with a preferred embodiment of the present invention;
FIG. 4 shows a reduced table derived from the emulated table of FIG. 3 in accordance with a preferred embodiment of the present invention;
FIG. 5 shows an even-indexed table derived from the reduced table of FIG. 4 and configured for use in the apparatus of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 6 shows an odd-indexed table derived from the reduced table of FIG. 4 and configured for use in the apparatus of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 7 shows an exemplary table having a non-integral-power-of-two number of data values to be emulated by the apparatus of FIG. 1 using the process of FIG. 2 in accordance with a preferred embodiment of the present invention;
FIG. 8 shows a reduced table derived from the emulated table of FIG. 7 in accordance with a preferred embodiment of the present invention;
FIG. 9 shows an even-indexed table derived from the reduced table of FIG. 8 and configured for use in the apparatus of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 10 shows an odd-indexed table derived from the reduced table of FIG. 8 and configured for use in the apparatus of FIG. 1 in accordance with a preferred embodiment of the present invention;
FIG. 11 shows a flowchart depicting a table-access subprocess of the process of FIG. 2 in accordance with a preferred embodiment of the present invention; and
FIG. 12 shows a flowchart depicting an output-determining subprocess of the process of FIG. 2 in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic block diagram depicting an apparatus 20 for and FIG. 2 depicts a flowchart depicting a process 22 for transparent data access and interpolation in accordance with a preferred embodiment of the present invention. FIGS. 3 through 6 show exemplary tables for emulation of an integral-power-of-two (IPOT) number of data values 24 by the apparatus of FIG. 1 using the process of FIG. 2 in accordance with a preferred embodiment of the present invention. FIG. 3 shows an emulated table 26 ′ having IPOT data values 24 to be emulated, FIG. 4 shows a reduced table 28 ′ derived from emulated table 26 ′, and FIGS. 5 and 6 show even-and odd-indexed tables 30 ′ and 32 ′ derived from reduced table 28 ′. Similarly, FIGS. 7 through 10 show exemplary tables for emulation of a non-integral-power-of-two (NPOT) number of data values 24 by the apparatus of FIG. 1 using the process of FIG. 2 in accordance with a preferred embodiment of the present invention. FIG. 7 shows an emulated table 26 ″ having NPOT data values 24 to be emulated, FIG. 8 shows a reduced table 28 ″ derived from emulated table 26 ″, and FIGS. 9 and 10 show even-and odd-indexed tables 30 ″ and 32 ″ derived from reduced table 28 ″. The following discussion refers to FIGS. 1 through 10.
The operation of transparent data access and interpolation apparatus 20 and process 22 therefor is demonstrated herein through the use of two related examples. A first example uses the data depicted in tables 26 ′, 28 ′, 30 ′, and 32 ′. Table 26 ′ is the table of data to be emulated, i.e., the table that the computer will think it is addressing. In the first example, table 26 ′ (FIG. 3) is composed of 2 V data values 24 , where V is a positive integer. That is, table 26 ′ has an integral-power-of-two (IPOT) number of data values 24 and is therefore an IPOT table. The first example is hereinafter the IPOT example.
Similarly, a second example uses the data depicted in tables 26 ″, 28 ″, 30 ″, and 32 ″. In this case, table 28 ″ (FIG. 7) is the table of data to be emulated. In the second example, table 26 ″ is composed of 2 V data values 24 , where V is a positive value but not an integer. That is, table 26 ″ has a non-integral-power-of-two (NPOT) number of data values 24 and is therefore an NPOT table. The second example is hereinafter the NPOT example.
For purposes of identification and simplicity of text, all items common to either both or neither of the IPOT and the NPOT examples have un-accented reference numbers, items peculiar to the IPOT example have prime reference numbers, and items peculiar to the NPOT example have double-prime reference numbers. For example, emulated table 26 references either IPOT emulated table 26 ′ or NPOT emulated table 26 ″ or both.
Data access and interpolation apparatus 20 is substantially transparent to a computer (not shown) to which it is coupled. That is, apparatus 20 appears to the computer as a single memory circuit containing a table of data values 24 . Emulated tables 26 (FIGS. 3 and 7) are typical of the tables the computer thinks it is addressing. The use of apparatus 20 allows the use of smaller tables and related circuitry, thereby realizing a significant savings in on-chip real estate over the original (emulated) table and memory circuit, with attendant reductions in power consumption. It is desirable, therefore, that table 26 be replaced by apparatus 20 .
In both the IPOT and NPOT examples, tables 26 contain a large number O V of consecutive data values 24 derived from a function, e.g., cosine values for one-half cycle as may be used in fast Fourier transform (FFT) analyses. In the IPOT example, table 26 ′ contains an integral-power-of-two number of consecutive data values 24 . In the example of FIG. 3, V=16, and table 26 ′ has O V =2 V =2 16 =65 536 data values 24 .
In the NPOT example, table 26 ″ contains a non-integral-power-of-two number of consecutive data values 24 . In the example of FIG. 7, V=6.807 354 92 . . . , and table 26 ″ has O V =2 V =2 26.807 354 92 . . . = 112 data values 24 .
In a task 34 (FIG. 2 ), process 22 generates data values 24 for reduced table 28 . Through the use of conventional techniques known to those skilled in the art, it may be determined that the data of table 26 may be reduced while maintaining acceptable interpolation accuracy. For simplicity, each of the reduced-table data values 24 may be computed as: R I = R W · O I O V ( 1 )
where:
O I is the emulated-table data-value index;
O V is the number of emulated-table data values;
R W is the number of reduced-table data values; and
R I is the reduced-table data-value index.
As depicted in FIGS. 3 and 7, reduced-table index R I is composed of an integral part A n and a fractional part A f . In the IPOT example (FIG. 3 ), the data of table 26 ′ may be reduced from O V =2 V =2 16 =65 536 data values 24 to R W =2 W =2 10 =1024 data values 24 . This may be demonstrated by an even sample 36 ′ where emulated-table index O I =6424 and an odd sample 38 ′ where emulated-table index O I =13 549. Using equation (1), even sample 36 ′ computes as: R I = R W · O I O V = 1024 · 6424 65526 = 100 24 64 (1-1)
where integral part A n =100 and fractional part A f ={fraction (24/64)}. Similarly, odd sample 38 ′ computes as: R I = R W · O I O V = 1024 · 13549 65526 = 211 45 64 (1-2)
where integral part A n =211 and fractional part A f ={fraction (45/64)}.
Fractional part A f has a resolution of 2 −6 ={fraction (1/64)}. Since tables 26 ′ and 28 ′ both have an IPOT number of data values 24 , the resolution of fractional part A f is also an integral power of two.
In the NPOT example, the data of table 26 ″ (FIG. 7) is reduced from O V =2 V =2 6.807 354 92 . . . =112 data values 24 to R W =2 W =2 4 =16 data values 24 . This may be demonstrated by an even sample 36 ″ where emulated-table index O I =90 and an odd sample 38 ″ where emulated-table index O I =93. Using equation (1), even sample 36 ″ computes as: R I = R W · O I O V = 16 · 90 211 = 12 6 7 (1-3)
where integral part A n =12 and fractional part A f ={fraction (6/7)}. Similarly, odd sample 38 ″ computes as: R I = R W · O I O V = 16 · 93 112 = 13 2 7 (1-4)
where integral part A n =13 and fractional part A f ={fraction (2/7)}.
The integral parts A n of reduced-table index R I form the indices of the data values 24 in reduced table 28 ″ (FIG. 8 ). Reduced table 28 ″ therefore has R W =2 W =2 4 =16 data values 24 at a first approximation.
Fractional part A f has a resolution of 2 −2.807 35 . . . ={fraction (1/7)}. This is not an integral power of two and cannot readily be expressed as a simple binary number. To achieve a reasonable accuracy, therefore, the resolution of the fractional part would desirably be increased to some power of two small enough to achieve the desired accuracy. In the example of FIG. 7, the pseudo power of two is 2 −9 ={fraction (1/512)}.
Those skilled in the art will appreciate that the hereinbefore discussed methodology for determining data values 24 for reduced table 28 is exemplary only and assumes a common sampling method having the greatest interpolation errors midway between on-curve samples (i.e., samples coincident with the curve) where the function exhibits the greatest curvature. The use of other methods, e.g., a piecewise linear least-squares method, may produce other data values 24 having reduced interpolation errors. Such other methods are well known to those of ordinary skill in the art and are beyond the scope of this discussion. The use of such other methods does not depart from the spirit of the present invention.
Reduced tables 28 contain R W =2 W data values 24 , which is fewer than the O V =2 V data values 24 of emulated tables 26 . Each reduced-table index R I has an integral part A n and a fractional part A f . The difference between adjacent values A n is interpolated by apparatus 20 to provide approximations of the original O V data values 24 . To do this, two adjacent data values 24 A n and A n +1, are used to provide the interpolation difference.
In the IPOT example, even sample 36 ′ where emulated-table index O I =6424 in emulated table 26 ′ (FIG. 3) produces a reduced-table index R I =100{fraction (24/64)}, i.e., where 100≦R I <101. Therefore, even sample 36 ′ at reduced table 28 ′ (FIG. 4) is at A n =100 and A n +1=101.
Similarly, odd sample 38 ′ where emulated-table index O I =13 549 in table 26 ′ produces a reduced-table index R I =211{fraction (45/64)}, i.e., where 211≦R I <212. Therefore, odd sample 38 ′ at reduced table 28 ′ is at A n =211 and A n +1=212.
In the NPOT example, even sample 36 ″ where emulated-table index O I =90 in table 26 ″ (FIG. 7) produces a reduced-table index R I =12{fraction (6/7)}, i.e., where 12≦R I <13. Therefore, even sample 36 ″ at reduced table 28 ″ (FIG. 8) is at A n =12 and A n +1=13.
Similarly, odd sample 38 ″ where emulated-table index O I =93 in table 26 ″ produces a reduced-table index R I =13{fraction (2/7)}, i.e., where 13≦R I <14. Therefore, odd sample 38 ″ at reduced table 28 ″ is at A n =13 and A n +1=14.
Because of this dual-sample property, it is desirable that reduced table contain R W +1=2 W +1 rather than R W =2 W data values 24 . The additional data value 24 , where R I =2 N , allows for dual sampling where sample A n =2 N −1 and sample A n +1=2 N . This is demonstrated in FIGS. 3 through 6 (tables 26 ′, 28 ′, 30 ′, and 32 ′) by maximum sample 40 ′.
In a task 42 (FIG. 2 ), process 22 indexes the 2 W +1 data values 24 of reduced tables 28 (FIGS. 4 and 8) from 0 to 2 N , where each index is integral part A n of reduced-table index R I for that data value 24 . Therefore, IPOT-example reduced table 28 ′ has R W +1=2 W +1=2 10 +1=1025 data values 24 indexed from 0 to 1024, and NPOT-example reduced table 28 ″ has R W +1=2 W +1=2 4 +1=17 data values 24 indexed from 0 to 16.
Reduced table 28 contains 2 W +1 data values 24 with consecutive indices from 0 to 2 W . In a task 44 (FIG. 2 ), process 22 stores even-indexed ones of data values 24 in even-indexed tables 30 . Even-indexed table 30 therefore contains 2 W−1 +1 data values having consecutive even indices from 0 to 2 W .
Similarly, in a task 46 (FIG. 2 ), process 22 stores odd-indexed ones of data values 24 in odd-indexed tables 32 . Odd-indexed table 32 therefore contains 2 W−1 data values having consecutive odd indices from 1 to 2 W −1.
Those skilled in the art will appreciate that, due to the limitations of flow charts, e.g., FIGS. 2, 11 , and 12 , a task sequence may be implied that is not a requirement of the present invention. For example, the order in which tasks 44 and 46 are performed is irrelevant to the present invention.
The computer (not shown) to which data access and interpolation apparatus 20 (FIG. 1) is coupled addresses apparatus 20 using a primary address B [M] . Because the computer only sees primary address B [M] , apparatus 20 is transparent, i.e., the computer believes itself to be addressing emulated table 26 using primary address B [M] .
In a task 48 , process 22 produces a direct address A [N+F] from primary address B [M] . Direct address A [N+F] has an integral address A [N] as a first address portion and a fractional address A [F] as a second address portion.
Primary address B [M] contains M address bits from B 0 through B M−1 , where M is a positive integer. Integral address A [N] represents the integral portion of direct address A [N+F] and contains N address bits from A 0 through A N−1 , where N is a positive integer. Fractional address A [F] represents the fractional portion of direct address A [N+F] and contains F address bits from A −F through A −1 , where F is a positive integer. Because fractional address A [F] is fractional, i.e., contains the address of a fractional data value, address bit A −1 =2 −1 =½, address bit A −2 =2 −2 =¼, etc.
In the IPOT example of FIGS. 3 through 6 (tables 26 ′, 28 ′, 30 ′, and 32 ′), emulated table 26 ′ has O V =2 V =2 16 =65 536 data values 24 , reduced table 28 ′ has R W =2 W =2 10 =1024 data values 24 , and fractional part A f has a resolution of 2 −F =2 −6 ={fraction (1/64)}. Therefore, V=M=16, W=N=10, and F=6. Indeed, where V and W are both integral powers of two:
M=N+F. (2)
This allows a direct relationship to exist between the bits of primary address B [M] and direct address A [N+F] . This direct relationship is:
primary
direct
address
address
B [M]
A [N+F]
B M−1
B 15
A 9
A N−1
B 14
A 8
. . .
. . .
B 1
A 1
B 6
A 0
integral address A [N]
B 5
A −1
fractional address A [F]
B 4
A −2
. . .
. . .
B 1
A −5
B 0
A −6
A −F
Because of this direct relationship between primary address B [M] and direct address A [N+F] , an optional address converter 50 , shown in FIG. 1, is not required.
In the NPOT example of FIGS. 7 through 10 (tables 26 ″, 28 ″, 30 ″, and 32 ″), however, emulated table 26 ″ has O V =2 V =2 6.807 354 92 . . . =112 data values 24 , reduced table 28 ″ has R W =2 W =2 4 =16 data values 24 , and fractional part A f has a resolution of 2 −F =2 −2.807 35 . . . ={fraction (1/7)}. This means that primary address B [M] must have at least seven bits (M≧7) where values above 112 are ignored. Similarly, fractional address A [F] must have at least three bits (F≧3), but preferably has more to reduce the rounding error to acceptability. For purposes of simplicity, in the NPOT example of FIG. 7, fractional address A [F] has nine bits (F=9) to allow resolution to the nearest {fraction (1/512)}, i.e., {fraction (1/7)}≈{fraction (73/512)}, {fraction (2/7)}≈{fraction (146/512)}, {fraction (3/7)}≈{fraction (219/512)}, {fraction (4/7)}≈{fraction (293/512)}, {fraction (5/7)}≈{fraction (366/512)}, and {fraction (6/7)}≈{fraction (439/512)}. Therefore, where V is not an integral power of two:
M≦N+F. (3)
Those skilled in the art will appreciate that a value of F=9 is purely arbitrary and was chosen here for simplicity. In actual applications, greater values of F may be used to improve accuracy, e.g., F=16 or F=20.
In both the IPOT and NPOT examples presented herein W is a positive integer, i.e., W=10 for the IPOT example and W=4 for the NPOT example. This results in reduced table 28 having an integral power of two entries, plus 1. In this case, W=N. This is not a requirement of the present invention, and those skilled in the art will appreciate that W, while positive, may not be an integer, i.e., reduced table 28 may have any desired number of entries. In such a case, W≦N.
Optional address converter 50 (FIG. 1) is used in the NPOT example to convert primary address B [M] into direct address A [N+F] . Those skilled in the art will appreciate that optional address converter 50 may be any of a plurality of well-know converters, e.g., a simple M by N+F look-up table array, without departing from the spirit of the present invention.
FIG. 11 shows a flowchart depicting a table-access subprocess 52 of process 22 in accordance with a preferred embodiment of the present invention. The following discussion refers to FIGS. 1, 2 , 5 , 6 , and 11 .
In subprocess 52 , process 22 utilizes an address control circuit 60 (FIG. 1) to access the addressed data values 24 within even- and odd-indexed tables 30 and 32 . Even-indexed table 30 contains substantially the even-indexed half of data values 24 of reduced table 28 and odd-indexed table 32 contains substantially the odd-indexed half of data values 24 of reduced table 28 . Since each of even- and odd-indexed tables 30 and 32 contains substantially half of reduced table 28 , each of even-and odd-indexed tables 30 and 32 is addressable as a half-integral address A [N−1:1] , which is integral address A [N] integer-divided by two: A [ N - 1 : 1 ] = int ( A [ N ] 2 ) . ( 4 )
Half-integral address A [N−1:1] is a partial address formed of the N−1 most-significant bits, A 1 through A N−1 , of integral address A [N] . A task 54 (FIG. 11) of subprocess 52 provides half-integral address A [N−1:1] to address control circuit 60 .
Half-integral address A [N−1:1] cannot differentiate between even-indexed table 30 and odd-indexed table 32 . To correct this, A [0] is utilized. Even/odd-integral address A [0] is a partial address formed of the 1 least-significant bit, A 0 , of integral address A [N] . A task 56 (FIG. 11) of subprocess 52 provides even/odd-integral address A [0] to address control circuit 60 .
Those skilled in the art will appreciate that the order in which tasks 54 and 56 are performed is irrelevant to the present invention, and the sequence described herein is due to the limitations of flow charts.
A task 58 (FIG. 11) of subprocess 52 addresses even-indexed table 30 . That is, task 58 derives an even-table address A [T1] from half-integral address A [N−1:1] and even/odd-integral address A [0] to through address control circuit 60 (FIG. 1) of data access and interpolation apparatus 20 .
Within address control circuit 60 , task 58 uses a summing circuit 62 to derive the sum of half-integral address A [N−1:1] plus even/odd-integral address A [0] . The resultant sum passes through an optional address mask circuit 64 and an optional address offset circuit 68 to become even-table address A [T1] .
Similarly, a task 70 of subprocess 52 passes half-integral address A [N−1:1] through optional address mask circuit 64 and optional address offset circuit 68 to become an odd-table address A [T2] .
Apparatus 20 incorporates a first memory circuit 72 and a second memory circuit 74 , each of which is coupled to address control circuit 60 . In the preferred embodiment of FIG. 1, first and second memory circuits 72 and 74 serve solely to contain even- and odd-indexed tables 30 and 32 , respectively. Therefore, even- and odd-indexed tables 30 and 32 are considered herein to be synonymous with first and second memory circuits 72 and 74 , and even- and odd-table addresses A [T1] and A [T2] are addresses of first and second memory circuits 72 and 74 , respectively.
Within address control circuit 60 , task 58 (FIG. 11) passes the sum of half-integral address A [N−1:1] plus even/odd-integral address A [0] through optional address mask circuit 64 and optional address offset circuit 68 to become even-table address A [T1] . Similarly, a task 70 of subprocess 52 passes half-integral address A [N−1:1] through optional address mask circuit 64 and optional address offset circuit 68 to become an odd-table address A [T2] . Those skilled in the art will appreciate that optional address mask circuit 64 and optional address offset circuit 68 are not requirements of the present invention. Address mask circuit 64 and address offset circuit 68 may be used in manners well-known to one of ordinary skill in the art to cause reduced table 28 , realized within even- and odd-indexed tables 30 and 32 , to become circular. The inclusion or omission of either optional address mask circuit 64 or optional address offset circuit 68 does not depart from the spirit of the present invention. For purposes of simplicity, this discussion shall assume the omission of both optional address mask circuit 64 and optional address offset circuit 68 , in which case:
A [T1] =A [N−1:1] +A [0] , (5)
and
A [T2] =A [N−1:1] (6)
The reason A [T1] =A [N−1:1] +A [0] and A [T2] =A [N−1:1] may be seen by following through address control circuit 60 with the IPOT example. In even sample 36 ′, A [N] =100 (FIG. 3 ). Therefore: A [ T1 ] = int ( A [ N ] 2 ) + A [ 0 ] = int ( 100 2 ) + 0 = 50 , and (5-1) A [ T2 ] = int ( A [ N ] 2 ) = int ( 100 2 ) = 50. (6-1)
In FIGS. 5 and 6, it may be seen that task 58 (FIG. 11) addresses even-indexed table 30 ′ at A [T1] =50 where A [N] =100, and task 70 addresses odd-indexed table 32 ′ at A [T2] =50 where A [N] =101. Therefore, A n =100 and A n +1=101. An even-table data value G t1 is the A n data value and an odd-table data value G t2 is the A n +1 data value.
Similarly, in odd sample 38 ′, A [N] =211 (FIG. 3 ). Therefore: A [ T1 ] = int ( A [ N ] 2 ) + A [ 0 ] = int ( 211 2 ) + 1 = 106 , and (5-2) A [ T2 ] = int ( A [ N ] 2 ) = int ( 211 2 ) = 105. (6-2)
Task 58 (FIG. 11) addresses even-indexed table 30 ′ at A [T1] =106 where A [N] =212, and task 70 addresses odd-indexed table 32 ′ at A [T2] =105 where A [N] =211. Therefore, A n =211 and A n +1=212. Odd-table data value G t2 is the A n data value and even-table data value G t1 is the A n +1 data value.
Those skilled in the art will appreciate that the order in which tasks 58 and 70 are performed is irrelevant to the present invention, and the sequence described herein is due to the limitations of flow charts.
Following even- and odd-indexed tables 30 and 32 in apparatus 20 is a routing circuit 76 (FIG. 1) coupled to both first and second memory circuits 72 and 74 . In a task 78 (FIG. 11 ), subprocess 52 provides a value of even/odd-integral address A [0] to routing circuit 76 . In the preferred embodiment of FIG. 1, routing circuit 76 is made up of two cross-coupled multiplexers 80 and 82 configured to output a first-indexed (i.e., A n indexed) data value G n and a second-indexed (i.e., A n +1 indexed) data value G n+1 , respectively.
In a query task 84 (FIG. 11 ), subprocess 52 determines if even/odd-integral address A [0] is even or odd. If task 84 determines that even/odd-integral address A [0] is even, then a task 86 acquires first-indexed data value G n from even-indexed table 30 and a task 88 acquires second-indexed data value G n+1 from odd-indexed table 32 . Conversely, if task 84 determines that even/odd-integral address A [0] is odd, then a task 90 acquires first-indexed data value G n from odd-indexed table 32 and a task 92 acquires second-indexed data value G n+1 from even-indexed table 32 . That is, G n =G t1 and G n+1 =G t2 when A [0] =0, and G n =G t2 and G n+1 =G t1 when A [N] =1.
Subprocess 52 (FIGS. 2 and 11) is thereby completed and control is returned to process 22 (FIG. 2 ).
FIG. 12 shows a flowchart depicting an output-determining subprocess 94 of process 22 in accordance with a preferred embodiment of the present invention. The following discussion refers to FIGS. 1, 2 , 5 , 6 , 9 , 10 , and 12 .
In subprocess 94 (FIG. 12 ), process 22 then utilizes an interpolation circuit 102 (FIG. 1) of apparatus 20 to produce an output data value G Out . In a task 96 , subprocess 94 provides the value A f of fractional address A [F] (FIG. 1) to interpolation circuit 102 . Fractional address A [F] is made up of bits whose values are negative integral powers of two. That is, fractional address A [F] has value A f that is always fractional, i.e.:
0≦A f <1. (7)
Typically, data values 24 in tables 26 , 28 , 30 , and 32 are expressed as floating-point values, rather than binary values. This being the case, a task 98 of subprocess 94 converts value A f of binary fractional address A [F] into a floating-point incremental value Δ in a fixed to floating-point converter 100 of apparatus 20 , where:
0≦Δ<1. (8)
In interpolation circuit 102 of apparatus 20 , a task 104 of subprocess 94 uses a subtracting circuit 106 to subtract first-indexed data value G n from second-indexed data value G n+1 to produce a data-difference value G Diff . That is:
G Diff =G n+1 −G n . (9)
In a multiplying circuit 108 of interpolation circuit 102 , a task 110 of subprocess 94 multiplies data-difference value G Diff by incremental value Δ to produce an interpolated data value G ΔDiff . That is:
G ΔDiff =Δ·G Diff . (10)
In a summing circuit 112 of interpolation circuit 102 , a task 114 of subprocess 94 adds interpolated data value G ΔDiff to first-indexed data value G n to produce output data value G Out . That is:
G Out =G n +G ΔDiff . (11)
This completes subprocess 94 and process 22 .
The following discussion follows even sample 36 ′ of the IPOT example from beginning to end.
In emulated table 26 ′ (FIG. 3 ), even sample 36 ′ indicates a desired data value 24 whose emulated-table index O I =6424. This data value is cos ( 6424 65536 π ) = 0.952 957 956 032 … .
Using equation 1, the values A n and A f of the reduced-table integral address A [N] and fractional address A [F] may be computed: R I = R W · O I O V = 1024 · 6424 65536 = 100 24 64 (1-1)
where integral part A n =100 and fractional part A f ={fraction (24/64)}. This being an IPOT example, a special relationship exists, where V=M, W=N, and M=N+F=10+6=16, and where primary address B [M] =6424 D =0001 1001 0001 1000 B (sixteen bits), integral address A [N] =100 D =00 0110 0100 B (ten most-significant bits of primary address B [M] ), and fractional address A [F] =0.375 D =0.0110 00 B (six least-significant bits of primary address B [M] ). Since 100≦R I <101, what will actually be fetched are: A [ T ] = int ( A [ N ] 2 ) + A [ 0 ] = int ( 100 2 ) + 0 = 50 , and (5-1) A [ T2 ] = int ( A [ N ] 2 ) = int ( 100 2 ) = 50. (6-1)
That is, the data values G t1 and G t2 in even- and odd-indexed tables 30 ′ and 32 ′ (FIGS. 5 and 6) whose addresses are A [T1] =50 and A [T2] =50, respectively. From even-indexed table 30 ′, G t1 = cos ( 100 1024 π ) = 0.953 306 040 354 … .
From odd-indexed table 32 ′, G t1 = cos ( 101 1024 π ) = 0.952 375 012 720 … .
In this case, A [0] =0, so first-indexed data value G n =G t1 and second-indexed data value G n+1 =G t2 . Using equation 9 to compute data-difference value G Diff : G Diff = G n + 1 - G n = 0.952 375 012 720 … - 0.953 306 040 354 … = - 0.000 931 027 634 … (9-1)
Ignoring fixed versus floating-point conversion so that incremental value Δ=A f =0.375, and using equation 10 to compute interpolated data value G ΔDIff : G Δ Diff = Δ · G Diff = ( - 0.000 931 027 634 … ) · 0.375 = - 0.000 349 135 363 … (10-1)
Then using equation 11 to compute output data value G Out : G Out = G n + G Δ Diff = 0.953 306 040 354 … + ( - 0.000 349 135 363 … ) = 0.952 956 904 991 … (11-1)
Which varies by only −0.000 001 051 041 . . . from the desired emulated value of 0.952 957 956 032 . . . .
Similarly, the following discussion follows odd sample 38 ′ of the IPOT example from beginning to end.
In emulated table 26 ′ (FIG. 3 ), odd sample 38 ′ indicates a desired data value 24 whose emulated-table index O I =13 549. This data value is cos ( 13549 65536 π ) = 0.796 388 074 554 … .
Using equation 1: R I = R W · O I O V = 1024 · 13549 65536 = 211 45 64 (1-2)
where integral part A n =211 and fractional part A f ={fraction (45/64)}=0.703 125. Since 211≦R I <212, what will actually be fetched are: A [ T1 ] = int ( A [ N ] 2 ) + A [ 0 ] = int ( 211 2 ) + 1 = 106 , and (5-2) A [ T2 ] = int ( A [ N ] 2 ) = int ( 211 2 ) = 105. (6-2)
That is, the data values G t1 and G t2 in even- and odd-indexed tables 30 ′ and 32 ′ (FIGS. 5 and 6) whose addresses are A [T1] =106 and A [T2] =105, respectively. From even-indexed table 30 ′, G t1 = cos ( 212 1024 π ) = 0.795 836 904 609 … .
From odd-indexed table 32 ′, G t2 = cos ( 211 1024 π ) = 0.797 690 840 943 … .
In this case, A [0] =1, so first-indexed data value G n =G t2 and second-indexed data value G n+1 =G t1 . Using equation 9 to compute data-difference value G Diff : G Diff = G n + 1 - G n = 0.795 836 904 609 … - 0.797 690 840 943 … = - 0.001 853 936 334 … (9-2)
Using equation 10 to compute interpolated data value G ΔDiff : G Δ Diff = Δ · G Diff = ( - 0.001 853 936 334 … ) · 0.703 125 = - 0.001 303 548 980 … (10-2)
Then using equation 11 to compute output data value G Out : G Out = G n + G Δ Diff = 0.797 690 840 943 … + ( - 0.001 303 548 980 … ) = 0.796 387 291 963 … (11-2)
Which varies by only −0.000 000 782 591 .. . from the desired emulated value of 0.796 388 074 554 . . . .
With the NPOT example, the process for obtaining the results is substantially identical to that of the IPOT example, with the exception that the value of the fraction part A F of reduced-table index R I is not an integral power of two. The accuracy of the result therefore depends heavily upon the resolution of the integral-power-of-two equivalent of the fractional address A [F] . In the NPOT examples herein, a resolution of 2 −9 =1/512, where F=9, was used for simplicity. In practice, a resolution of 2 −16 ={fraction (1/65 536)} or 2 −20 =1/1 048 576 would not be uncommon.
Those skilled in the art will appreciate that certain timing considerations must be made within apparatus 20 . For this reason, a first delay circuit 116 has been added to apparatus 20 to effect a delay of incremental value Δ so that incremental value Δ and data-difference value G Diff arrive at multiplying circuit 108 substantially simultaneously. Similarly, a second delay circuit 118 has been added to apparatus 20 to effect a delay of first-indexed data value G n so that first-indexed data value G n and interpolated data value G ΔDiff arrive at summing circuit 112 substantially simultaneously. The use of these and/or other timing circuits does not depart from the spirit of the present invention.
In summary, the present invention teaches a transparent data access and interpolation apparatus 20 and method 22 therefor. Apparatus 20 and method 22 reduce power consumption during access. Apparatus 20 significantly reduces on-chip memory area. Method 22 is transparent to the accessing computer (not shown) and obtains two values A n and A n +1 for interpolation in a single access operation. Being transparent, method 22 is usable with pre-existing software.
Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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An apparatus ( 20 ) and method ( 22 ) for transparently accessing and interpolating data are provided. Consecutive data values ( 24 ) of a function are generated and indexed. Even-indexed data values ( 24 ) are stored in an even-indexed table ( 30 ) and odd-indexed data values ( 24 ) are stored in an odd-indexed table ( 32 ). Adjacent-indexed data values ( 24 ) are acquired substantially simultaneously from even- and odd-indexed tables ( 30,32 ) with the first-indexed value (G n ) extracted from the even-indexed table ( 30 ) when an integral portion (A [N] ) of a memory address (A [N+F] ) is even and from the odd-indexed table ( 32 ) when the integral portion (A [N] ) is odd. A fractional portion (A [F] ) of the memory address (A [N+F] ) is converted into an incremental value (Δ). An interpolation circuit ( 102 ) then produces an output data value (G Out ) as a sum of the first-indexed value (G n ) plus a product of the incremental value (Δ) times a difference of the second-indexed value (G n+1 ) less the first-indexed value (G n ).
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The present invention relates to a process for treating a fiber or a fiber-based material to improve its adsorption (complexing) properties. The present invention also relates to a fiber or fiber-based material, such as a textile, with improved adsorption properties.
BACKGROUND OF THE INVENTION
Improving the complexing properties of fibers allows different active compounds such as fragrances, insecticides, bactericidal agents, antistatic agents, anti-bacterial agents or repellent agents to be adsorbed onto a fiber or fiber-based material. Because the adsorbed active product subsequently diffuses into the surrounding atmosphere (release), the complexing phenomenon, which occurs in the fibers, endows the fiber or any material containing it with the different chemical properties of the adsorbed product for a set period that depends on the rate of diffusion of the complexed product (release rate).
One known method for improving the adsorbent properties of a fiber is fixing (grafting) molecules of cyclodextrin(s) onto the fiber.
Cyclodextrins (α-cyclodextrin, β-cyclodextrin and γ-cyclodextrin) have long been known to be molecules possessing complexing properties, i.e., molecules that are capable of reversibly trapping certain other small molecules of a hydrophobic nature, in particular aliphatic or aromatic molecules, from their solutions, vapors or solid mixtures. The adsorbed molecules are bonded to the cyclodextrin by the formation of inclusion complexes.
The release rate of the product complexed by cyclodextrins is small, so fibers functionalized by cyclodextrins are perfectly suited to produce fiber-based materials, in particular textiles, which possess the chemical properties of the complexed product in a stable manner and for long periods, and also to produce adsorbent materials. These adsorbent materials have a number of applications, in particular in water purification and contaminated gas purification.
Textile materials functionalized with cyclodextrins with adsorbed fragrances, antistatic agents, antimicrobial agents, insect repellents, bactericidal agents, or insecticides, have been respectively described in the following documents: Japanese patent JP-A-06-116871, U.S. Pat. No. 5,376,287, JP-A-09 315920, JP-A-04-263617, JP-A-09-228144, JP-A-05-311509, U.S. Pat. No. 5,670,456 and JP-A-03-59178.
Textile materials functionalized by cyclodextrins and with hygroscopic and odor adsorption properties have been described in JP-A-06-322670, JP-A-02-127573, JP-A-03-14678, JP-A-08-199478, JP-A-02-251681 and JP-A-163372.
Textiles functionalized with cyclodextrins and used as adsorbents, in particular as barriers to contaminants, have been described in U.S. Pat. No. 5,776,842.
These examples are not limiting. Potential applications for textiles functionalized with cyclodextrins have been cited by Denter and Schollmeyer in the document “Proceedings of the Eighth International Symposium on Cyclodextrins”, Budapest, Hungary, 1996, J. Szejtli and L. Szente Eds, Kluwer Academic Publishers.
The principal technical difficulty in producing fibers and textiles functionalized by cyclodextrins or their inclusion complexes is to fix molecules of cyclodextrin(s) or their inclusion complexes onto fibers and textile materials in a durable manner. A number of fixing methods has been developed.
U.S. Pat. No. 4,357,468 describes a method for fixing cyclodextrin(s) using epichlorhydrin.
European patent EP-A-0 697 415, German patent DE-A-19520967 and Denter U., Schollmeyer E., J. Inclusion Phenom. Mol. Recognit. Chem. 25(1–3), 197–202 (1996) describe a method for fixing cyclodextrins using chlorinated heterocyclic compounds.
EP-A-0 488 294 and JP-A-03-59178 disclose a fixing method using reactive aminosiloxanes and siloxanes.
U.S. Pat. No. 5,098,793 describes polymers obtained by reacting cyclodextrin with an activated dicarboxylic acid. Such polymers form a film that adheres to the surface of a substrate that can be a cellulose substrate, for example. They do not contain any residual carboxylic acid functions because they come from dicarboxylic acid and since both of its carboxylic acid functions have been reacted.
JP-A-06-322670 describes a fixing method using a resin based on an aminosilicone and/or polyurethane.
JP-A-02—127573 describes a fixing method using a polymer (Hercosett 57) obtained by cross-linking a polyamide with epichlorhydrin.
JP-A-09-228144 describes a fixing method by incorporating cyclodextrins or their inclusion complexes into the chemical fiber spinning dope.
Finally, DE-A-4035378 describes a method for fixing cyclodextrin(s) or cyclodextrin derivative(s) using reactants carrying dimethylol urea groups or derivatives of such groups that react both with a hydroxyl group of the cyclodextrin and with a functional group of the fiber, bonding the cyclodextrin molecule to the fiber.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention proposes a novel method for fixing cyclodextrin(s) or cyclodextrin derivative(s) that can fix molecules of cyclodextrin(s) or cyclodextrin derivative(s) in a durable manner to a fiber or a fiber based material such as a textile, regardless of the nature of the fiber or fiber-based material under consideration.
The present invention concerns a process for treating a fiber or a fiber-based material such as a yarn, a woven, knitted or nonwoven textile material, paper, leather, or a material based on wood fibers, to improve its adsorption properties, wherein the following successive operations are carried out on said fiber or said material: applying a solid mixture of cyclodextrin(s) and/or cyclodextrin derivative(s) and/or their inclusion complexes, at least one poly(carboxylic) acid and/or at least one poly(carboxylic) acid anhydride and optionally a catalyst, heating to a temperature in the range 150° C. to 220° C., washing with water and drying the product obtained.
The above inclusion complexes can, for example, be formed from an active agent complexed by a molecule of cyclodextrin or a cyclodextrin derivative. A material treated with an inclusion complex has a better guarantee of cyclodextrin complexing properties; the presence of a complexed agent retains accessibility to the cavity of the cyclodextrin.
The process of the present invention is of particular advantage in that it is applicable to any natural or artificial fiber and to any type of fiber-based material such as a textile material, paper or leather, which is capable of tolerating a heating step without undergoing either physical or chemical degradation. In particular, the process of the invention is applicable to fibers and to yarns composed of natural and artificial cellulose fibers, natural and artificial protein fibers, synthetic fibers such as polyesters, polyamides, acrylics, aramids, fluorofibers, or mineral fibers and to fiber-based materials and textiles of the woven, knitted or nonwoven type and containing one or more types of the above yarns and fibers.
The molecules of cyclodextrin(s) are fixed to the fiber or fiber-based material by two mechanisms that depend on the chemical nature of the fiber or the fiber-based material.
When treating fibers or materials composed of fibers comprising a hydroxyl and/or amine function, implementing the process of the invention initially forms an anhydride of the poly(carboxylic) acid that reacts with the fiber or fiber-based material by forming a covalent amide or ester type bond between the fiber or the fibers of the treated material and the poly(carboxylic) acid. Then, in the simplest case, a second poly(carboxylic) acid anhydride is formed bonded to the fiber; this reacts with a molecule of cyclodextrin or cyclodextrin derivative by creating an ester bond between the molecule of cyclodextrin or cyclodextrin derivative and that of the poly(carboxylic) acid. Possible formation of an anhydride from a further carboxyl function of the poly(carboxylic) acid bonded to the fiber then allows a reaction with a further molecule of cyclodextrin or cyclodextrin derivative. In that reaction, one or more molecules of cyclodextrin(s) or cyclodextrin derivative(s) is obtained bonded via an ester function to a molecule of poly(carboxylic) acid which is itself bonded to a fiber via a covalent bond.
Further, a second type of reaction may occur, either in parallel with or independently of the reaction fixing the cyclodextrin or cyclodextrin derivative to the fiber via a covalent bond. Because of the presence of poly(carboxylic) acid, a copolymer of cyclodextrin and/or cyclodextrin derivative(s) and/or their inclusion complexes with poly(carboxylic) acid(s) is formed; this copolymerization produces copolymers that are either linear, branched or cross-linked.
When the copolymer forms from a molecule of cyclodextrin fixed to the fiber via a covalent bond, it therefore has at least one covalent bond with a fiber. When the copolymer forms from molecules of poly(carboxylic) acid and/or poly(carboxylic) acid anhydride and cyclodextrin and/or cyclodextrin derivative(s) not bonded to a fiber, if it is cross-linked, i.e., forms a three-dimensional network mingling with or coating the fiber or the fibers of a fiber-based material, it may be mechanically fixed in a permanent manner to the fiber or material under consideration.
The basic mechanism using a molecule of poly(carboxylic) acid and a molecule of cyclodextrin or a cyclodextrin derivative is most probably similar to the mechanism for cross-linking cellulose with poly(carboxylic) acids in the presence of a catalyst proposed by Welsh C. M. in American Dyestuff Reporter 83(9), 19–26 (1994). Such a treatment, described in particular in U.S. Pat. No. 4,820,307 and carried out on cotton cellulose, renders cotton textiles crease-resistant by cross-linking cotton fibers. However, that process is intended to modify the physical properties of a textile material exclusively constituted by cellulose fibers, such as cotton, and not to modify the adsorption properties of a fiber or a fiber-based material by fixing cyclodextrin(s) or cyclodextrin derivative(s) to the fiber or to the structure of the fiber-based material, independently of the chemical nature of that fiber or material, as in the present invention.
Further, certain synthetic fibers or materials based on such fibers do not possess functional groups that can react with the mechanism proposed above. In this case, the cyclodextrin(s) and/or cyclodextrin derivative(s) and/or their inclusion complexes are fixed by forming a cross-linked copolymer obtained by exclusive reaction between the molecules of cyclodextrin(s) and/or cyclodextrin derivative(s) and at least one poly(carboxylic) acid. The cross-linked copolymer formed coats the fiber or the fiber-based material in a permanent manner.
In the case of a fiber comprising an amine or hydroxyl function, such as keratinous or cellulose fibers, or a material comprising such fibers, the two fixing mechanisms coexist, namely fixing via a covalent bond to the fiber and forming a sheath of cross-linked copolymer on the fiber.
The complexing properties of the cyclodextrins described above are supplemented by those of the residual carboxylic acid functions which have not reacted by esterification, either with the fiber or with the cyclodextrin. These carboxylic acid functions endow the fibers not only with odor absorption properties but also with cation exchange properties. On the other hand, these carboxylic acid functions endow the fibers with better affinity for water (hydrophilic nature) and improve the wettability of the treated material, in particular for materials based on slightly hydrophilic or hydrophobic fibers.
A further advantage of the process of the invention is that it is cheap, easy to carry out using equipment that is conventional in the textile industry and that it does not necessitate the use of toxic reactants.
In a preferred implementation, the solid mixture is applied by impregnating the fiber or fiber-based material with an aqueous solution of cyclodextrin(s) and/or cyclodextrin derivative(s) and/or their inclusion complexes, at least one poly(carboxylic) acid and/or at least one poly(carboxylic) acid anhydride and optionally, a catalyst, then drying the impregnated fiber or impregnated fiber-based material.
This impregnation and drying allows better incorporation of the solid reactive mixture into the fibers or causes it to penetrate it into the fibers, which subsequently facilitates both the reaction fixing the cyclodextrin to the fiber and obtaining a uniform deposit or coat of the copolymer onto the fiber or the fibers of a fiber-based material.
In a preferred variation, the fiber or fiber-based material is dried at a temperature in the range 40° C. to 150° C., preferably 110° C. or substantially 110° C. before the heating operation proper, at a temperature in the range 150° C. to 220° C.
This prior drying step is particularly recommended in the case of natural fibers such as wool or cotton, to prevent their thermal degradation.
This prior drying is advantageously carried out to obtain a solid mixture incorporated into the fiber or the fibers of the fiber-based material treated using the process of the invention, this drying being that following impregnation by an aqueous solution as described above.
Heating proper is intended to permanently fix molecules of cyclodextrin(s) to the fiber or fiber-based material, by reaction between poly(carboxylic) acid and/or poly(carboxylic) acid anhydride and the fiber or fiber-based material (chemical grafting by covalent bonding between the fiber and the molecule of cyclodextrin or cyclodextrin derivative, or the copolymer of cyclodextrin(s) and poly(carboxylic) acid(s) and/or by reaction between the poly(carboxylic) acid and the cyclodextrin and/or cyclodextrin derivative(s) to form a cross-linked copolymer (mechanical grafting by coating).
Preferably, the poly(carboxylic) acid and poly(carboxylic) acid anhydride used in the process of the invention are selected from the following poly(carboxylic) acids and poly(carboxylic) acid anhydrides: saturated and unsaturated acyclic poly(carboxylic) acids, saturated and unsaturated cyclic poly(carboxylic) acids, aromatic poly(carboxylic) acids, hydroxypoly(carboxylic) acids, preferably selected from citric acid, poly(acrylic) acid, poly(methacrylic) acid, 1,2,3,4-butanetetracarboxylic acid, maleic acid, citraconic acid, itaconic acid, 1,2,3-propane-tricarboxylic acid, aconitic acid, all-cis-1,2,3,4-cyclopentanetetracarboxylic acid, mellitic acid, oxydisuccinic acid, and thiodisuccinic acid.
Preferably, the mixture contains a catalyst selected from dihydrogen phosphates, hydrogen phosphates, phosphates, hypophosphites, alkali metal phosphites, alkali metal salts of polyphosphoric acids, carbonates, bicarbonates, acetates, borates, alkali metal hydroxides, aliphatic amines and ammonia, preferably selected from sodium hydrogen phosphate, sodium dihydrogen phosphate and sodium hypophosphite.
Preferably, the cyclodextrin is selected from α-cyclodextrin, β-cyclodextrin and γ-cyclodextrin and the cyclodextrin derivatives are selected from hydroxypropyl, methyl or acetyl derivatives of α-cyclodextrin, β-cyclodextrin and γ-cyclodextrin and inclusion complexes formed from said cyclodextrins and said cyclodextrin derivatives.
The present invention also concerns fibers or fiber-based materials preferably obtained using the process described above, which are selected from fibers or fiber-based materials that comprise a hydroxyl function and/or an amine function and which are bonded, via a covalent bond of an ester or amide type, to at least one molecule of cyclodextrin or to an inclusion complex of cyclodextrin or to a linear and/or branched and/or cross-linked compound of cyclodextrin(s) and/or cyclodextrin derivative(s) and/or to an inclusion complex with at least one poly(carboxylic) acid and wherein the structure comprises the repetition of a unit with general formula:
where 2<y<x−2; x≧3 and
n is 1 or more, and in which:
[Cell] represents the macromolecular chain of a natural or artificial cellulose fiber;
[Ker] represents the macromolecular chain of a natural or artificial protein fiber;
represents the molecular chain of a poly(carboxylic) acid
where at least two carboxylic acid functions (COOH) y have undergone esterification and/or amidation and which comprises at least one carboxylic acid function (COOH) x-y that has not undergone an esterification or amidation reaction; and
[CD] represents the molecular structure of α-cyclodextrin, β-cyclodextrin γ-cyclodextrin, a derivative of cyclodextrin(s), preferably a hydroxypropyl, methyl or acetyl α-cyclodextrin, β-cyclodextrin or γ-cyclodextrin derivative, or an inclusion complex of said cyclodextrins or said cyclodextrin derivatives.
The —O—CO— ester bond originates from the reaction between the hydroxyl function of the cellulose fiber and the carboxylic function of the poly(carboxylic) acid, while the amide bond —NH—CO— originates from the reaction between the amine function of the keratinous fiber and the carboxylic function of the poly(carboxylic) acid. The poly(carboxylic) acid undergoes an esterification and/or amidation reaction of at least two of its carboxylic acid functions and the cyclodextrin or cyclodextrin derivative undergoes esterification with the poly(carboxylic) acid of at least one of its hydroxyl functions.
In the case of a fiber or a fiber-based material that does not react with poly(carboxylic) acids, the fiber or material obtained by the process of the invention is simply coated with a cross-linked copolymer of cyclodextrin(s) and poly(carboxylic) acid(s). In contrast, when the fiber or fiber-based material is based on cellulose and/or keratin or comprises hydroxyl and/or amine functions, the molecules of cyclodextrin(s) are fixed to the fiber or fiber-based material in accordance with the two fixing modes described above, namely direct fixation by covalent bonding to the fiber and coating of the fiber with a cross-linked copolymer.
The present invention accommodates these two types of fibers or materials, whether or not obtained by the process of the invention. The present invention concerns fibers or fiber-based materials onto which molecules of cyclodextrin(s) and/or cyclodextrin derivative(s) are fixed only by covalent bonding, fibers or fiber-based materials onto which molecules of cyclodextrin(s) and/or cyclodextrin derivative(s) are fixed by covalent bonding and by coating the fiber or fibers of the material with a cross-linked copolymer of cyclodextrin(s), and fibers or fiber-based materials onto which cyclodextrin is fixed solely by coating with a cross-linked copolymer, without limitation to the nature or structure of said fibers or said fiber-based materials.
The materials can, for example, be knitted, woven or nonwoven textiles containing cellulose and/or keratinous fibers and/or synthetic fibers. Such fibers or fiber-based materials comprising carboxylic acid functions possess excellent odor adsorption properties and, to a lesser extent, improved water absorption properties.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be better understood from the following non-limiting examples, which better illustrate the characteristics of the process of the invention and the fibers and fiber-based materials of the present invention.
Examples 1 to 11 illustrate the process of the present invention. Examples 12 and 13 illustrate the adsorbent properties of the materials of the present invention and their possible use, in particular for the production of mosquito-proof clothing and mosquito nets.
EXAMPLE 1
5 grams (g) of a bleached cotton fabric with a weight of 100 grams/meter 2 (g/m 2 ) was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 grams/liter (g/l)), citric acid (100 g/l) and sodium hydrogen phosphate [12-hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 18%.
EXAMPLE 2
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), citric acid (100 g/l) and sodium dihydrogen phosphate [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 3 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 13%.
EXAMPLE 3
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), citric acid (100 g/l) and sodium hypophosphite [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 12%.
EXAMPLE 4
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), 1,2,3,4-butanetetracarboxylic acid (100 g/l), and sodium dihydrogen phosphate [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 18%.
EXAMPLE 5
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), polyacrylic acid (100 g/l) and sodium hypophosphite [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 19%.
EXAMPLE 6
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing γ-cyclodextrin (150 g/l), 1,2,3,4-butanetetracarboxylic acid (100 g/l) and sodium hypophosphite [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 22%.
EXAMPLE 7
5 g of a bleached cotton fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing α-cyclodextrin (150 g/l), polyacrylic acid (100 g/l) and sodium hypophosphite [hydrate] (30 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 22%.
EXAMPLE 8
5 g of a wool fabric with a weight of 120 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (150 g/l), 1,2,3,4-butanetetracarboxylic acid (100 g/l), and sodium hypophosphite [hydrate] (60 g/l). The take-up was 100%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 195° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 20%.
EXAMPLE 9
5 g of a hydrolyzed polyester fabric with a weight of 130 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), citric acid (100 g/l), and sodium hydrogen phosphate [12-hydrate] (30 g/l). The take-up was 90%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 190° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 19%.
EXAMPLE 10
5 g of a polyester fabric with a weight of 100 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), citric acid (100 g/l), and sodium hydrogen phosphate [12-hydrate] (30 g/l). The take-up was 32%. The fabric was dried for 3 minutes at 90° C., then treated for 5 minutes at 190° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 6%.
EXAMPLE 11
5 g of a polyacrylonitrile knitted fabric with a weight of 300 g/m 2 was impregnated, with the aid of a mangle, with an aqueous solution containing β-cyclodextrin (100 g/l), citric acid (100 g/l) and sodium hydrogen phosphate [12-hydrate] (30 g/l). The take-up was 90%. The fabric was dried for 7 minutes at 90° C., then treated for 5 minutes at 180° C., washed with copious quantities of water and dried. The dry weight gain for the fabric was 8%.
EXAMPLE 12
This example illustrates the adsorbent properties of fabrics functionalized with β-cyclodextrin using the process of the invention. Cyclodextrins are known to be capable of forming inclusion complexes with phenolphthalein. Six samples of fabric functionalized with β-cyclodextrin using the process of the invention, with a known mass and containing different quantities of β-cyclodextrin were placed in solutions of phenolphthalein with known concentrations. The variation in the concentration of free phenolphthalein in each solution (A 0 –A 96 ) was measured by visible spectroscopy at 552.4 nanometers (nm) after 96 hours. The changes in phenolphthalein concentration, expressed as the variation in the optical density per gram of functionalized fabric, are shown in the table below:
Weight ratio of β-cyclodextrin
0
1.8
3.6
5.4
6.0
6.6
fixed to fabric (%)
A 0 –A 96 /g of fabric
0.5
1.3
1.8
2.2
2.4
2.6
The ratio of cyclodextrin fixed to the textiles was measured using the difference in dry weight gain between a fabric treated with a cyclodextrin/poly(carboxylic) acid/catalyst mixture and a fabric treated with a poly(carboxylic) acid/catalyst mixture.
EXAMPLE 13
This example illustrates the use of textile materials of the invention obtained by the process of the invention as textiles with mosquito repellent properties. Diethyltoluamide (DEET) is a well known, widely used synthetic mosquito repellent. Three samples of cotton fabric with a known weight functionalized with cyclodextrins and obtained using the process of the invention using citric acid, sodium hydrogen phosphate [12-hydrate] and α-, β- and γ-cyclodextrins were placed in solutions of DEET of known concentration. Adsorption of DEET onto the textile materials was determined by measuring the change in absorbance of the initial solution at 270 nm after 96 hours. The results are shown in the table below:
Type of
cyclodextrin
Weight gain after
used for
functionalization
A 0 –A 96 /g
Sample
functionalization
(%)
of fabric
1
α-cyclodextrin
14
0.24
2
β-cyclodextrin
15
0.36
3
γ-cyclodextrin
15
0.34
The samples cited above were successfully tested as mosquito-repellent textiles. The repellent properties of the fabrics were evaluated after impregnation with DEET and after the following treatments: aging by exposure to air for several weeks, irradiation using a UV lamp, raising the temperature, and washing with water. In some cases, the control based on cotton not functionalized with cyclodextrin, simply impregnated with DEET and which had undergone an identical treatment, had lost 100% of its effectiveness, while the fabrics of the present invention, which had been impregnated with DEET, retained 100% of their mosquito repellent activity.
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The present invention concerns a process for treating a fiber or a fiber-based material such as a yarn, a woven, knitted or nonwoven textile material, paper, or leather, to improve its adsorption properties, wherein the following successive operations are carried out on said fiber or said material:
a) applying a solid mixture of cyclodextrin(s) and/or cyclodextrin derivative(s) and/or inclusion complex(es) of cyclodextrin and/or cyclodextrin derivatives, at least one poly(carboxylic) acid and/or at least one poly(carboxylic) acid anhydride and optionally a catalyst; b) heating to a temperature in the range 150° C. to 220° C.; c) washing with water; and d) drying.
The present invention also concerns fibers or fiber-based materials with improved cation exchange properties and improved hydrophilic characteristics.
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FIELD OF THE INVENTION
This invention relates to novel amino acid derivatives useful as a therapeutic agent. More particularly, this invention relates to amino acid derivatives which have a human renin inhibitory effect when administered orally, and thus which are useful for treatment of hypertension, especially reninassociated hypertension.
BACKGROUND OF THE INVENTION
Renin is a proteolytic enzyme having a molecular weight of about 40,000, produced and secreted by juxtaglomerular cells in the kidney. This acts on the plasma renin substrate, angiotensinogen, to yield decapeptide angiotensin I which is converted into angiotensin II by an angiotensin I converting enzyme.
It is well known that angiotensin II contracts the vascular smooth muscle and acts on the adrenal cortex to secrete the aldosterone which regulates salts and water balance. Accordingly, the reninangiotensin system plays an important role in hypertension. An effective inhibitor of renin has long been sought as an agent for treatment of hypertension, especially renin-associated hypertension. As a result, it has been found that certain peptides show a renin inhibitory effect, as described in U.S. Pat. No. 4,548,926, Japanese patent application (OPI) Nos. 163899/85, 275257/86, 78795/86, 227851/84, 155345/84, 110661/84, (The term "OPI" as used herein refers to an unexamined Japanese patent application).; Japanese patent publication No. 39149/83, Biochemical and Biophysical Research Communications, Vol. 118, pages 929-933, 1984; and European patent application Nos. 77029(A 2 ), 77028(A 2 ) and 81783(A 2 ).
Of these prior art references, Japanese patent application (OPI) No. 163899/85 discloses peptides represented by the following formula: ##STR2## wherein R 1 CO represents an aliphatic acyl group, an aromatic acyl group, an aromatic aliphatic acyl group, a heterocyclic acyl group or a heterocyclic aliphatic acyl group, said acyl groups being able to have an amino group, a protected amino group, a hydroxy group, a substituted a dithio group, an alkyl group, an alkoxy group, an alkoxycarbonyl group, a halogen atom or a nitro group as a substituent;
R 2 represents an isobutyl group or a sec-butyl group;
X represents a group of formula ##STR3## in which R 3 represents a carboxyl group, and substituted carbamoyl group, a carbazoyl group, an N-substituted carbazoyl group or an acyl group, A represents a single bond or an alkylene group, Y represents a hydroxy group, a mercapto group or a formyl group, or a group of formula ##STR4## in which R 4 represents a substituted alkyl group having a carboxyl group, a protected carboxy group, an N-substituted carbamoyl group, a carbazoyl group, an N-substituted carbazoyl group or an acyl group as a substituent;
His represents an L-histidyl group;
and pharmaceutically acceptable salts and esters thereof.
Japanese patent application (OPI) No. 78795/86 also discloses optical isomers of peptides disclosed in Japanese patent application (OPI) No. 163899/85.
Japanese patent application (OPI) No. 275257/86 discloses peptides closely related to compounds of this invention. Although this reference does not specifically disclose, the compounds having following formula is included within the broad scope thereof: ##STR5## wherein R 5 represents an alkoxy group having 1 to 10 carbon atoms, a mono or di-alkylamino group having 1 to 10 carbon atoms or a heterocyclic group, said heterocyclic group being connected the carbonyl group in the formula with the nitrogen atom in said heterocyclic group, and pharmaceutically acceptable salts thereof.
However, this reference does not teach that compounds having a morpholinocarbonylmethyl group instead of the morpholinoethyl group exhibit an excellent renin inhibitory activity.
Furthermore, with regard to peptides related to those of this invention, the inventors of this invention also have filled some U.S. patent applications Ser. Nos. 789,597 (filed Oct. 21, 1985), 824,341 (filed Jan. 31, 1986), 852,260 (filed Apr. 15, 1986), now U.S. Pat. No. 4,656,269, 879,741 (filed June 27, 1986) and 903,803 (filed Sept. 14, 1986).
On the other hand, by someone of the present inventors and others, analogous peptides to those of this invention have been published in European Journal of Pharmacology Vol. 129, No. 3, 393-396, 1986, and have been reported in the 50th Annual Scientific Meeting of the Japanese Circulation Society, March, 1986, the 59th General Meeting of the Japanese Pharmacological Society, April, 1986, the 106th Annual Meeting of Pharmaceutical Society of Japan, April, 1986, the 37th Regional Meeting (Kita area) of the Japanese Pharmacological Society, August, 1986.
SUMMARY OF THE INVENTION
An object of this invention is to provide new amino acid derivatives which exhibit a specific inhibitory effect on renin when administered orally to mammalia including humans.
Another object of this invention is to provide new amino acid derivatives and pharmaceutically acceptable salts thereof.
A further object of this invention is to provide pharmaceutical compositions comprising new amino acid derivatives or pharmaceutically acceptable salts thereof.
A still further object of this invention is to provide methods for the treatment of hypertension using new amino acid derivatives or pharmaceutically acceptable salts thereof.
Other objects, features and advantages of this invention will be apparent from the following description of the invention.
The present invention provides new amino acid derivatives represented by formula (I): ##STR6## wherein His represents an L-histidyl group, X represents a straight or branched alkoxy group having 1 to 7 carbon atoms, a straight or branched alkylamino group having 1 to 7 carbon atoms, a cycloalkyloxy group having 3 to 7 carbon atoms, a morpholino group or said alkoxy group having one or more halogen atoms as substituents; or pharmaceutically acceptable salts thereof.
DETAILED DESCRIPTION OF THE INVENTION
The amino acid derivatives of formula (I) of this invention and pharmaceutically acceptable salts thereof exhibit an renin inhibitory activity in a human renin-sheep renin substrate system and human plasma renin activity. Furthermore, the amino acid derivatives of this invention are stable against proteolytic enzymes such as pepsin and chymotrypsins.
These findings demonstrate that the amino acid derivatives of formula (I) of this invention exhibit a human renin inhibitory effect when administered orally to mammalia, including humans, and thus are useful for treatment of hypertension, especially renin-associated hypertension.
The amino acid derivatives of formula (I) of this invention can be prepared according to well-known methods. That is, the amino acid derivatives of this invention represented by formula (I): ##STR7## wherein His and X have the same meanings as defined above, can be prepared by reacting a compound represented by formula (II): wherein (S) represents S-configuration, with a compound represented by formula (III): ##STR8## wherein X has the same meaning as defined above, or by reacting a compound representd by formula (IV): ##STR9## wherein (S) has the same meaning as defined above, with the compound of formula (III) above in the presence of a condensing agent.
The compounds of formulae (II) and (IV) as starting materials can be prepared by an analogous method to that described in Japanese patent application (OPI) 236770/86.
The compounds represented by formula (III) used as another starting material can be prepared in an analogous method to that described in the literature.
The compound represented by formula (III) can be prepared by hydrogenating N-(tert-butoxycarbonyl)-L-phenylalanine over rhodium on alumina powder, reducing the obtained N-(tert-butoxycarbonyl)-L-cyclohexylalanine in the presence of a reducing agent such as a borane compound, treating the obtained N-(tert-butoxycarbonyl)-L-cyclohexylalaninol with pyridine sulfur trioxide complex in dimethyl sulfoxide in the presence of triethylamine, reacting the obtained N-(tert-butoxycarbonyl)-L-cyclohexylalaninal with potassium cyanide, and hydrolyzing the resultant compound, and then esterifying or amidating the amino acid derivative obtained by conventional method.
The reaction of the compound represented by formula (II) and the compound of formula (III) can be carried out according to a usual manner.
That is, the amino acid derivative of formula (I) of this invention can be prepared by suspending the compound of formula (II) in N,N-dimethylformamide, passing hydrogen chloride in a proportion of from about 3 to about 5 molar amounts per mole of the compound of formula (II) into the suspension, adding isoamyl nitrite in a proportion of from about 1 to about 3 molar amounts per mole of the compound of formula (II) to the mixture, reacting the mixture for about 5 to about 30 minutes at about -20° C. to about -5° C., and adjusting a pH of the reaction mixture to about 8 to about 9 by addition of triethylamine. The mixture is added dropwise to a solution of the compound of formula (III) and triethylamine in an equimolar amount to the compound of formula (II) in N,N-dimethylformamide under ice-cooling, preferably -20° C. to 0° C., and the mixture is treated for about 5 to about 20 hours at 0° C. to room temperature. To the reaction mixture was added a 5% aqueous sodium bicarbonate solution, followed by extracting with ethyl acetate, evaporating the ethyl acetate layer, and then purifying the residue by preparative silica gel thin layer chromatography, silica gel flash column chromatography or high performance liquid chromatography.
The reaction of the compound represented by formula (III) and the compound represented by formula (IV) can also be preferably carried out by dissolving the compound represented by formula (IV) in N,N-dimethylformamide, adding 1-hydroxybenzotriazole and dicyclohexylcarbodiimide, and reacting the mixture for 10 to 20 hours at room temperature, and then treating the reaction mixture according to a usual manner to obtain the desired compound.
The amino acid derivatives represented by formula (I) of this invention contain four asymmetric carbon atoms including one in the L-histidine moiety, and therefore, various stereoisomers of the amino acid derivatives exist depending upon the configuration of each asymmetric carbon atoms. Although configurations of the asymmetric carbon atoms affect the renin inhibitory activity of the compound represented by formula (I), the configurations of the asymmetric carbon atoms other than that of the L-histidine moiety are not limited in this invention with respect to these isomers.
In the amino acid derivatives represented by formula (I), the configuration of the carbon atom on which the amino group is substituted in the moiety of the compound represented by formula (III) is preferably S-configuration, whereas the configuration of the carbon atom on which the hydroxy group is substituted in the above moiety affects the activity. R-configuration is preferable, but a mixture of S- and R-configuration can be employed.
The optically active starting materials used for preparation of those optically active compounds can be prepared by performing an optical resolution according to a usual manner or using an optically active compound.
The amino acid derivatives represented by formula (I) of this invention can be converted according to conventional methods into pharmaceutically acceptable salts thereof. Examples of such pharmaceutically acceptable salts include pharmaceutically acceptable inorganic or organic acid salts such as a hydrochloric acid salt, a sulfuric acid salt, a p-toluenesulfonic acid salt, an acetic acid salt, a citric acid salt, tartaric acid salt, a succinic acid salt, a fumaric acid salt and the like. These salts have a renin inhibitory effect as high as the corresponding compound having a free amino group and are stable against proteolytic enzymes, and thus they show the desired renin inhibitory effect even by oral administration.
The amino acid derivatives represented by formula (I) of the present invention possess a strong inhibitory effect on human renin, for example, the amino acid derivatives of formula (I) produce a 50% inhibition in human renin-sheep substrate system and in human high renin plasma at 3.7×10 -7 to 2.4×10 -9 and 2.6×10 -7 to 4.1×10 -9 molar concentrations, respectively, and reduce blood pressure of marmosets in a high renin state with a low toxicity, and thus are useful as a therapeutically active agent for treatment of hypertension, especially renin-associated hypertension.
The amino acid derivatives represented by formula (I) and the pharmaceutically acceptable salts thereof of this invention can be administered to mammalia, including humans, by oral, intravenous, intramuscular, or intrarectal administration, and for administration they can be formulated into pharmaceutical compositions together with conventional pharmaceutically acceptable carriers or excipients.
The amino acid derivatives and the pharmaceutically acceptable salts of the formula (I) of this invention can be administered in various dosage forms depending upon the intended therapy. Typical dosage forms which can be used are tablets, pills, powders, liquid preparations, suspensions, emulsions, granules, capslues, suppositories, and injectable preparations.
In molding the pharmaceutical compositions into a tablet form, a wide variety of conventional carriers known in the art can be used. Examples of suitable carriers are excipients such as glucose, lactose, starch, cacao butter, hardened vegetable oils, kaolin and talc, binders such as gum arabic powder, tragacanth powder, and ethanol, and disintegrants such as laminaria and agar. The tablets, if desired, can be coated into sugar coated tablets, gelatin-coated tablets, film-coated tablets, or tablets coated with two or more layers.
When the pharmaceutical composition is formulated into an injectable preparation, it is preferred that the resulting injectable solution and suspension are sterilized and rendered isotonic with respect to blood. In making the pharmaceutical composition in a form of solution or suspension, any diluents customarily used in the art can be employed. Examples of suitable diluents include water, ethyl alcohol, propylene glycol, polyoxyethylene sorbitol, and sorbitan esters. Sodium chloride, glucose or glycerol may be incorporated into such a liquid preparation in an amount sufficient to prepare an isotonic solution. The therapeutic agent may further contain ordinary dissolving aids, buffers, pain-alleviating agents, and preservatives, and optionally, coloring agents, fragrances, flavors, sweeteners, and other pharmacologically active agents which are known in the art.
The dosage of the amino acid derivatives of this invention may be in the range from about 5 mg to 5,000 mg per adult human by oral administration per day, or from about 1 mg to 1,000 mg per adult human by parenteral administration per day in multiple doses depending upon the type of disease, the severity of condition to be treated, and the like.
This invention is further illustrated in more detail by way of the following Examples, Reference Examples, Text Example. The melting points of the product obtained were uncorrected. The NMR spectra of the products were measured by JEOL's High Resolution NMR Spectrometer Type JNM-GX 270. The Mass spectra of the products were measured by JEOL's Mass Spectrometer Type JMS-DX 300 according to the FAB method. Thin layer chromatography was carried out using Merck's precoated plates silica gel 60 F 254 and column chromatography was carried out by employing Merck's Kiesel gel 60 (230-400 mesh). Thin layer chromatography was carried out by using a lower layer of a mixture of chloroform, methanol and water in a proportion of 8/3/1 (by volume) (mixture A) and mixture of chloroform and methanol in a proportion of 5/1 (by volume) (mixture B) as eluent, and an Rf 1 (mixture A) value and Rf 2 (mixture B) value were calculated.
REFERENCE EXAMPLE 1
2-(1-Naphthylmethyl)-3-(morpholinocarboyl)propionic acid
To a solution of 32.3 g of ethyl succinate and 29.0 g of 1-naphthaldehyde in 320 ml of absolute ethyl alcohol was added 10.7 g of a 50% sodium hydride (dispersion in mineral oil) with stirring under ice-cooling, and then the mixture was heated under reflux for 30 minutes. To the reaction mixture was added 230 ml of a 2N-aqueous sodium hydroxide soluiton, and then the mixture was heated under reflux for an hour. The reaction mixture was evaporated under reduced pressure, and to the residue was added water. The mixture was extracted with ethyl ether to remove neutral materials. The aqueous layer was acidified by adding concentrated hydrochloric acid, and then extracted with ethyl ether. The ethereal layer was washed with a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. Benzene was added to the residue, and the precipitated crystals were collected by filtration to obtain 26.5 g of 2-(1-naphthylmethylene)succinic acid as yellow crystals.
A mixture of 24.5 g of 2-(1-naphthylmethylene)succinic acid and 260 ml of acetic anhydride was heated at 60° C. for an hour, and then the reaction mixture was evaporated under reduced pressure. To the residue was added a mixture of benzene and hexane (1/1, by volume). The precipitated crystals were collected by filtration to obtain 16.0 g of 2-(1-naphthylmethylene)succinic anhydride as orange-yellow crystals.
The solution of 1.00 g of the 2-(1-naphthylmethylene)succinic anhydride and 0.37 g of morpholine in 31 ml of dry dichloromethane was stirred for 2 hours at room temperature. The reaction mixture was evaporated under reduced pressure, and the residue was triturated with a mixture of ethyl acetate, benzene and hexane (1/1/1 by volume) to obtain 1.10 g of 2-(1-naphthylmethylene)-3-(morpholinocarbonyl)propionic acid as colorless crystals.
A mixture of 1.00 g of the acid and 0.1 g of a 10% palladium charcoal in 40 ml of methyl alcohol was hydrogenated under atmospheric pressure. After filtration of the catalyst, the filtrate was evaporated under reduced pressure, and the residue was triturated with hexane to obtain 0.90 g of 2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionic acid as a white powder.
Rf 1 : 0.67
MS: MH + , 328
melting point: 64°-68° C.
IR (KBr): νco 1720, 1640 cm -1
NMR (CDCl 3 ) δ: 2.35-2.7(m, 2H), 3.05-3.85(m, 11H), 7.25-8.2(m, 7H)
REFERENCE EXAMPLE 2
N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine hydrazide
To a suspension of 0.89 g of 2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionic acid and 0.79 g of L-histidine methyl ester dihydrochloride in 23 ml of N,N-dimethylformamide were added 0.70 ml of diphenylphosphoryl azide and 1.50 ml of triethylamine with stirring under ice-cooling, and then the mixture was additionaly stirred for 16 hours. The reaction mixture was evaporated under reduced pressure, and to the residue was added a 5% aqueous sodium bicarbonate solution. The mixture was extracted with ethyl acetate, and the ethyl acetate layer was washed with water, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. To the residue was added diethyl ether, and the precipitate was collected by filtration to obtain 1.25 g of N-[2-(1-naphthylmethyl)-3 -(morpholinocarbonyl)propionyl]-L-histidine methyl ester as a white powder. To a soluiton of 0.98 g of the ester compound in 10 ml of methanol was added 0.52 g of hydrazide monohydrate, and then the mixture was stirred for 4 hours. The reaction mixture was evaporated under reduced pressure, and the residue was purified by silica gel column chromatography (eluent: chloroform/methanol=10/1 by volume) to obtain 0.23 g of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine hydrazide having an Rf 1 value of 0.49 as a white powder.
melting point: 115°-119° C.
Rf 1 : 0.49
MS: MH + , 479
IR (KBr): νco 1620 cm -1
REFERENCE EXAMPLE 3
(3S)-3-Amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester hydrochloride (2RS and 2R forms)
To a solution of 13.25 g of N-(tert-butoxycarbonyl)-L-phenylalanine in 25 ml of methanol was added 1.2 g of a 5% rhodium on alumina powder, and then mixture was hydrogenated under a pressure of 3.5 kg/cm 2 . After filtration of the catalyst, the filtrate was evaporated under reduced pressure to obtain 13.4 g of N-(tert-butoxycarbonyl)-L-cyclohexylalamine as a white powder.
A mixture of 2.71 g of N-(tert-butoxycarbonyl)-L-cyclohexylalanine in 5 ml of dry tetrahydrofuran was added dropwise to 20 ml of a 1M boron tetrahydrofuran solution keeping a temperature at 5° C. to 8° C. under an atmosphere of argon, and then the mixture was still stirred for 3 hours. The reaction mixture was adjusted to a pH of 4 by adding a 10% acetic acid methanol solution, and the mixture was evaporated under reduced pressure. To the residue was added diethyl ether, and the mixture was washed successively with an aqueous citric acid solution, an aqueous sodium bicarbonate solution and a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure to obtain 2.42 g of N-(tert-butoxycarbonyl)-L-cyclohexylalaninol.
A mixture of 2.4 g of N-(tert-butoxycarbonyl)-L-cyclohexylalaninol, 6.5 ml of dry triethyl amine, 3 ml of dry benzene and 6.6 ml of dry dimethyl sulfoxide was cooled to 15° C., and then 7.4 g of sulfur trioxide pyridine complex was added portionwise to the mixture keeping a temperature at 15° C. to 20° C. The mixture was still stirred for 10 minutes. The reaction mixture was poured into water, and the mixture was extracted with ethyl acetate. The ethyl acetate layer was washed successively with a saturated sodium bicarbonate aqueous solution and water, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure to obtain 2.9 g of N-(tert-butoxycarbonyl)-L-cyclohexylalaninal.
A solution of 2.9 of sodium sulfite in 20 ml of water was added to 2.9 g of N-(tert-butoxycarbonyl)-L-cyclohexylalaninal, and the mixture was stirred for 14 hours under ice-cooling. To the reaction mixture was added a solution of 1.82 g of potassium cyanide in 5 ml of water and 40 ml of ethyl acetate, and then the mixture was stirred for 4 hours at room temperature. The ethyl acetate layer was washed with a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. To the residue was added 21 ml of a 23% hydrochloric acid, and the mixture was heated under reflux for 12 hours to obtain the reaction mixture [A].
Method 1 (2RS form)
The reaction mixture [A] was washed with diethyl ether, and the aqueous layer was evaporated under reduced pressure to obtain 2.5 g of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid hydrochloride as a white powder.
Hydrogen chloride was passed into a solution of 100 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid hydrochloride in 12 ml of isopropyl alcohol with stirring under ice-cooling, and the mixture was heated under reflux for 2 hours. The reaction mixture was evaporated to dryness under reduced pressure, and the residue was purified by silica gel column chromatography (eluent: chloroform/methanol =15/1 by volume), and the eluate was acidified by adding hydrochloric acid. The mixture was evaporated to dryness under reduced pressure to obtain 108 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2hydroxybutyric acid isopropyl ester hydrochloride as a white powder.
IR (KBr): νco 1735 cm -1
NMR (D 2 O) δ:0.8-1.8(m, 19H), 3.6-3.8(m, 1H), 4.3-4.6(m, 1H), 5.0-5.2(m, 1H)
Method 2 (2R form)
The reaction mixture [A] was washed with toluene, and the aqueous layer was evaporated to about 30 ml under reduced pressure. The solution was allowed to stand overnight, and the precipitated crystals were collected by filtration and washed with toluene to obtain 1.0 g of (2R, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid hydrochloride as a white powder.
Hydrogen chloride was passed into a suspension of 1.0 g of (2R, 3S)-3-amino-4-cyclohexyl-2-hydroxy butyric acid hydrochloride in 10 ml of isopropyl alcohol with stirring under ice-cooling, and the mixture was heated under reflux for 2 hours. After evaporation of the reaction mixture, benzene was added to the residue and the mixture was evaporated under reduced pressure. The residue was dissolved in 10 ml of ethyl acetate and the precipitated crystals were collected by filtration to obtain 1.0 g of (2R, 3S)3-amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester hydrochloride as a white powder.
melting point: 113°-115° C.
IR (KBr): νco 1720 cm -1
MNR (D 2 O) δ:0.8-1.8(m, 19H), 3.6-3.8(m, 1H), 4.37(d, 1H, J=4.9Hz), 5.0-5.2(m, 1H)
REFERENCE EXAMPLE 4
(2RS, 3S)-3-Amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide hydrochloride
In a mixture of 10 ml of water and 10 ml of dioxane were dissolved 1.4 g of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid hydrochloride and 1.64 ml of triethylamine, and to the solution was added 3.2 g of di-tert-butyldicarbonate. The mixture was stirred for 16 hours at room temperature, and to the reaction mixture was added 20 ml of water. The mixture was extracted with diethyl ether to remove neutral materials. The aqueous layer was acidified by adding an aqueous citric acid solution, and then extracted with diethyl ether. The ethereal layer was washed with a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure to obtain 0.9 g of (2RS, 3S)-3-tert-butoxycarbonylamino-4-cyclohexyl-2-hydroxybutyric acid as a colorless oil.
To a solution of 400 mg of the butyric acid compound, 175 mg of isobutylamine hydrochloride, 270 mg of 1-hydroxybenzotiazole and 0.22 ml of triethylamine in 20 ml of ethyl acetate was added 300 mg of dicyclohexylcarbodiimide with stirring under ice-cooling, and then the mixture was still stirred for 16 hours. The reaction mixture was cooled, and filtered to remove insoluble materials. The filtrate was washed successively with an aqueous citric acid solution, a 5% aqueous sodium bicarbonate solution and a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure to obtain 595 mg of (2RS, 3S)-3-(tert-butoxycarbonyl)amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide.
To a solution of 590 mg of the amide compound in 10 ml of methyl alcohol was added 3.3 ml of a 2N-hydrochloric acid, and the mixture was heated under reflux for 2 hours. The reaction mixture was evaporated under reduced pressure to obtain 254 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide hydrochloride as a white powder.
IR (KBr): νco 1640 cm -1
NMR (D 2 O) δ: 0.8-2.0(m, 2H), 2.9-3.2(m, 2H), 3.5-3.7(m, 1H), 4.2-4.5(m, 1H)
REFERENCE EXAMPLE 5
N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine methyl ester
To a suspension of 0.89 g of 2-(1-naphthylmethyl)3-(morpholinocarbonyl)propionic acid and 0.79 g of L-histidine methyl ester dihydrochloride in 23 ml of N,N-dimethylformamide were added 0.70 ml of diphenylphosphoryl azide and 1.50 ml of triethylamine with stirring under ice-cooling, and then the mixture was additionaly stirred for 16 hours. The reaction mixture was evaporated under reduced pressure, and to the residue was added a 5% aqueous sodium bicarbonate solution. The mixture was extracted with ethyl acetate, and the ethyl acetate layer was washed with water, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. The residue was purified by silica gel column chromatography (eluent: chloroform/methanol=20/1, by volume) to obtain 0.25 g of N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine methyl ester having an Rf 2 value of 0.56 as a white powder.
Recrystallization of 0.25 g of the methyl ester from benzene was made to obtain 0.20 g of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine methyl ester containing one mole of benzene as colorless needles.
Rf 1 : 0.61
Rf 2 : 0.56
IR (KBr): νco 1755, 1630, 1610 cm -1
REFERENCE EXAMPLE 6
(2RS, 3S)-3-Amino-4-cyclohexyl-2-hydroxybutyric acid cyclopentyl ester hydrochloride
Hydrogen chloride was passed into a solution of 300 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid hydrochloride, which was prepared in Reference Example 2, in 5 ml of cyclopentyl alcohol with stirring under ice-cooling, and then the mixture was heated at 90° C. for 5 hours. The reaction mixture was evaporated under reduced pressure, and the residue was purified by silica gel column chromatography (eluent: chloroform/methanol=15/1 by volume). The eluate was acidified by adding hydrochloric acid, and then evaporated to dryness under reduced pressure to obtain 380 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2hydroxybutyric acid cyclopentyl ester hydrochloride as a white powder.
IR (KBr): νco 1730 cm -1
NMR (D 2 O) δ: 0.8-2.0(m, 21H), 3.6-4.0(m, 1H), 4.3-4.7(m, 1H), 5.2-5.4(m, 1H)
REFERENCE EXAMPLE 7
The following ester compounds were prepared in an analogous manner to that described in Reference Examples 2 and 6.
(2RS, 3S)-3-Amino-4-cyclohexyl-2-hydroybutyric acid cyclohexyl ester hydrochloride
Viscous colorless oil
IR (neat): νco 1730 cm -1
NMR (D 2 O) δ: 0.8-2.0(m, 23H), 3.5-4.0(m, 1H), 4.3-4.7(m, 1H), 4.8-5.0(m, 1H)
(2RS, 3S)-3-Amino-4-cyclohexyl-2-hydroxybutyric acid 1,3-difluoro-2-propyl ester
White powder
IR (KBr): νco 1735 cm -1
NMR (CDCl 3 ) δ: 0.8-2.0 (m, 13H), 3.3-3.9 (m, 1H), 4.1-5.0(m, 5H), 5.2-5.6(m, 1H)
REFERENCE EXAMPLE 8
4-[(2RS, 3S)-3-Amino-4-cyclohexyl-2-hydroxybutyryl]morpholine hydrochloride
To a solution of 200 mg of (2RS, 3S)-3-tertbutoxycarbonylamino-4-cyclohexyl-2-hydroxybutyric acid which was prepared in Reference Example 4, 0.06 ml of morpholine and 13 mg of 1-hydroxybenzotriazole in 6 ml of ethyl acetate was added 150 mg of dicyclohexylcarbodiimide with stirring under ice-cooling, and the mixture was stirred for 16 hours at room temperature. The reaction mixture was cooled, and filtered to remove insoluble materials. The filtrate was washed successively with an aqueous citric acid solution, a 5% aqueous sodium bicarbonate solution and a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure to obtain 296 mg of 4-[(2RS, 3S)-3-(tertbutoxycarbonyl)amino-4-cyclohexyl-2-hydroxybutyryl]morpholine.
To a solution of 290 mg of the amide compound in 5 ml of methyl alcohol was added 1.0 ml of a 2N-hydrochloric acid, and the mixture was heated under reflux for 3 hours. The reaction mixture was evaporated under reduced pressure to obtain 206 mg of 4-[(2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyryl]morpholine hydrochloride as a white powder.
IR (KBr): νco 1620 cm -1
NMR (D 2 O) δ: 0.8-1.9(m, 13H), 3.4-3.9(m, 9H), 4.4-4.7(m, 1H)
EXAMPLE 1
(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl)amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester (Compound A)
To a solution of 100 mg of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine hydrazide in 5 ml of N,N-dimethylformamide were added successively a solution of 0.12 ml of a 5.95N-dry hydrogen chloride in N,N-dimethylformamide and 0.043 ml of isoamyl nitrite at -20° C. with stirring. After disappearance of the hydrazide compound, the reaction mixture was cooled to -30° C., and then neutralized by adding 0.10 ml of triethylamine to prepare a solution of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine azide. The azide solution was added to a solution of 58 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester hydrochloride and 0.064 ml of triethylamine in 2 ml of N,N-dimethylformamide with stirring under ice-cooling, and then the mixture was still stirred for 16 hours. To the reaction mixture was added a 5% aqueous sodium bicarbonate solution, and the mixture was extracted with ethyl acetate. The ethyl acetate layer was washed with a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. The residue was purified by preparative silica gel thin layer chromatography (developing solvent: chloroform/methyl alcohol =5/1 by volume) to obtain 55 mg of (2RS, 3S)-3-{N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester having an Rf 2 value of 0.50 as a white powder.
melting point: 103°-106° C.
Rf 1 : 0.60
Rf 2 : 0.50
MS: MH + , 690
EXAMPLE 2
(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide (Compound B)
To a solution of 100 mg of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine methyl ester in 5 ml of methyl alcohol was added 0.42 ml of a 1N-aqueous sodium hydroxide solution with stirring under ice-cooling, and then the mixture was stirred for 16 hours at room temperature. The reaction mixture was evaporated under reduced pressure. The residue, 61 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide hydrochloride and 43 of 1-hydroxybenzotriazole were dissolved in 5 ml of N,N-dimethylformamide, and to the solution was added 48 mg of dicyclohexylcarbodiimide with stirring under ice-cooling. The mixture was stirred for 16 hours at room temperature. The reaction mixture was evaporated under reduced pressure, and to the residue was added a 5% aqueous sodium bicarbonate solution. The mixture was extracted with ethyl acetate, and the ethyl acetate layer was washed with a saturated sodium chloride aqueous solution, dried over anhydrous magnesium sulfate, and evaporated under reduced pressure. The residue was purified by preparative silica gel thin layer chromatography (developing solvent: chloroform/methyl alcohol=5/1 by volume) to obtain 6.5 mg of (2RS, 3S)-3-{N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxy-N-isobutylbutyramide as a white powder.
melting point: 119°-125° C.
Rf 1 : 0.54
Rf 2 : 0.41
MS: MH + , 703
EXAMPLE 3
(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl)amino-4-cyclohexyl-2-hydroxybutyric acid cyclopentyl ester (Compound C)
To a solution of 100 mg of N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidine methyl ester in 1 ml of methyl alcohol was added 0.20 ml of a 1N-aqueous sodium hydroxide solution with stirring under ice-cooling. The mixture was stirred for 1 hour under ice-cooling, and then stirred for 14 hours at room temperature. The reaction mixture was evaporated under reduced pressure. To a solution of the residue and 55 mg of (2RS, 3S)-3-amino-4-cyclohexyl-2-hydroxybutyric acid cyclopentyl ester hydrochloride in 2 ml of N,N-dimethylformamide were added 0.046 ml of diphenylphosphoryl azide and 0.030 ml of triethylamine with stirring under ice-cooling, and then the mixture was stirred for 14 hours under ice-cooling. The reaction mixture was evaporated under reduced pressure, and a 5% aqueous sodium bicarbonate solution was added to the residue. The mixture was extracted with ethyl acetate, and the ethyl acetate layer was washed with a saturated sodium chloride aqueous solution, dried over anhydous magnesium sulfate, and evaporated under reduced pressure. The residue was purified by preparative silica gel thin layer chromatography (developing solvent: chloroform/methyl alcohol =5/1, by volume) to obtain 41 mg of (2RS, 3S)-3-{N-[2-(1-naphthylmethyl)-3-(morpholinocarbonyl)propoionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyric acid cyclopentyl ester having an Rf 2 value of 0.58 as a white powder.
melting point: 95°-100° C.
Rf 1 : 0.59
Rf 2 : 0.58
MS: MH + , 716
EXAMPLE 4
The following compounds were prepared in an analogous manner to that described in Example 3.
(2R, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyric acid isopropyl ester (Compound D)
White powder
melting point: 99°-104° C.
Rf 1 : 0.60
Rf 2 : 0.50
MS: MH + , 690
(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyric acid cyclohexyl ester (Compound E)
White powder
melting point: 110°-115° C.
Rf 1 : 0.59
Rf 2 : 0.58
MS: MH + , 730
4-[(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyryl]morpholine (Compound F)
White powder
melting point: 118°-125° C.
Rf 1 : 0.57
Rf 2 : 0.51
MS: MH + , 717
(2RS, 3S)-3-{N-[2-(1-Naphthylmethyl)-3-(morpholinocarbonyl)propionyl]-L-histidyl}amino-4-cyclohexyl-2-hydroxybutyric acid 1,3-difluoro-2-propyl ester (Compound G)
White powder
melting point: 116°-122° C.
Rf 1 : 0.57
Rf 2 : 0.53
MS: MH + , 726
TEST EXAMPLE 1
Inhibitory effect on human renin-sheep renin substrate reaction system in vitro
To a mixture of 200 μl of a 125 mM pyrophosphate buffer (pH 7.4) containing 5 mM EDTA.2Na and a 0.1% neomycin sulfate, 25 μl of a 20 mM L-phenylalanyl-L-alanyl-L-proline as an angiotensin converting enzyme inhibitor, 50 μl of semipurified sheep renin substrate (2000 ng angiotensin I:eq./ml), 50 μl of dimethyl sulfoxide solution of an amino acid derivative of the present invention and 150 μl of deionized water was added 25 μl of purified human renin (20-30 ng angiotensin I/ml/hr). The mixture was incubated for 15 minutes on a water bath at 37° C., and the reaction mixture was allowed to stand for 5 minutes on a water bath at 100° C. to stop the reaction. After cooling, 200 μl of the solution was taken up and the amount of angiotensin I produced by the addition of renin was determined by radioimmunoassay using renin riabead kit (DAINABOT).
The inhibitory effect was calculated by the following equation.
As a control, the same procedure as above was carried out by using 50 μl of dimethyl sulfoxide alone in place of the 50 μl of dimethyl sulfoxide solution containing an amino acid compound of the present invention. ##EQU1##
The molar concentration producing a 50% inhibition (IC 50 ) was calculated from the inhibition values obtained, and the results are shown below.
______________________________________ IC.sub.50Compound molar concentration______________________________________A 6.5 × 10.sup.-9B 2.9 × 10.sup.-7C 2.5 × 10.sup.-9D 2.4 × 10.sup.-9E 6.6 × 10.sup.-9F 3.7 × 10.sup.-7G 2.9 × 10.sup.-9______________________________________
TEST EXAMPLE 2
Renin inhibitory effect in a human high renin plasma
A mixture of 350 μl of a 0.5 M phosphate buffer (pH 7.0) containing 14 mM EDTA.2Na and a 0.3% neomycin sulfate, 50 μl of a 20 mM L-phenylalanyl-L-alanyl-L-proline as an angiotensin converting enzyme inhibitor and 100 μl of dimethyl sulfoxide solution containing an amino acid derivative of the present invention was added to 500 μl of human high renin plasma. Two hundred μl of the mixture was placed on an ice bath, at 4° C., and remaining mixture (800 μl ) was incubated for 60 minutes at 37° C. on a water bath. Two hundred μl of the incubated remaining mixture was chilled immediately on an ice bath, and the amount (A) of angiotensin I produced was determined by radioimmunoassay using renin riabead kit (DAINABOT).
The amount (B) of angiotensin I in the mixture placed on an ice bath at 4° C. was also determined by radioimmunoassay.
As a control, the same procedure as above was carried out by using 100 μl of dimethyl sulfoxide alone in place of 100 μl of dimethyl sulfoxide solution containing an amino acid compound of the present invention.
The net amount was estimated as the difference between A and B.
The inhibitory effect was calculated by the following equation. ##EQU2##
The molar concentration producing a 50% inhibition (IC 50 ) was calculated from the inhibition values obtained, and the results are shown below.
______________________________________ IC.sub.50Compound (molar concentration)______________________________________A 1.0 × 10.sup.-8B 2.6 × 10.sup.-7C 6.8 × 10.sup.-9D 4.7 × 10.sup.-9E 3.0 × 10.sup.-8F 1.3 × 10.sup.-7G 4.1 × 10.sup.-9______________________________________
TEST EXAMPLE 3
Renin inhibitory effect in plasma on common marmoset
The experiment was carried out by using common marmoset as described in K. G. Hofbauer et al., Clinical and Experimental hypertension, Vol. A5, Nos. 7 & 8 (1983), pages 1237-1247.
Furosemide was administered orally three times to common marmoset having a lower salt diet at 15 mg per Kilogram per day every other day to create a high renin state. The experiment was carried out on the third day after the last furosemide dose.
Measurement
Conscious female and male marmosets weighing 335 to 375 g were placed into small restraining chair, and by using a catheter into the femoral artery, blood collecting was carried out at intervals of 20, 40, 60, 120, 180 and 300 minutes.
Collected blood samples were centrifuged at 1200 g for 15 minutes at 4° C. Two hundred μl of the plasma was taken up and incubated for 60 minutes at 37° C., and the plasma renin activity was measured by radioimmunoassay using renin riabead kit (DAINABOT).
Compound A of this invention was dissolved in dilute hydrochloric acid, and administered orally at single dose of 30 mg/kg using catheter.
The results obtained are shown below.
______________________________________ Inhibition percent of plasma renin Number of activity animals used______________________________________20 minutes after 68.2 3administration40 minutes after 88.1 3administration60 minutes after 87.1 3administration120 minutes after 88.8 3administration180 minutes after 79.6 3administration300 minutes after 53.4 2administration______________________________________
TEST EXAMPLE 4
Hypotensive effect in marmoset
The experiment was carried out by using common marmoset as described in K. G. Hofbauer et al., Clinical and Experimental Hypertension, Vol. A5, Nos. 7 & 8 (1983), pages 1237-1247.
Furosemide was administered orally three times to common marmoset at 15 mg per kilogram per day every other day to create a high renin state. Blood pressure of conscious marmoset was measured on the third day after the last furosemide dose.
Measurement of blood pressure
A conscious male marmoset weighing 460 g was placed into small restraining chair. Blood pressure was measured on the tail cuff method using pretismograph. Compound C was dissolved in dilute hydrochloric acid, and administered orally at 30 mg/kg by using a catheter. The result obtained is shown below.
______________________________________Time after administration Blood pressure(hours) (mmHg)______________________________________Control 89.30.5 78.01 73.32 66.03 71.05 71.87 71.7______________________________________
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Amino acid derivatives represented by formula ##STR1## wherein His represents an L-histidyl group, X represents a straight or branched alkoxy group having 1 to 7 carbon atoms, a straight or branched alkylamino group having 1 to 7 carbon atoms, a cycloalkyloxy group having 3 to 7 carbon atoms, a morpholino group, said alkoxy group having one or more halogen atoms as substituents; or a pharmaceutically acceptable salt, are useful in the treatment of hypertension.
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BACKGROUND OF THE INVENTION
The present invention relates to an improved locknut key construction and to a wrench-locknut key combination.
By way of background, there are in common use locknuts for securing an automotive wheel rim to an axle to prevent unauthorized removal therefrom. These locknuts have an endless curvilinear groove which receives a ridge of a mating key for tightening and loosening the locknut. Locknuts and keys of the foregoing type are disclosed in U.S. Pat. No. 3,241,408. In the past, precise manipulation was required to insert the curvilinear ridge of the key into its mating curvilinear groove in the locknut. In addition, a balanced force had to be applied to the locknut key to maintain the curvilinear ridge in good mating relationship with its associated groove, or the possibility existed that the two could lose contact. It is with overcoming the foregoing deficiencies of prior constructions that the present invention is concerned.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide an improved locknut key construction which centers the ridge on the locknut key relative to the locknut groove so that the two can be mated by merely turning the key relative to the locknut.
Another object of the present invention is to provide an improved locknut key having a shroud which fits over the locknut body during the mounting operation to not only center the ridge of the locknut key relative to the locknut groove but to also stabilize the locknut key on the locknut so that an uncentered turning force can be applied to the locknut.
Another object of the present invention is to provide an improved wrench-locknut key combination wherein the locknut key is secured to the wrench in an extremely simple and expedient manner.
Yet another object of the present invention is to provide an improved locknut key fabricated from a plurality of parts which can be assembled in an extremely simple and expedient manner. Other objects and attendant advantages of the present invention will readily be perceived hereafter.
The present invention relates to a locknut key construction comprising a key body having first and second key body ends and a central portion therebetween, nut means on said first key body end, a locknut shroud having first and second shroud ends, first mounting means mounting said first shroud end on said central portion, a key having first and second key ends, second mounting means mounting said first key end on said second key body end within said locknut shroud with said second shroud end extending beyond said second key end, and key means on said second key end.
The present invention also relates to a wrenchlocknut key combination comprising a wrench having a shank and a socket mounted thereon; a locknut key having an outer surface with a pair of spaced annular grooves therein; and a clip including a U-shaped spring member; mounting means mounting said clip on said shank with said U-shaped spring member in position to receive one of said annular grooves therein, a flexible tie member having first and second tie ends, first securing means for securing said first tie end to said clip, and second securing means for securing said second tie end in said second groove, said tie member being of a sufficient length so that said locknut key can be received in said socket after being demounted from said U-shaped spring member.
The various aspects of the present invention will be more fully understood when the following portions of the specification are read in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary exploded side elevational view partially in cross section showing the combination of an L-handle lug wrench with its associated locknut key and various types of locknuts which are shown relative to a wheel rim mounted on an axle-carried stud;
FIG. 1A is a cross sectional view taken substantially along line 1A--1A of FIG. 1;
FIG. 2 is a view taken substantially in the direction of arrows 2--2 of FIG. 1 and showing the configuration of the spring clip used to mount the locknut key on the handle of the L-handle wrench;
FIG. 3 is a side elevational view of the spring clip taken substantially in the direction of arrows 3--3 of FIG. 2;
FIG. 4 is a view taken substantially in the direction of arrows 4--4 of FIG. 1, and showing the key-receiving groove in the end of one type of locknut;
FIG. 5 is a view taken substantially in the direction of arrows 5--5 of FIG. 1 and showing the key-receiving groove in the end of another type of locknut;
FIG. 6 is an exploded view, partially in side elevation, and partially in cross section of the three components of the locknut key;
FIG. 7 is a view taken substantially in the direction of arrows 7--7 of FIG. 6 and showing the end of the key portion of the locknut key;
FIG. 8 is a side elevational view, partially in cross section, showing the locknut key in assembled relationship and mounted on the end of one type of locknut; and
FIG. 9 is a view similar to FIG. 8 and showing the locknut key mounted on the end of another type of locknut.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Locknuts, such as 10 and 11, may be threadably mounted on a stud, such as 12, which is carried by axle 13 of an automotive vehicle for mounting a wheel rim 14. The locknuts require a special key to thereby prevent unauthorized removal of rim 14. Locknuts of the foregoing general type are generally described in U.S. Pat. No. 3,241,408. In mounted position, the noses 15 and 17 of locknuts 10 and 11, respectively, bear against frustoconical annular portion 19 of rim 14. Locknuts 10 and 11 also include internally threaded portions 20 and 21, respectively, which thread onto threaded stud 12. Locknuts 10 and 11 include grooves 22 and 23, respectively, in their ends 24 and 25, respectively, for receiving a key of mating configuration to unscrew a nut from stud 12. It will be appreciated that either locknut 10 or locknut 11 can be mounted on the stud 12, and further that locknuts 10 and 11 are representative of numerous different types of locknuts which are used.
The improved locknut key 26 of the present invention enables locknuts, such as 10 and 11, to be removed by the use of an L-handle lug wrench 27 which has a shank 29 which includes a portion 30 which mounts a socket 31 having a hexagonal depression 32 therein. A prying tip 36, of the type used to pry a wheel cover from its associated rim, is located at the opposite end of shank 29. The reason an L-handle wrench 27 can be used is because the locknut key 26 provides an extremely stable connection between the head 31 of wrench 27 and a locknut, such as 10 and 11, so that there will be no slippage of locknut key 26 from mounted relationship on locknuts.
The locknut key 26 is an assembly of three component parts, namely, a key body 33, a locknut shroud 34 and a key 35. Locknut body 33 includes a central portion 37 having splines 39 which are received in bore 40 of locknut shroud 34 when the two are pressed together with a press-fit. In its assembled relationship with shroud 34, annular shoulder 41 of key body 33 bears against annular shoulder 42 of shroud 34. Key 35 has an end 43 with splines 44 thereon press-fitted into bore 45 at end 46 of key body 33. An annular shoulder 47 of key 35 bears against end 49 of key body 33. A ridge 50 of the configuration shown in FIG. 7 is formed at the end of key 35 for mating insertion into grooves, such as 22 and 23 of nuts 10 and 11, respectively. A base 51 is located within the confines of ridge 50 and when key 35 is in assembled relationship with the associated nut 10 or 11, islands 52 or 56, respectively, within grooves 22 or 23, respectively, of nuts 10 or 11, respectively, will be received within the irregular confines of ridge 50 and will sit firmly on base 51.
Key shroud 34 includes an internal cylindrical cavity 53 which receives either the outer surface 54 of nut 10 or the outer surface 58 of nut 11. As can be seen from FIG. 8, when locknut key 26 is used with nut 10, the internal cylindrical surface 53 fits closely over outer cylindrical surface 54 of nut 10. This centers locknut key 26 relative to locknut 10 so that the mere rotation of locknut key 26 relative to locknut 10 will result in ridge 50 falling into endless curvilinear groove 22. In other words, ridge 50 and groove 22 are on the same centerline, so that when locknut key shroud 34 is placed over locknut surface 54, the centers of ridge 50 and groove 22 are aligned. Furthermore, the closeness of the fit between internal cylindrical surface 53 of shroud 34 and cylindrical surface 54 of the locknut prevents ridge 50 from cocking out of engagement with groove 22. This is especially important when it is considered that when the hexagonal opening 32 of wrench socket 31 is placed over hexagonal nut 55 of locknut body 33 and an offcenter force is applied to wrench shank or handle 29, such an offcenter force will be incapable of moving ridge 50 out of groove 22 because of the bearing relationship between internal shroud surface 53 and external nut surface 54.
The same general relationship discussed above relative to FIG. 8 also applies between the internal cylindrical surface 53 of locknut key 26 and the external spherical surface 58 of locknut 11. In this respect, it can be seen that there is a bearing relationship between the closest portions of surfaces 53 and 58 for stabilizing locknut key 26 against cocking to the extent wherein there is a loss of engagement between ridge 50 and groove 23.
In order to prevent loss of locknut key 26, it is secured to and mounted on the shank of L-handle wrench 27 by a spring clip 57. More specifically, spring clip 57 is made of spring metal and it includes a coiled spring portion 59 which merges into a U-shaped clip portion 60. Coiled spring portion 59 is firmly mounted on shank 29 and is maintained in position thereon by the biasing force which it exerts. In order to mount coiled spring portion 59 on shank 29, it is forced to a more open condition by applying an opening force which opposes its normal biasing force and is slipped onto shank 29. When the opening force is removed, it will spring back to its original shape wherein it clamps itself onto shank 29. U-shaped portion 60 is normally of a slightly smaller diameter than annular groove 61 in key shroud 34. Therefore, the locknut key 26 can be mounted on spring clip 57 by forcing groove 61 into spring clip 57. The foregoing structure thus retains locknut key 26 in mounted position on shank 29 when wrench 27 is not being used.
In order to prevent the loss of locknut key 26 when it is demounted from spring clip 57, an elongated tie member 62 fastens them together. Tie member 62 is a metal cable having an end which fits through loop 63 at the end of coil spring portion 59. An enlarged member 64 is pressed onto the end of tie member 62 to prevent it from slipping out of loop 63. The opposite end of tie member 62 is formed into a loop 65 which is rotatably received in annular groove 67 of shroud 34 and a locking member 69 locks the loop in position. Thus, locknut key 26 is firmly tied to shank 29 both when it is received in U-shaped portion 60 and when it is removed therefrom to mount on a nut, such as 10 or 11. Tie member 62 is sufficiently long so that hexagonal cavity 32 of socket 31 can fit on hexagonal nut portion 55 of body member 33.
It can thus be seen that the improved locknut key construction and wrench-locknut key combination are manifestly capable of achieving the above enumerated objects and while preferred embodiments of the present invention have been disclosed, it will be appreciated that it is not limited thereto but may be otherwise embodied within the scope of the following claims.
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A locknut key including a key body, a key shroud mounted on the key body and a key member mounted on the key body within the shroud, the shroud extending for a substantial distance beyond the key to guide the key over the outer surface of a locknut which is to be turned by the key. A wrench-locknut key combination including a wrench having a shank, a U-shaped spring clip secured to the shank, a groove on the locknut key for receiving the U-shaped spring clip, and an elongated tie member for attaching the locknut key to the spring member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to semiconductor light-emitting devices such as semiconductor lasers, light-emitting diodes, etc. and in particular relates to semiconductor light-emitting devices having emission wavelengths in a range which includes the blue to ultra-violet region of the spectrum.
2. Description of the Prior Art
In recent years semiconductor lasers have been realized in practice, which utilize AlGaAs/GaAs III-V semiconductor materials. When a semiconductor laser is used in a data processing application such as data readout from an optical disc, or in a laser printer, it is desirable that the emission wavelength of the light produced from the semiconductor laser should be as short as possible, in order to maximize the data processing performance. However with semiconductor lasers that have been utilized hitherto, even if the activation layer of the laser is formed of a material such as AlGaInP, which has a large size of forbidden energy gap and is among the direct-transition type III-V semiconductor materials, it is only possible to achieve an emission wavelength that is in the range 580 to 690 nm. Thus, the emission wavelength cannot be made sufficiently short to reach the blue region of the visible spectrum. Another direct-transition type compound semiconductor material which has an even larger value of forbidden energy gap is Zn(SSe), which is a II-VI compound semiconductor. There is a possibility to achieve a semiconductor laser having a shorter wavelength of the emission light with the double-heterostructure. However, due to the difficulty encountered in controlling p-type conduction in this material, it has not been possible to utilize it practically to obtain emission in the blue to ultra-violet region of the spectrum up to the present.
On the other hand, the possibility of production of pn junction type light-emitting devices is known which is obtained by combining n-type II-VI compound semiconductor and p-type chalcopyrite type compound semiconductor. Sigurd Wagner; Journal of Applied Physics, Vol. 45, No. 1, January (1974) p246 and Satoshi Kobayashi et al.; Japanese Journal of Applied Physics, Vol. 30 NO. 10A, October (1991), pp. L1747, describe methods of production of hetero-junction diodes by combining II-VI compound semiconductor and chalcopyrite type compound semiconductor which are materials having a large size of forbidden energy gap. The former reported that a green light emission was obtained with combination of CdS-CuGaS 2 . The latter reports a green light emission with combination of ZnS-CuGaS 2 .
As mentioned above, there is a need for a capability for practical manufacture of semiconductor light-emission devices having wavelengths in a range which includes the blue to ultra-violet region of the spectrum. The inventor studied a lot of combinations of II-VI compound semiconductor and chalcopyrite type compound semiconductor. As result, the inventor found a new combination of II-VI compound semiconductors and chalcopyrite type compound semiconductors for providing wavelengths in a range which includes the blue to ultra-violet region of the spectrum.
SUMMARY OF THE INVENTION
The present invention has been developed in order to remove the above-described drawbacks inherent to the conventional semiconductor light-emitting device.
According to the present invention there is an LED (light-emitting diode) or a semiconductor laser as a semiconductor light-emitting device having emission wavelengths in a range which includes the blue to ultra-violet region of the spectrum.
According to the present invention there is provided an LED as the semiconductor light-emitting device comprises a substrate and an p-n junction structure formed on the substrate, the p-n junction structure having first and second chalcopyrite type semiconductor layers having a large size of forbidden energy gap, each consisting essentially of (Cu a Ag 1-a )(Al b Ga 1-b )(Se o S 1-o ) 2 , wherein 0≦a≦1, 0≦b≦1, and 0≦c≦1, the first semiconductor layer being doped with N, P, or As, the second semiconductor layer being doped with Zn, Cd, Cl, Br, or I. This LED having emission wavelengths in a range from 330 to 730 nm.
According to the present invention there is also provided a semiconductor laser comprises a substrate and a double-heterostructure formed on the substrate, the double-heterostructure having: a p-type semiconductor layer, an active layer comprising a semiconductor II-VI layer formed on the p-type semiconductor layer, and n-type semiconductor layer formed on the active layer, each of the p-type semiconductor layer and n-type semiconductor layer consisting essentially of (Cu a Ag 1-a )(Al b Ga 1-b )(Se o S 1-o ) 2 , wherein 0≦a≦1, 0≦b≦1, and 0≦c≦1, the active layer consisting essentially of (Zn d Cd 1-d )(Se m S n Te 1-m-n ), wherein 0≦d≦1, 0≦m≦1, 0≦n≦1, and m+n≦1. This semiconductor laser having emission wavelengths in a range from 380 to 690 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
The object and features of the present invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a cross-sectional view of the first embodiment of the present invention;
FIG. 2 is a cross-sectional view of the second embodiment of the present invention;
FIG. 3 is a cross-sectional view of the third embodiment of the present invention;
FIG. 4 is a cross-sectional view of the fourth embodiment of the present invention;
FIG. 5 is a cross-sectional view of a first modified embodiment;
FIG. 6 is a cross-sectional view of a second modified embodiment;
FIG. 7 is a cross-sectional view of a third modified embodiment; and
FIG. 8 is a cross-sectional view of a fourth modified embodiment.
The same or corresponding elements or parts are designated as like references throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
Hereinbelow will be described a first embodiment of this invention. FIG. 1 is a cross-sectional view of the first embodiment of the present invention, which is an light-emitting diode (LED) as a semiconductor light-emitting device. In FIG. 1, numeral 1 denotes a substrate which is formed of n-type GaAs. On the substrate 1, an n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2, which is a chalcopyrite semiconductor, having a substantially identical value of lattice constant to that of GaAs, that is, 5.653A is formed (lattice matching) by epitaxial growth. On the n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2, p-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3, which is a chalcopyrite semiconductor, also having a substantially identical value of lattice constant to that of GaAs, that is, 5.653A is formed by epitaxial growth. On the p-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3, an In-Ga electrode 4 is formed on the p-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3 as a p-type electrode on the opposite side of the n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2. On the substrate 1, an Au-Ge electrode 5 is formed on the opposite side of the n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2. Forbidden energy gap of these n-type and p-type layers are approximately 2.76 eV.
This LED is formed by the MBE (molecular beam epitaxy) method. That is, the n-type GaAs substrate 1 is heated to about 400° C. Then, the n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2 is formed by epitaxial growth to have a thickness of about 1 μm in the condition that a flux ratio of Se/Al is 2 and that of Cu/Al is 1, using Cu, Ag, Al, and Se as source materials. During this processing, Zn is doped into the (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2 at 10 18 /cm 3 to have n-type characteristic. Then, in the same growth condition, the (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3 is formed by epitaxial growth to have a thickness of about 1 μm using Cu, Ag, Al, and Se as source materials. During this processing, As is doped into the (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3 to form a p-type film having a carrier density up to 10 18 /cm 3 .
It has been found that when a current is passed through this LED having the above configuration to estimate a current to voltage characteristic, this LED emits blue light of 100 mcd stable at wavelength of 450 nm when the forward current is 20 mA.
Hereinbelow will be described a second embodiment of this invention. FIG. 2 is a cross-sectional view of the second embodiment of the present invention, which is a light emitting diode (LED) as a semiconductor light-emitting device. In FIG. 2, numeral 6 denotes a substrate which is formed of n-type GaP. On the substrate 6, an n-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 7, which is a chalcopyrite semiconductor, having a substantially identical value of lattice constant to that of GaP substrate 6, that is, a=5.449A is formed by epitaxial growth. On the n-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 7, a p-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 8, which is a chalcopyrite semiconductor, having a substantially identical value of lattice constant to that of GaP substrate 6, that is, a=5.449A is formed by epitaxial growth. On the p-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 8, the In-Ga electrode 4 is formed as a p-type electrode on the opposite side of the n-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 7. On the GaP substrate 6, an Au-Si electrode 9 is formed on the opposite side of the n-type layer (Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) 7.
Forbidden energy gaps of these n-type and p-type layers of the second embodiment are approximately 2.70 eV.
This LED is formed by the MBE method as similar to the first embodiment. That is, the n-type GaP substrate 6 is heated to about 400° C. Then, the n-type Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) 7 is formed by epitaxial growth at 400° C. to have a thickness of about 1 μm. During this processing, Zn is doped. Then, in the same growth condition, the Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 8 is formed by epitaxial growth to have a thickness of about 1 μm. During this processing, As is doped into the Cu(Al 0 .60 Ga 0 .40) (Se 0 .46 S 0 .54) layer 8 to have p-type characteristic.
It has been found that when a current is passed through this LED having the above configuration of the second embodiment to estimate a current to voltage characteristic, this LED emits blue light of 100 mcd stable at wavelength of 460 nm when the forward current is 20 mA.
Hereinbelow will be described a third embodiment of this invention. FIG. 3 is a cross-sectional view of the third embodiment of the present invention, which is a semiconductor laser as a semiconductor light-emitting device. In FIG. 3, on the n-type GaAs substrate 1, a double-heterostructure is provided with lattice matching. The double-heterostructure comprises: a (Zn 0 .66 Cd 0 .34) (Se 0 .5 S 0 .5) active layer 12; an n-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 10, which is a chalcopyrite semiconductor; and a p-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 11, one of chalcopyrite semiconductors. The (Zn 0 .66 Cd 0 .34) (Se 0 .5 S 0 .5) active layer 12 is sandwiched between the n-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 10 and the p-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 11. Forbidden energy gaps of these n-type and p-type layers are approximately 3.1 eV.
In the first and second embodiments, dopant levels of N, P, and As are 1×10 18 cm -3 . Among these dopants, As is most easily to be treated. Moreover, dopant levels of Zn, Cd, Cl, Br, and I are 1×10 18 cm -3 , 1×10 17 cm -3 , 1×10 18 cm -3 , 1×10 17 cm -3 , and 1×10 17 cm -3 respectively. Among these dopants, Zn and Cl are preferable and the LED doped with either or both these elements emits light brightest.
This semiconductor laser of the third embodiment is formed by the MBE method as similar to the first embodiment. That is, on the n-type GaAs substrate 1, the Zn-doped n-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 10 is formed with Zn-doping by epitaxial growth at 400° C. to have a thickness of 1 μm. Then, the (Zn 0 .66 Cd 0 .34) (Se 0 .5 S 0 .5) active layer 12 is formed by epitaxial growth at 300° C. to have a thickness of about 0.12 μm. Then, the p-type (Cu 0 .27 Ag 0 .73) (Al 0 .4 Ga 0 .6)S 2 layer 11 is formed with As-doping to have a thickness of about 1 μm by epitaxial growth at 400° C.
It has been found that when a current is passed through this light-emitting device having the above configuration to estimate a current to light output characteristic, this semiconductor laser emits blue light of 5 mW stable at wavelength of 430 nm when the forward current is 80 mA.
Hereinbelow will be described a fourth embodiment of this invention. FIG. 4 is a cross-sectional view of the fourth embodiment of the present invention, which is a semiconductor laser as a semiconductor light-emitting device. In FIG. 4, on an n-type InP substrate 13, a double-heterostructure is provided with lattice matching. The double-heterostructure comprises: a Zn(Se 0 .55 Te 0 .45) active layer 16; an n-type (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1) Se 2 layer 14, which is a chalcopyrite semiconductor; and a p-type (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1)Se 2 layer 15, which is a chalcopyrite semiconductor. The Zn(Se 0 .55 Te 0 .45) active layer 16 is sandwiched between the n-type (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1)Se 2 layer 14 and the p-type (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1)Se 2 layer 15. In FIG. 4, numeral 17 is an Au-Sn electrode as n-type electrode.
Forbidden energy gaps of these n-type and p-type layers except the active layer 16 are approximately 2.7 eV. A forbidden energy gap of the active layer 16 is about 2.5 eV.
This Semiconductor laser of the fourth embodiment is formed by the MBE method as similar to the first embodiment. That is, on the n-type InP substrate 13, the (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1)Se 2 layer 14 is formed with Zn-doping by epitaxial growth at 400° C. to have a thickness of 1 μm. Then, the Zn(Se 0 .55 Te 0 .45) active layer 16 is formed by epitaxial growth at 300° C. to have a thickness of about 0.12 μm. Then, the (Cu 0 .32 Ag 0 .68) (Al 0 .9 Ga 0 .1)Se 2 layer 15 is formed with As-doping to have a thickness of about 1 μm by epitaxial growth at 400° C.
It has been found that when a current is allow to flow through this light-emitting device having the above configuration in order to estimate a current to light output characteristic, this semiconductor laser emits blue light of 5 mW stable at wavelength of 500 nm when the forward current is 80 mA.
In the third and fourth embodiments, assuming the active layer 12 or 16 consists essentially of (Zn d Cd 1-d ) (Se m S n Te 1-m-n ), wherein 0≦d≦1, 0≦m≦1, 0≦n≦1, and m+n≦1, the preferred range of m+n is given by:
0.2≦m+n≦1.
This results from the possible range for lattice matching of the active layer 12 or active layer 16 with chalcopyrite type compound semiconductor. However, this is not absolute condition but only preferably condition.
In the embodiments mentioned above, As is used as a p-type dopant and Zn is used as an n-type dopant. However, the same production method is applicable when N, P, or Sb is used as a p-type dopant and Cd, Cl, Br, or I is used as an n-type dopant. In that case, a plurality of dopants can be used at the same time.
Moreover, in the embodiments mentioned above, since n-type substrates are used, the semiconductor layers extend from the substrate successively in the sequence n-type layer, active layer, p-type layer. However if a p-type substrate were to be used, of course the layers of the device would be successively arranged extending from the substrate in the sequence p-type layer, active layer, and n-type layer.
For example, such modified embodiment is shown in FIGS. 5 to 9. FIG. 5 is a cross-sectional view of a first modified embodiment showing an LED which corresponds to the first embodiment. Numeral 1' is a p-type GaAs substrate. The p-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3 is formed on the p-type substrate 1'. The n-type layer (Cu 0 .89 Ag 0 .11)AlSe 2 2 is formed on the p-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 3. The Au-Zn electrode 18 is formed on the p-type substrate 1'. The In-Ga electrode 4 is formed on the n-type (Cu 0 .89 Ag 0 .11)AlSe 2 layer 2. FIG. 6 is a cross-sectional view of a second modified embodiment which corresponds to the second embodiment. FIG. 7 is a cross-sectional view of a third modified embodiment which corresponds to the third embodiment. FIG. 8 is a cross-sectional view of a fourth modified embodiment which corresponds to the fourth embodiment. These second to fourth modified embodiments are effected on the basis of the similar technique to the modified embodiment shown in FIG. 5. Therefore, a detailed descriptions are omitted.
Moreover, in this invention, it would also be possible to form such a device having a buffer layer or to form such a device in a stripe pattern, to achieve current concentration (i.e. to form the electrodes as stripes, or the semiconductor layers). Further, various modifications can be considered without deviation from the subject matter of this invention.
It can be understood from the above that the present invention enables semiconductor light-emitting devices to be manufactured which provide emission wavelengths corresponding to the blue to ultra-violet region of the spectrum, which has not hitherto been possible. The main reason for this fact is considered that this invention enables p-type and n-type conduction control with good-property films obtained by formation of chalcopyrite compound semiconductor by the epitaxial growth on a high quality substrate such as GaAs, GaP, or InP. Therefore, this invention can increase the number of colors which can be used in display applications and improve performance of the optical disc or laser printer applications.
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A semiconductor light-emitting device, such as LEDs AND laser diodes having emission wavelengths in a range which includes the blue to ultra-violet region of the spectrum are disclosed. The LED comprises a substrate and an p-n junction structure formed on the substrate, the p-n junction structure having first and second semiconductor layers, each consisting essentially of (Cu a Ag 1-a )(Al b Ga 1-b )(Se o S 1-o ) 2 , wherein 0≦a≦1, 0≦b≦1, and 0≦c≦1, the first semiconductor layer being doped with N, P, or As, the second semiconductor layer being doped with Zn, Cd, Cl, Br, or I. A semiconductor laser comprises a substrate and a double-hetero structure formed on the substrate, the double-hetero structure having: a p-type semiconductor layer, an active layer formed on the p-type semiconductor layer, and n-type semiconductor layer formed on the active layer, each of the p-type semiconductor layer and n-type semiconductor layer consisting essentially of (Cu a Ag 1-a )(Al b Ga 1-b )(Se o S 1-o ) 2 , wherein 0≦a≦1, 0≦b≦1, and 0≦c≦1, the active layer consisting essentially of (Zn d Cd 1-d )(Se m S n Te 1-m-n ), wherein 0≦d≦1, 0≦m≦1, 0≦n≦1, and m+n≦1.
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CROSS-REFERENCE TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
This invention relates to a method of increasing the strength of a paper mat of fibers produced in a papermaking process. Paper mat comprises water and solids and is commonly 4 to 8% water. The solid portion of the paper mat includes fibers (typically cellulose based fibers) and can also include filler. Increasing the strength of the paper mat would allow one to increase the proportion of the solids that is filler content. This is desirable because it reduces raw materials costs, reduces energy needed in the papermaking process, and increases the optical properties of the paper. Prior Art discloses paper mat having a solid portion of between 10% and 40% filler. The Prior Art however also discloses that increasing the filler content coincides with a loss in strength in the resulting paper.
Fillers are mineral particles that are added to paper mat during the papermaking process to enhance the resulting paper's opacity and light reflecting properties. Some examples of fillers are described in U.S. Pat. No. 7,211,608. Fillers include inorganic and organic particle or pigments used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. Some examples of fillers include one or more of: kaolin clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, pigments such as calcium carbonate, and the like. Previous attempts to increase the filler content in paper without losing paper strength are described in British Patent GB 2016498, and U.S. Pat. Nos. 4,710,270, 4,181,567, 2,037,525, 7,211,608, and 6,190,663.
Calcium carbonate filler comes in two forms, GCC (ground calcium carbonate) and PCC (precipitated calcium carbonate). GCC is naturally occurring calcium carbonate rock and PCC is synthetically produced calcium carbonate. Because it has a greater specific surface area, PCC has greater light scattering abilities and provides better optical properties to the resulting paper. For the same reason however, PCC filled paper mat produces paper which is weaker than GCC filled paper.
Paper strength is a function of the number and the strength of the bonds formed between interweaved fibers of the paper mat. Filler particles with greater surface area are more likely to become engaged to those fibers and interfere with the number and strength of those bonds. Because of its greater surface area, PCC filler interferes with those bonds more than GCC.
As a result, papermakers are forced to make an undesirable tradeoff. They must either choose to select a paper with superior strength but inferior optical properties or they must select a paper with superior optical properties but inferior strength. Thus there is a clear need for a method of papermaking that facilitates a greater amount of filler in the paper, a paper that has a high opacity, and a filled paper that has a high degree of strength.
BRIEF SUMMARY OF THE INVENTION
At least one embodiment of the invention is directed towards a method of papermaking having an increased filler content that does not coincide with a loss in strength in the resulting paper. The method comprises the steps of: providing a blend of filler particles, at least one strength additive, and cellulose fiber stock; treating the filler particles with a composition of matter; combining the filler particles with the cellulose fiber stock; and forming a paper mat by removing some of the water from the combination. At least 10% of the filler particles are the precipitated form of calcium carbonate (PCC) and at least 10% of the filler particles are the ground form of calcium carbonate (GCC). The cellulose fiber stock comprises a plurality of cellulose fibers and water. The composition of matter inhibits the strength additive from adhering to the filler particles. In at least one embodiment, the cellulose fiber stock and the filler particles are combined to form a furnish and subsequently the filler particles are treated with the composition of matter.
At least one embodiment of the invention is directed towards a method in which the blend of filler particles further comprises one item selected from the list consisting of: calcium carbonate, organic pigment, inorganic pigment, clay, talc, titanium dioxide, alumina trihydrate, barium sulfate, magnesium hydroxide, and any combination thereof.
At least one embodiment of the invention is directed towards a method in which the composition of matter is an AcAm/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the strength additive is glyoxylated Acrylamide/DADMAC copolymer. At least one embodiment of the invention is directed towards a method in which the strength additive and the composition of matter carry the same charge.
At least one embodiment of the invention is directed towards a method in which the calcium carbonate is in one form selected from the list consisting of: dry calcium carbonate, dispersed slurry calcium carbonate, chalk, and any combination thereof. At least a portion of the calcium carbonate can be in a dispersed slurry calcium carbonate form, the dispersed slurry calcium carbonate further comprising at least one item selected from: polyacrylic acid polymer dispersants, sodium polyphosphate dispersants, Kaolin clay slurry, and any combination thereof. The blend of filler particles can be 50% GCC and 50% PCC. The composition of matter can be a coagulant and can be selected from the list consisting of: inorganic coagulants, organic coagulants, condensation polymerization coagulants, and any combination thereof. The coagulant can have a molecular weight range of between 200 and 1,000,000.
At least one embodiment of the invention is directed towards a method in which the composition of matter is a coagulant selected from the list consisting of alum, sodium aluminate, polyaluminum chlorides, aluminum chlorohydroxide, aluminum hydroxide chloride, polyaluminum hydroxychloride, sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, epichlorohydrin-dimethylamine (EPI-DMA), EPI-DMA ammonia crosslinked polymers, polymers of ethylene dichloride and ammonia, condensation polymers of multifunctional diethylenetriamine, condensation polymers of multifunctional tetraethylenepentamine, condensation polymers of multifunctional hexamethylenediamine condensation polymers of multifunctional ethylenedichloride, melamine polymers, formaldehyde resin polymers, cationically charged vinyl addition polymers, and any combination thereof.
At least one embodiment of the invention is directed towards a method in which the ratio of strength additive relative to the solid portion of the paper mat can be 0.3 to 5 kg of additive per ton of paper mat. At least some of the GCC particles can be treated with the composition of matter. At least one embodiment of the invention is directed towards a method in which none of the PCC particles are treated with the composition of matter. The strength additive can be a cationic starch. The filler particles can have a mass which is up to 50% of the combined mass of the solid portion of the paper mat. The strength additive and the composition of matter can carry the same charge.
At least one embodiment of the invention is directed to a composition of matter for use in a papermaking process. The composition of matter comprises: cellulose, filler particles, a strength additive, and a coating surrounding at least some of the filler particles. The coating is constructed and arranged to prevent the strength additive from adhering to the filler particles. In at least one embodiment, at least some of the filler particles are calcium carbonate. In at least one embodiment, the filler particles are GCC, PCC, or a combination of the two. In at least one embodiment, the filler particles comprise at least 10% PCC and 10% GCC.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
FIG. 1 is a graph showing the improved strength of paper made according to the invention.
FIG. 2 is a second graph showing the improved strength of paper made according to the invention.
FIG. 3 is a graph showing the Scott Bond strengths of paper blends made according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In at least one embodiment of the invention is a method of making paper which is strong, has a high filler content, has a high PCC content, and has superior optical properties. In at least one embodiment of the invention the method of papermaking comprises the steps of: creating a filler blend of PCC and GCC in which PCC comprises at least 10% by mass of the filler and GCC comprises at least 10% of the filler mass, pre-treating at least some of the filler particles with a coating that decreases the adhesion between a strength additive and the filler particles, and adding both the filler blend and the strength additive to the paper mat.
It has been known for some time that adding strength additives to paper mat increases the strength of the resulting paper. Some examples of strength additives are described in U.S. Pat. No. 4,605,702. Some examples of strength additives are cationic starches, which adhere to the cellulose fibers and tightly bind them together.
Unfortunately it is not practical to add large amounts of strength additives to compensate for the weakness that results from using large amounts of filler in paper mat. One reason is because strength additives are expensive and using large amounts of additives would result in production costs that are commercially non-viable. In addition, adding too much strength additive negatively affects the process of papermaking and inhibits the operability of various forms of papermaking equipment. As an example, in the context of cationic starch strength additives, the cationic starch retards the drainage and dewatering process, which drastically slows down the papermaking process.
Furthermore cellulose fibers can only adsorb a limited amount of strength additive. This imposes a limit on how much additive and therefore how much filler can be used. One reason why this is so is because strength additive tend to neutralize the anionic fiber/filler charges and when these charges are too neutralized further adsorption of strength additives is inhibited.
Unfortunately, adding filler to the paper mat also reduces the effectiveness of the strength additive. The strength additive has a tendency to coat the filler particles. The more filler particles present, the more strength additive coats the filler particles, and therefore there is less strength additive available to bind the cellulose fibers together. Because there is a maximum amount of strength additive that can be added, more filler has always meant less effective strength additive. This effect is more acute with PCC than GCC because PCC's higher surface area becomes more coated with strength additive than GCC.
In at least one embodiment of the invention at least some of the filler particles are pre-treated with a composition of matter to at least partially prevent the adherence of strength additive to the filler particles. The pre-treatment contemplates entirely coating some or all of one or more filler particles with the composition of matter. In the alternative, the pre-treatment contemplates applying the composition of matter to only a portion of one or more of the filler particles, or completely coating some filler particles and applying the composition of matter to only a portion of some other particles. In at least one embodiment the pre-treatment is performed with at least some of the compositions of matter described in U.S. Pat. No. 5,221,435 and in particular the cationic charge-biasing species described therein. In at least one embodiment the pre-treatment is performed with a diallyl-N,N-disubstituted ammonium halide-acrylamide copolymer described in U.S. Pat. No. 6,592,718.
While pre-treating filler particles is known in the art, prior art methods of pre-treating filler particles are not directed towards affecting the adhesion of the strength additive to the filler particles. In fact, many prior art pre-treatments increase the adhesion of the strength additive to the filler particles. For example, U.S. Pat. No. 7,211,608 describes a method of pre-treating filler particles with hydrophobic polymers. This pre-treatment however does nothing to the adhesion between the strength additive and the filler particles and merely repels water to counterbalance an excess of water absorbed by the strength additive. In contrast, the invention decreases the interactions between the strength additive and the filler particles and results in an unexpectedly huge increase in paper strength. This can best be appreciated by reference to FIG. 1 .
FIG. 1 plots tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper. As shown in FIG. 1 , the relationship between increasing filler content and decreasing paper strength is a linear relationship. This is because the reduced effectiveness of the strength additive is directly proportional to the increase in strength additive trapped against the filler particles. FIG. 1 also shows that for any given proportion of prior art filler to paper mat, if the filler is pure PCC it will often have a lower strength than if it is partially GCC. FIG. 1 also illustrates the unexpectedly high strength that paper made according to the inventive method possesses. In FIG. 1 , a sample of paper mat containing 32% by mass of filler which was 50% PCC and 50% GCC pre-treated with a strength additive-repelling coagulant produced a paper with a greater strength than that produced by a paper mat having only 20% pure GCC filler. This result is doubly unexpected because: a) a PCC containing filler is producing a greater strength paper than pure GCC filler does, and b) the more than 12% increase in allowable filler is extremely large. The high paper strength is a result of the GCC content reducing the interference between cellulose fiber bonds and the pre-treatment allowing the strength additive to achieve or come close to achieving the maximum paper strength.
At least some of the fillers encompassed by this invention are well known and commercially available. They include any inorganic or organic particle or pigment used to increase the opacity or brightness, reduce the porosity, or reduce the cost of the paper or paperboard sheet. The most common fillers are calcium carbonate and clay. However, talc, titanium dioxide, alumina trihydrate, barium sulfate, and magnesium hydroxide are also suitable fillers. Calcium carbonate includes ground calcium carbonate (GCC) in a dry or dispersed slurry form, chalk, precipitated calcium carbonate (PCC) of any morphology, and precipitated calcium carbonate in a dispersed slurry form. The dispersed slurry forms of GCC or PCC are typically produced using polyacrylic acid polymer dispersants or sodium polyphosphate dispersants. Each of these dispersants imparts a significant anionic charge to the calcium carbonate particles. Kaolin clay slurries also are dispersed using polyacrylic acid polymers or sodium polyphosphate.
In at least one embodiment, the treating composition of matter is any one of or combination of the compositions of matter described in U.S. Pat. No. 6,592,718. In particular, any of the AcAm/DADMAC copolymer compositions described in detail therein are suitable as the treating composition of matter. An example of an AcAm/DADMAC copolymer composition is product# Nalco-7527 from Nalco Company of Naperville, Ill. (hereinafter referred to as 7527).
The treating composition of matter can be a coagulant. The coagulants encompassed in this invention are well known and commercially available. They may be inorganic or organic. Representative inorganic coagulants include alum, sodium aluminate, polyaluminum chlorides or PACs (which are also known as aluminum chlorohydroxide, aluminum hydroxide chloride, and polyaluminum hydroxychloride), sulfated polyaluminum chlorides, polyaluminum silica sulfate, ferric sulfate, ferric chloride, and the like and blends thereof.
Some organic coagulants suitable as a treating composition of matter are formed by condensation polymerization. Examples of polymers of this type include epichlorohydrin-dimethylamine (EPI-DMA), and EPI-DMA ammonia crosslinked polymers.
Additional coagulants suitable as a treating composition of matter include polymers of ethylene dichloride and ammonia, or ethylene dichloride and dimethylamine, with or without the addition of ammonia, condensation polymers of multifunctional amines such as diethylenetriamine, tetraethylenepentamine, hexamethylenediamine and the like with ethylenedichloride and polymers made by condensation reactions such as melamine formaldehyde resins.
Additional coagulants suitable as a treating composition of matter include cationically charged vinyl addition polymers such as polymers, copolymers, and terpolymers of (meth)acrylamide, diallyl-N,N-disubstituted ammonium halide, dimethylaminoethyl methacrylate and its quaternary ammonium salts, dimethylaminoethyl acrylate and its quaternary ammonium salts, methacrylamidopropyltrimethylammonium chloride, diallylmethyl(beta-propionamido)ammonium chloride, (beta-methacryloyloxyethyl)trimethyl ammonium methylsulfate, quaternized polyvinyllactam, vinylamine, and acrylamide or methacrylamide that has been reacted to produce the Mannich or quaternary Mannich derivatives. Preferable quaternary ammonium salts may be produced using methyl chloride, dimethyl sulfate, or benzyl chloride. The terpolymers may include anionic monomers such as acrylic acid or 2-acrylamido 2-methylpropane sulfonic acid as long as the overall charge on the polymer is cationic. The molecular weights of these polymers, both vinyl addition and condensation, range from as low as several hundred to as high as several million. Preferably, the molecular weight range should be from about 20,000 to about 1,000,000. In at least one embodiment, the pre-treatment is preformed by a combination of one, some, or all of any of the compositions of matter described as suitable compositions of matter for pre-treating the filler particles.
In at least one embodiment, the strength additive carries the same charge as the composition of matter suitable for treating the filler particles. When the two carry the same charge, the filler additive is less likely to adsorb strength additives on its surface. In at least one embodiment, the strength additive is cationic starch. Strength additives encompassed by the invention include any one of the compositions of matter described in U.S. Pat. No. 4,605,702 and US Patent Application 2005/0161181 A1 and in particular the various glyoxylated Acrylamide/DADMAC copolymer compositions described therein. An example of a glyoxylated Acrylamide/DADMAC copolymer composition is product# Nalco 64170 (made by Nalco Company, Naperville, Ill.)
In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay. In at least one embodiment, the fillers used are PCC, GCC, and/or kaolin clay with polyacrylic acid polymer dispersants or their blends. The ratio of strength additive relative to solid paper mat can be 3 kg of additive per ton of paper mat.
The foregoing may be better understood by reference to the following example, which is presented for purposes of illustration and is not intended to limit the scope of the invention.
EXAMPLE 1
1(i) Filler Pre-Treatment
A blend of filler particles was obtained from a paper mill. The blend was a mixture of 50% PCC and 50% GCC. The PCC was un-dispersed Albacar HO (manufactured by Specialty Mineral of Bethlehem, Pa.), and the GCC (also manufactured by Specialty Mineral of Bethlehem, Pa.) was chemically dispersed. For purposes of this application, the definition of the term “un-dispersed” is distributed through a fluid without the aid of a chemical dispersant. For purposes of this application, the definition of the term “chemically dispersed” is distributed through a fluid with the aid of a chemical dispersant.
The filler blend was diluted to 18% solid content with tap water. 200 mL of the diluted filler blend was placed in a 500 mL glass beaker. Stirring was conducted for at least 30 seconds prior to the addition of coagulant. The stirrer was a EUROSTAR Digital overhead mixer with a R1342, 50 mm, four-blade propeller (both from IKA Works, Inc., Wilmington, N.C.). A coagulant solution was slowly added after the initial 30 seconds of mixing under stirring with 800 rpm. The coagulant solution used was 7527. The dose of coagulant was 1 kg/ton based on dry filler weight. Stirring continued at 800 rpm until all the coagulant was added. Then the stirring speed increased to 1500 rpm for one minute.
1(ii) Use of Filler
A thick stock of cellulose fibers was obtained from a paper mill. The stock was cooled and then diluted with clarified white water to a consistency of approximately 0.7%. The cellulose fibers were 60% hardwood bleached kraft pulp (HBKP), 20% softwood bleached kraft pulp (SBKP), and 20% bleached chemi-thermo mechanical pulp (BCTMP). Samples of various filler compositions indicated in FIG. 1 were added. Strength additive 64170 was also added. The tensile strength of paper made with each sample was then measured and plotted in FIG. 1 .
Strength analysis of the samples revealed the following: Replacement of pure PCC with 50% PCC and 50% GCC consistently allows for an approximately 3% increase in filler content without any loss of paper strength. However, the combination of a 50% PCC and 50% GCC filler with pretreatment of the GCC particles with the strength additive 64170 and repelling coagulant 7527 resulted in an allowance of an astounding 12% increase in filler content with no loss in paper strength. As a result, it is clear that the steps of the inventive method allow for more filler to be used in papermaking, more PCC to be used in papermaking, while improving the optical properties of the resulting paper.
EXAMPLE 2
The cellulose mixture and filler were provided as in Example 1. The filler was treated as in Example 1. 3 kg/ton strength additive 64170 was added to three samples, one containing 100% PCC, one containing 50% PCC-50% GCC, and one containing 50% PCC-50% GCC with the GCC pre-treated with 7527. The resulting paper samples were analyzed and results were shown in FIG. 2 , which plots tensile strength of a given paper versus the percentage of filler relative to the total solid portion of the paper mat used to produce the given paper.
When 3 kg/ton additive 64170 was added with 100% PCC, only 3% filler content could be increased without strength loss. At around 34% filler content, strength improved 12%. When 100% PCC was switched to 50% PCC-50% GCC, strength increased and it could allow a 3.5% filler content increase without losing sheet strength. When 3 kg/ton additive 64170 was added, about another 2.5% filler content could be increased without sacrificing sheet strength. At 35% filler content, sheet strength improved 14% with the addition of 3 kg/ton 64170. Compared with 50% PCC-50% GCC, 7527 pre-treated 50% PCC-50% GCC could increase 2% filler without losing strength. When add 3 kg/ton N-64170 to the furnish with pre-treated 50% PCC-50% GCC, the filler content could be increased by 4% without losing sheet strength compared with pre-treated 50% PCC-50% GCC only. At 36% filler content, addition of 3 kg/ton N-64170 increased the strength 19%. This experiment demonstrated that with the same amount of strength additive 64170, the efficiency of improving sheet strength was increased significantly by pre-treating the filler.
EXAMPLE 3
A machine trial was run in which a papermaking machine made 108 gsm coated base paper with machine speed of 1360 m/min. A composition was provided whose cellulose fibers were 40% Bleached Chemi-Thermo-Mechanical Pulp (BCTMP), 40% HBKP 40%, SBKP 20%. The furnish also contained a filler blend which was 70% PCC and 30% GCC. During the trial, all the wet end additives including retention aids, sizing agents, and cationic starches were kept constant. The resulting paper strength was measured using a Scott Bond tester.
FIG. 3 shows the resulting Scott Bond strengths of paper blends that included 8 blends that have various amounts of 7527 and 64170. When no 7527 and no 64170 were added, the strength was 0.92 kg cm. When 2.5 kg/ton of 64170 was added, the strength increased to 1.14 kg cm, a 24% strength improvement. Upon the further addition of 0.5 kg/ton of 7527 however the strength increased from 1.14 kg cm to 1.30 kg cm a further 14% improvement. This trial demonstrated that with addition of a small amount of coagulant, the efficiency of 64170 is greatly improved.
A person of ordinary skill in the art will recognize that all of the previously described methods are also applicable to paper mat comprising other non-cellulose based fibrous materials, paper mats comprising a mixture of cellulose based and non-cellulose based fibrous materials, and/or synthetic fibrous based materials.
Changes can be made in the composition, operation, and arrangement of the method of the invention described herein without departing from the concept and scope of the invention as defined in the claims. While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein. All patents, patent applications, and other cited materials mentioned anywhere in this application or in any cited patent, cited patent application, or other cited material are hereby incorporated by reference in their entirety.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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The invention provides a method of producing paper with a higher proportion of mineral filler particles than is otherwise be possible without the expected loss in paper strength. The method allows for the use of the greater amount of filler particles by coating at least some of the filler particles with a material that prevents the filler materials form adhering to a strength additive. The strength additive holds the cellulose fibers together tightly and is not wasted on the filler particles. The method is particularly effective when the filler particles are a PCC-GCC blend and when the GCC particles are coated with the adherence preventing coating.
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RELATED APPLICATIONS
The present application is a Continuation of allowed U.S. patent application Ser. No. 10/393,615 entitled COMPUTER NETWORK EQUIPMENT ENCLOSURE HAVING EXCHANGEABLE SECURING MECHANISMS filed Mar. 21, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/256,541 entitled LOCK ASSEMBLY HAVING SECURE ENGAGEMENT PLATE filed Sep. 26, 2002, now issued as U.S. Pat. No. 6,722,170, which claims priority to U.S. Provisional Patent Application Ser. No. 60/325,431 entitled LOCK ASSEMBLY HAVING SECURE ENGAGEMENT PLATE filed Sep. 26, 2001, the disclosures of which are herein incorporated by reference. A series of two related applications claiming priority to U.S. patent application Ser. No. 10/256,541, mentioned above, include a first Continuation, U.S. patent application Ser. No. 10/827,490, entitled LOCK ASSEMBLY HAVING SECURE ENGAGEMENT PLATE, filed Apr. 19, 2004, now issued as U.S. Pat. No. 7,024,896, and a further Continuation, U.S. patent application Ser. No. 11/284,512, entitled LOCK ASSEMBLY HAVING SECURE ENGAGEMENT PLATE, filed Nov. 22, 2005, now issued as U.S. Pat. No 7,225,650.
FIELD OF THE INVENTION
The present invention provides computer network equipment enclosures having a lock assembly including a mounting plate for securing the lock assembly to an enclosure door. The lock assembly is easily changed out by the owner when security needs require a different type of lock assembly. In preferred embodiments, the lock assembly includes components of an electronic lock, preferably including a Dallas™ chip, which enables the lock to monitor entry into the computer enclosure. The present invention also includes a plurality of gangable enclosures, linked together. In alternate embodiments, the enclosures can be co-location units, which may also be ganged together.
BACKGROUND OF THE INVENTION
Locks to limit access to enclosures are well known in the art as are locks which monitor access to enclosures. Such locks are manufactured by a number of companies, most prominently Sargent & Greenleaf Lock Manufacturer's, Inc., Nicholasville, Ky.; LaGard, Inc., Torrance, Calif. and Kaba Mas, Inc. of Lexington, Ky. These locks can limit access to the inside of an enclosure to individuals who have a specific entry code which they are required to enter when seeking access to the enclosure. The locks can also monitor and keep a record of which codes are used to obtain access to the enclosure and when such access is obtained. These types of locks are well known in the art.
Unfortunately, from time to time the lock may need to be serviced or the owner of an enclosure may wish to upgrade from one lock to another. The installation of such a lock is time consuming and often requires an owner to request service from an outside service provider. In addition, original equipment manufacturers (OEM's) are also generally looking to simplify installation so that costs for labor can be reduced, thereby reducing the overall cost to the consumer of using the OEM's lock.
In the Detailed Description of this application, a description is provided of an AUDITCON™ lock made by Kaba Mas, Inc., Lexington, Ky. The preferred embodiment of the present invention may include such a lock or such other lock that would provide similar security features.
In the past, Mas-Hamilton and other lock manufacturers have provided their locks to manufacturers of enclosures, preferably enclosures used to enclose banking equipment, computer servers and other sensitive electronic equipment, to which owners of such equipment wish to limit access and document all such access. The Mas-Hamilton locks of this type limit access by providing an electronic lock or latch mechanism and document access that is granted. It will be appreciated that installation requires a fair amount of skilled labor and care. In addition to the difficulty associated with securing the locks, a further concern is the security provided by the locks when they are attached to an enclosure door. It may be possible to strike such a lock from the outside of the enclosure, that the outer portion and the inner portion of the lock assembly are disengaged from the enclosure door, allowing the enclosure to fall open.
It will be appreciated from the foregoing, therefore, that prior art devices and methods of installing these devices present problems which are in need of solutions. It also will be appreciated that further enhancements of the security provided by such locks are needed. The present invention provides solutions for these and other problems.
SUMMARY OF THE INVENTION
An enclosure suitable for use to house computer equipment, such as, a data storage network, a telecommunications network or a data communications network is provided. The enclosure has at least four sides including a front side, a rear side, a first side and a second side opposite the first side and further includes a frame, the frame including upright supports suitable for mounting equipment for use in the data storage network, telecommunications network or data communications network. The enclosure further includes an interior space defined in part by the four sides; wherein at least one of the four sides includes an enclosure door and an side opening through which the interior space is accessible when the enclosure door is in a first unsecured or open position. The opening is capable of receiving a lock assembly, the opening is defined by opening edges; the enclosure further comprising a first lock assembly secured to the door so that the door can be releasably secured in a second secured closed position when the door is closed and access to the interior space through the enclosure door opening is prevented. The first lock assembly including a securing mechanism selected from the group consisting of a lock cylinder, an electronic lock, a quarter turn latch, a compression latch, a folding T latch, a lift and turn compression latch, a pawl/cam action latch, a multi-point latch system and a bolt for securing to a rotary latch secured to the enclosure; and a mounting plate having an interior surface and an exterior surface. The securing mechanism is secured to the interior surface; wherein the first lock assembly is secured within the opening of the enclosure door by at least one bracket secured to the interior surface of the mounting plate and effectively gripping at least one of the plurality of opening edges, so that the first lock assembly is effectively secured to the first enclosure door; wherein the first lock assembly is easily exchanged with a second lock assembly by disengaging the first lock assembly from the opening and inserting the second lock assembly into the opening and securing the second lock assembly within the opening of the enclosure door with at least one bracket secured to the interior surface of the mounting plate and effectively gripping at least one of the plurality of opening edges, so that the second lock assembly is effectively secured to the first enclosure door. The second lock assembly includes a securing mechanism selected from the group consisting of a lock cylinder, an electronic lock, a quarter turn latch, a compression latch, a folding T latch, a lift and turn compression latch, a pawl/cam action latch, a multi-point latch system and a bolt for securing to a rotary latch secured to the enclosure; and a mounting plate having an interior surface and an exterior surface; the securing mechanism being secured to the interior surface. In certain embodiments, the enclosure is a co-location enclosure or unit, having a plurality of enclosure doors to a plurality of communicating interior spaces. In alternate embodiments, the present invention includes a plurality of such enclosures, one or more of which may be a co-location unit.
In a preferred embodiment, the enclosure suitable for housing network equipment includes first and second enclosure doors, each of the enclosure doors having an opening capable of receiving a lock assembly, each enclosure door having a plurality of opening edges proximate the opening; the enclosure further including first and second lock assemblies secured to the first and second enclosure doors, respectively. The first and second lock assemblies each including a securing mechanism selected from the group consisting of a lock cylinder, an electronic lock, a quarter turn latch, a compression latch, a folding T latch, a lift and turn compression latch, a pawl/cam action latch, a multi-point latch system and a bolt for securing to a rotary latch secured to the enclosure; and a mounting plate having an interior surface and an exterior surface; each securing mechanism being secured to the respective interior surface; wherein the first and second lock assemblies are secured within the respective opening of the respective enclosure door by at least one bracket secured to the interior surface of the respective mounting plate and effectively gripping at least one of the opening edges, so that each lock assembly is effectively secured to each respective enclosure door.
The present invention also provides a method of securing a lock assembly to an enclosure door of a computer equipment enclosure. The method includes providing an enclosure having at least four sides including a front side, a rear side, a first side and a second side opposite the first side and further includes a frame, the frame including upright supports or devices suitable for mounting equipment for use in the data storage network, telecommunications network or data communications network. The enclosure further includes an interior space defined in part by the four sides; wherein at least one of the four sides includes an enclosure door and a side opening through which the interior space is accessible when the enclosure door is in a first unsecured or open position. The enclosure door has an opening capable of receiving a lock assembly, the opening is defined by a plurality of opening edges; the enclosure further comprising a first lock assembly secured to the enclosure door so that the enclosure door can be releasably secured in a second secured or closed position when the enclosure door is closed so that unauthorized access to the interior space through the side opening is prevented. The method further including providing an opening in the enclosure door, the opening having a plurality of edges proximate the opening; inserting a first lock assembly into and at least partially through the opening; the first lock assembly including a securing mechanism selected from the group consisting of a lock cylinder, an electronic lock, a quarter turn latch, a compression latch, a folding T latch, a lift and turn compression latch, a pawl/cam action latch, a multi-point latch system and a bolt for securing to a rotary latch secured to the enclosure; and a mounting plate having an interior surface and an exterior surface; the securing mechanism being secured to the interior surface; wherein the first lock assembly is secured within the opening of the enclosure door by at least one bracket secured to the interior surface of the mounting plate and effectively gripping at least one of the opening edges, so that the first lock assembly is effectively secured to the first enclosure door; disengaging the first lock assembly from the opening; inserting a second lock assembly into the opening; wherein the second lock assembly includes: a securing mechanism selected from the group consisting of a lock cylinder, an electronic lock, a quarter turn latch, a compression latch, a folding T latch, a lift and turn compression latch, a pawl/cam action latch, a multi-point latch system and a bolt for securing to a rotary latch secured to the enclosure; and a mounting plate having an interior surface and an exterior surface; the securing mechanism being secured to the interior surface; and securing the second lock assembly within the opening of the enclosure door with at least one bracket secured to the interior surface of the mounting plate and effectively gripping at least one of the plurality opening edges, so that the second lock assembly is effectively secured to the first enclosure door.
The present invention is alternately directed to an enclosure including an enclosure door having a lock assembly including a dial assembly or lock actuating mechanism and a lock bolt, securing mechanism or lock case assembly, which sandwich an engagement plate or a mounting plate to which each is secured to form the lock assembly. The mounting plate preferably includes a number of different functional parts which allow the respective assemblies to be secured to the mounting plate and also allow the mounting plate to permit the lock assembly to be secured within an opening within an enclosure door. The lock assembly is just one of a number of lock assemblies that can be substituted for one another with relative ease, giving the present invention a practical value to owners, that can easily substitute one lock assembly for another when the security requirements for an enclosure changes, requiring differing security parameters.
In one preferred embodiment, the mounting plate includes a plurality of drilled and tapped holes, a plurality of Standoffs and a plurality of securing studs. In the further preferred embodiment, a lock assembly for attachment to an enclosure door is provided, comprising: a lock case assembly including a bolt having at least first and second positions; a lock actuating mechanism interconnected with the lock case assembly such that the lock actuating mechanism can actuate a change in the position of the bolt from the first position to the second position; and a mounting plate having an interior surface and an exterior surface; the lock actuating mechanism being secured to the mounting plate on the exterior surface and the lock case assembly being secured to the mounting plate on the interior surface. The lock case assembly is preferably secured within an opening by at least one bracket secured to the interior surface of the mounting plate and effectively gripping an edge of an opening in the enclosure door.
In further preferred embodiments, the present invention provides an enclosure door having a lock assembly, including a mounting plate such as the mounting plate disclosed hereinabove, secured within an opening in the enclosure door.
In a further preferred embodiment, the present invention provides a method for securing a lock assembly to an enclosure door, the method including providing an opening in the enclosure door, inserting the lock assembly in the opening and securing the lock assembly to the enclosure door.
The lock assembly preferably includes a lock case assembly having a bolt that can be moved between at least two positions; a lock actuating mechanism interconnected with the lock case assembly such that the lock actuating mechanism can actuate a change in the position of the bolt from one position to the other; and a mounting plate having an interior surface and an exterior surface. The lock actuating mechanism is secured to the mounting plate on the exterior surface and the lock case assembly is secured to the mounting plate on the interior surface. The lock assembly itself is secured within the opening of the enclosure door by a bracket, preferably two such brackets, which are secured to the interior surface of the mounting plate and effectively grip an edge or preferably edges of the enclosure door proximate the opening so that the lock assembly is secured to the enclosure door.
It is an object of the present invention to provide an enclosure for computer equipment that allows secure access. In preferred embodiments, access will be monitored by electronic locks that record information regarding access to the interior space within the enclosure.
It is a further object to provide a series of lock assemblies including a standardized mounting plate for securing to a standardized opening in enclosure doors of the preferred enclosures. This allows a range of lock assemblies to be secured to each of the respective enclosure doors. In this way, the manufacturer may deliver the enclosure or enclosures to a purchaser with any type of lock assembly or with none at all. The purchaser may then determine which type of lock assembly is desirable to meet the purchaser's needs at any particular time. In this way, the enclosures have significant versatility and the type of lock assembly may be easily changed without the assistance of workers having mechanical skills other than relatively low-level assembly skills. It is envisioned that this versatility will provide significant cost savings to purchasers and greater satisfaction with the enclosures purchased in view of this projection cost savings. It will be appreciated that in certain situations simple lock assemblies may be suitable for a particular enclosure. In other situations, an electronic lock will be required. It will be appreciated that it is an object of the present invention to provide enclosures having easily interchangeable securing mechanisms.
It is a further object of the present invention to provide an enclosure having two enclosure doors, the first of which includes an electronic lock and the second of which is secured in a closed position by a simple latch that can be released from the interior space of the enclosure, once the enclosure door secured by the electronic lock is opened, thereby reducing the need for a more substantial or, perhaps, more expensive, securing assembly on the second enclosure door.
It will be appreciated that the enclosures of the present invention may have a variety of lock or securing assemblies, each having a mounting plate which has standard features to allow the respective securing lock assemblies to be secured to a standardized securing assembly opening in the enclosure door or doors. In certain embodiments, a number of gangable enclosures will be ganged together as a series of computer equipment enclosure devices. In other embodiments, the enclosure may be a co-location enclosure device having a series of communicating or non-communicating interior spaces secured by separate enclosure doors. It will be appreciated that these co-location enclosure units may also be gangable and secured together in a series of enclosure units.
It will be appreciated that the present lock assembly reduces the complexity of installation of locks of this type and reduces the expense associated with such installation and also reduces the amount of time and energy associated with such installation.
It is a further object of the present invention, to provide a lock assembly, which can be installed in a standard enclosure door in a straightforward and expeditious manner without disassembly of the securing assembly prior to installation. In the most preferred embodiment, the lock assembly is installed by placing the lock assembly within an opening provided in the enclosure door and securing the lock assembly to the enclosure door by placing at least one, preferably two, brackets over respective pairs of securing studs, securing the brackets to the respective securing studs with stud securing nuts which are tightened such that the brackets grip edges of the opening of the enclosure door.
It is a further object of the present invention to provide a simplified electronic securing assembly which is easy to install, easy to remove for repair or enhancement and easy to reinstall or replace.
It is a further object of the present invention to provide a system for enhanced security for enclosure doors by providing a mounting plate which secures the lock case assembly to the enclosure door even if the lock actuating mechanism is destroyed or disengaged from the mounting plate.
It is a further object of the present invention to provide a mounting plate which is specifically designed to secure the lock case or securing mechanism to the interior surface of the mounting plate while the enclosure door is secured to the interior side of the mounting plate as well, thereby enhancing the security provided by the mounting plate, as well as the present lock assembly.
It is a further object of the present invention to provide a kit including the mounting plate and other accessories, preferably brackets and a plurality of stud securing nuts for securing the mounting plate to an enclosure door having an opening suitable for mounting the present mounting plate.
The above-described features and advantages along with various other advantages and features of novelty are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and objects attained by its use, reference should be made to the drawings which form a further part hereof and to the accompanying descriptive matter, preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, in which like reference numerals refer to equivalent elements in a series of embodiments of the present invention:
FIG. 1 is a perspective view of a preferred lock assembly 2 of the present invention showing an exterior surface 9 a of a mounting plate 8 sandwiched between a lock actuating mechanism 4 and a lock case assembly 6 ;
FIG. 2 is a further perspective view of the lock assembly 2 shown in FIG. 1 , but showing an interior surface 9 b of the mounting plate 8 ;
FIG. 3 is an exploded perspective view of the lock assembly 2 shown in FIGS. 1 and 2 as it would come apart when secured within an opening 26 within an enclosure door 28 ;
FIG. 4 is a side plan view of the lock assembly shown in FIGS. 1 and 2 from the inside 29 of the enclosure door 28 showing the outline of the mounting plate 8 and the outline of the opening 26 at least partially in phantom;
FIG. 5 is a side elevation of the lock assembly 2 when engaged with the enclosure door 28 as seen from line 5 - 5 of FIG. 4 , showing the enclosure door 28 in a cross-section;
FIG. 6 is a partial cross-sectional view from the top of the lock assembly 2 shown in FIG. 4 as seen from the line 6 - 6 showing the enclosure door 28 and the mounting plate 8 in cross-section and wherein the lock actuating mechanism 4 and the lock case or bolt case assembly 6 are shown in phantom;
FIG. 7 is a to plan view of the mounting plate 8 showing the interior surface 9 b;
FIG. 8 is a right side elevation of the mounting plate 8 , shown in FIG. 7 , showing one of the two standoffs 46 in partial cross-section and the tapped hole in the other standoff 46 in phantom;
FIG. 9 is a perspective view of a vertical cabinet or enclosure 102 having an electronic lock assembly 2 of the kind shown in FIGS. 1-6 , and also showing the electronic lock assembly 2 secured to the front door 104 of the enclosure 102 in the manner shown in FIGS. 3-6 ;
FIG. 10 is a perspective view of the enclosure 102 shown in FIG. 9 , but showing both the front enclosure door 104 and the rear enclosure door 106 in unsecured open positions;
FIG. 11 is a perspective view of the enclosure 102 , showing the rear enclosure door 106 in an open position;
FIG. 12 is a view from the line 12 - 12 of FIG. 11 , but when the rear enclosure door 106 is in a secured or closed position; the figure showing a rotary latch assembly 114 secured to components of the enclosure 102 , shown in phantom, in such a manner that the rotary latch 115 grips a bolt assembly 116 to secure the rear enclosure door 106 (shown in phantom) in the secured or closed position as shown;
FIG. 13 is a view similar to that shown in FIG. 12 , except that the rear enclosure door 106 is open and slightly ajar and the bolt assembly 116 is not in contact with the rotary latch 115 ;
FIG. 14 is a side view of a release 126 of the rotary latch assembly 114 as seen from line 14 - 14 of FIG. 12 ;
FIG. 15 is a side view of an alternate release 126 ′ used in an alternate rotary latch assembly 126 ′ (not shown) that is the same as the rotary latch assemble 126 shown in FIGS. 12 and 13 , except for the alternate release 126 ′;
FIG. 16 is an exploded perspective view showing parts of the bolt assembly 116 , shown in FIGS. 12 and 13 and showing the interior surface 9 b ′ of the mounting plate 8 ′ and the interior surface 108 of the rear enclosure door 106 ;
FIG. 17 is an exploded perspective view showing parts of the bolt assembly shown in FIGS. 12 , 13 and 16 and showing the exterior surface 9 a ′ of the mounting plate 8 ′ and the exterior surface 109 of the rear enclosure door 106 ;
FIG. 18 is a perspective view of a first alternate locking T-handle assembly 2 ′ having a T-handle 158 ;
FIG. 19 is a front elevation of a second alternate locking L-handle assembly 2 ″ similar to the first alternate lock assembly 2 ′ except for the L-handle 159 in place of the T-handle 158 ;
FIG. 20 is a front elevation of a keyed compression lock assembly 2 ′″ having a mounting plate 8 ″″ generally the same as those shown in FIGS. 16-19 ; and
FIG. 21 is a front elevation of a keyed cam lock cylinder assembly 2 ″″ having a mounting plate 8 ′″″ generally the same as the mounting plates shown in FIGS. 16-20 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2 , the present invention preferably includes a lock assembly 2 including a dial assembly or lock actuating mechanism 4 , a lock case or bolt assembly 6 and a mounting plate 8 . The mounting plate has an exterior surface 9 a , shown primarily in FIG. 1 , and an interior surface 9 b , shown primarily in FIG. 2 .
Referring now also to FIG. 3 which provides an exploded view of parts of the preferred lock assembly 2 when secured to an enclosure door 28 , as shown in FIGS. 4 and 5 , to which reference is also made at this time.
The preferred lock assembly 2 shown in FIGS. 1-5 includes a mounting plate 8 having a center hole 10 through which a spindle 12 , extending from the lock case assembly 6 can extend to become engaged within the lock actuating mechanism. The preferred lock actuating mechanism 4 and lock case assembly 6 are respective parts of an AUDITCON™ lock available from Kaba Mas, Inc., Lexington, Ky., such as the series 50R, 52R, 100R, 200R, 400R, 500R and 2100R series AUDITCON™ locks.
Other locks may be substituted for the preferred lock. These locks include the V series, LP series, Vindication™ series, X08/X07 series, LC series and the like locks from Kaba Mas or Mas-Hamilton, the ComboGuard®, DelaGuard®, TimeDealy™, SafeGuard™, TwoBolt™, Privat®, SmartGuard™, DigiGuard®, LGAudit™, LGBasic™, LGCombo™, eCam®, MultiGuard™, VisionGuard™ and the like series from LeGard, and the Comptronic® 6120, 6121, 6123, 6124, 6125, 6140, 6150 and the like series from Sargent & Greenleaf, along with any other similar two, or more, component lock systems from these or other access lock or other lock manufacturers.
The preferred lock actuating mechanism 4 includes a keypad 14 , which allows the user to enter an access code which, once entered, will cause the lock actuating mechanism to actuate movement of a bolt 22 in the lock case assembly 6 by turning the spindle 12 . Mas-Hamilton also produces similar locks having a low profile housing (now shown) and a vertical lock housing (not shown). The Mas-Hamilton locks have two different modes of operation, an independent mode and a Supervisory/Subordinate mode. Within each operation mode, two access modes are available: Single User access and Dual User access. In Single User access, only one combination is required to open the lock. In Dual User access, two combinations must be correctly and consecutively entered to open the lock.
Independent mode—When operating in Independent mode, only one (Single User access) or two (Dual User access) combinations are required to open the lock. In Dual User access, either combination can be entered first. However, you should not turn the dial or press Clear between combination entries.
Supervisory/Subordinate mode (Super/Sub mode)—When operating in Super/Sub mode, a Supervisor must first enable lock access for Subordinate User(s) in order for them to be able to open the lock. In Single User access, two separate combinations are required to open the lock. A Supervisor combination followed by an assigned Supervisor ID must be entered first to enable lock access for a Subordinate User combination. The Subordinate User combination can be entered an unlimited number of times thereafter to open the lock. Once the Supervisor combination and the assigned Supervisor ID are re-entered to disable lock access for a Subordinate User, the Subordinate User combination will no longer open the lock.
In Dual User access, three separate combinations are required to open the lock. A Supervisor combination followed by an assigned Supervisor ID must be entered first to enable lock access for two Subordinate User combinations. The Subordinate User combinations can be entered an unlimited number of times thereafter (and in any order) to open the lock. Once the Supervisor combination and the assigned Supervisor ID are re-entered to disable lock access for the Subordinate User(s), these Subordinate User combinations will no longer open the lock.
There are four different types of classifications of personnel who can access the lock:
Master User—The Master User performs the initial lock setup activities. There is a maximum of one Master User per lock. The Master User combination will not open the lock.
Access User—In Independent mode, a user added by a Master User.
Supervisor—In Supervisory/Subordinate mode, a user added by the Master User and who has the ability to add/delete other Subordinate users. The maximum number of Supervisors per lock varies according to lock model. A Supervisor cannot open the lock.
Subordinate User—In Supervisor/Subordinate mode, a user who is added by and assigned to a Supervisor.
Referring now also to FIGS. 4 , 5 and 6 , the preferred lock assembly 2 includes a lock actuating mechanism for, a lock case or bolt assembly 6 and a mounting plate 8 as shown in FIGS. 1 and 2 , when fully assembled. When secured to an enclosure door 28 , as shown in FIGS. 4-6 , the interior side or surface 9 b of the mounting plate 8 is secured against an outer surface of the enclosure door 28 . In FIG. 6 , the tip of the bolt 22 is shown in phantom once in a first position, A, where the tip is extended out away from the lock case assembly housing 7 and a second position, B, in which the tip of the bolt 22 protrudes only slightly from the lock case assembly housing 7 . It is envisioned that the bolt 22 will engage a structure (not shown) associated with the enclosure (not shown) when the enclosure door 28 , preferably pivotally attached, is attached to the enclosure (not shown). In this way, the bolt 22 will provide a mechanism for engaging the enclosure structure (not shown) when it is in the first position in which the lock assembly 2 will engage the enclosure (not shown) to keep the enclosure door 28 in a secured and closed position (not shown).
Referring now also to FIGS. 7 and 8 , the mounting plate 8 of the present invention preferably has a shape similar to that shown in FIG. 7 . In alternate embodiments, the shape of the mounting plate may vary, and the position of the various openings, holes or attachments to the mounting plate may be varied as well in order to accommodate a variety of lock actuating assemblies, lock case assemblies and the like. The main feature of the mounting plate 8 , however, is that it will provide a plate having an exterior surface 9 a and an interior surface 9 b . The preferred mounting plate 8 includes four securing studs 42 attached to the interior surface 9 b . In the present application, the term “securing stud” means a protrusion extending away from the interior surface 9 b of the mounting plate 8 , to which a securing bracket 64 may be secured. These securing studs 42 can be threaded studs, welded or weld studs, PEM® studs or the like. A securing bracket 64 , such as the interior mounting plate securing bracket 64 , see FIGS. 4-6 , can be secured to the securing studs, but other well known fastening systems can also be used. In preferred embodiments, the securing studs are threaded such that they accept stud securing nuts which screw onto the securing studs 42 to secure a securing bracket 64 which can grip an edge 27 of the opening 26 in the enclosure door 28 . In a preferred embodiment, the securing studs 42 are PEM® studs from Pem Fastening Systems, Danboro, Pa. that are pressed into drilled or drilled and tapped holes, stamped holes, or the like. Alternatively, the securing studs 42 are spot welded onto the interior surface 9 b of the mounting plate 8 .
The mounting plate 8 also includes four T-nuts 46 or standoffs 46 having standoff receiving openings 44 in which standoff screws 52 , for securing the lock case assembly 6 , can be secured. In preferred embodiments, the lock assembly 2 includes a plurality of Standoff spacers 50 that are used to separate the lock case assembly 6 from the mounting plate 8 a sufficient distance to permit the standoff screw to bind the lock assembly standoff screws 52 to tightly secure the lock case assembly 6 to the mounting plate 8 . A washer 51 is also used to space the head 52 a of the screw 52 away from an upper surface 6 a of the lock assembly so that the standoff screw 52 effectively secures the lock assembly 6 to the mounting plate by engaging the threaded standoff receiving openings 44 in the standoffs 46 .
The mounting plate also includes the center hole 10 , which allows the spindle 12 to pass through the mounting plate 8 from the lock case assembly 6 to the lock actuating mechanism 4 . A wire harness 13 also passes through the mounting plate to connect the lock actuating mechanism 4 electronically with the lock case assembly 6 so that the act of entering a recognized code into the keypad 14 of the lock actuating mechanism is effective to permit the spindle 12 to turn within the lock case assembly 6 and move the bolt 22 from the first position 22 a to the second position 22 b (shown in FIG. 6 in phantom). The preferred mounting plate 8 also includes four drilled and tapped holes 47 which accept lock actuating mechanism securing screws 48 which secure the lock actuating mechanism 4 to the exterior surface 9 a of the mounting plate 8 .
The preferred electronic assembly 2 is assembled by displacing the keypad 14 from the lock actuating mechanism 4 in order to secure the remaining housing for A to the exterior surface 9 a of the mounting plate 8 . Lock actuating mechanism securing screws 52 or standoff screws 52 are used to secure the lock actuating mechanism housing 4 a to drilled and tapped holes 47 in the mounting plate. The keypad 14 is then secured to the lock actuating mechanism housing 4 a . The lock case or bolt assembly 6 is also secured to the mounting plate 8 using screws 52 . Four standoff screws 52 are used to secure the lock case assembly to the interior surface of the mounting plate.
The lock assembly 2 also includes two brackets 64 which can be secured to the interior surface 9 b of the mounting plate 8 by a plurality of stud securing nuts 68 which can secure the brackets 64 to the weld stud 42 in the manner shown in FIG. 2 .
To secure the lock assembly 2 to the enclosure door 28 , however, the brackets 64 are preferably disengaged from the securing studs 42 and engaged with the enclosure door 28 within the opening 26 . To secure the lock assembly 2 , within the opening 26 , the brackets 64 are placed over the securing studs 42 when the lock assembly 2 is in place in the enclosure door 28 within the opening 26 , thereby sandwiching edges 27 of the opening 26 between the mounting plate 8 and respective brackets 64 . Stud securing nuts 68 are used to secure the brackets against the edges 27 of the opening so as to grip the enclosure door 28 between the brackets 64 , respectively, and the mounting plate 8 .
In a preferred embodiment, the present invention provides a kit including a mounting plate 8 of the present invention and two brackets 64 . In preferred embodiments, the kit also includes stud securing nuts 68 , spacers 50 and standoff screws 52 .
In a further, preferred embodiment of the present invention, a method of securing the lock assembly 2 to an enclosure door 28 is provided, including the steps of creating an opening 26 in the enclosure door 28 ; placing the lock assembly 2 within the opening 26 in the enclosure door 28 ; and securing the lock assembly 2 within the opening by securing at least one bracket to the interior surface 9 b of the mounting plate 8 and sandwiching at least a portion of the enclosure door 28 between the bracket and the mounting plate 8 in such a manner that the lock assembly 2 is functionally secured to the enclosure door 28 .
The present lock assembly 2 has been designed to simplify the installation of a lock, preferably an AUDITCON™ lock available from Kaba Mas, Inc. Installation using the lock assembly 2 , requires providing a hole 26 in a door 28 to an enclosure (not shown), preferably a rectangular or square hole in certain embodiments, although the hole may vary in its configuration and size.
It is an object of the present invention to provide an assembly 2 which preferably includes components of a lock such as the AUDITCON™ lock for incorporation into an enclosure door 28 to limit access to an interior (not shown) of an enclosure (not shown). It is a further object of the present invention to provide a quickly attached assembly 2 for such use.
In order to install the preferred lock assembly 2 of the present invention in a computer enclosure (not shown), the enclosure door opening 26 is preferably provided in the enclosure door 28 . In preferred embodiments, the enclosure door opening 26 is a rectangular or, perhaps, square opening.
The lock assembly 2 is secured to the enclosure door 28 , within the enclosure door opening 26 by placing the lock assembly 2 within the enclosure door opening 26 and securing brackets 64 to the respective securing studs 42 using alternate stud securing nuts 68 , such as Nyloc nuts or the like. The preferred stud securing nuts 68 hold the brackets 64 against the enclosure door 28 at edges 27 of the enclosure door opening 26 to secure the lock assembly 2 to the enclosure door 28 . In the side view of the lock assembly 2 , shown in FIGS. 4-6 , the lock assembly 2 is shown secured to the enclosure door 28 .
The simplicity with which the preferred lock assembly 2 can be installed within a computer enclosure door 28 is discussed. In preparation for installation, an opening 26 is provided in the enclosure door 28 . The lock assembly 2 is then inserted into the opening 26 from the outside of an enclosure door 28 so that the lock case assembly 6 is inserted into the opening 26 and each of the securing studs 42 are placed within the opening 26 so that the mounting plate 8 abuts against the outside or exterior 30 of the enclosure door 28 . As shown in FIG. 3 , the brackets 64 are then placed on the securing studs 42 , thereby sandwiching the edges 27 of the opening 26 between the brackets 64 , respectively, and the mounting plate 8 . Once the brackets 64 are placed on the respective securing studs 42 , stud securing nuts 68 are screwed onto the securing studs 42 to secure the lock assembly 2 to the enclosure door 58 as shown in FIGS. 4-6 . The stud securing nuts may be tightened using an appropriate tightening tool not shown.
Although the preferred electronic lock of the present invention is an AUDITCON™ lock in the R series, AUDITCON™ locks having a low profile housing (LP) or a vertical lock housing (V) are also encompassed by the present invention. Furthermore, a number of different electronic locks may also be substituted for the AUDITCON™ locks including any of the electronic locks mentioned above, which are presently available in the industry, and any other similar locks. If necessary, minor modifications to accommodate attachment of the lock actuating mechanism and the lock case assembly for these alternate electronic locks may be made without departing from the scope of the present invention.
In preferred embodiments, the lock assembly 2 is both mechanically and electronically interconnected with the lock case assembly. The lock actuating mechanism 4 includes a code receiving mechanism 14 for entering access codes and an actuating member 16 operatively connected with the lock case assembly 6 . The code receiving mechanism is electronically connected with the lock case assembly 6 such that the lock case assembly 6 can function, in response to an electronic signal from the lock actuating mechanism 4 resulting from entering a predetermined access code into the code receiving mechanism 14 , in a manner permitting the position of the bolt 22 to be changed from the first position to the second position by separately mechanically actuating the change of position of the bolt 22 from the first position to the second position by using physical force to change the position of the actuation member 16 .
There are other two component locks systems that operate somewhat differently from the lock of the preferred embodiment. In an alternate embodiment (not shown), the alternate lock includes a bolt is spring biased such that the bolt is biased toward the first position, the lock actuating mechanism is electronically interconnected with the lock case assembly and the lock actuating mechanism includes a code receiving mechanism for entering access codes, wherein the code receiving mechanism is electronically connected with the lock case assembly such that the lock case assembly can function, in response to an electronic signal from the lock actuating mechanism resulting from entering a predetermined access code into the code receiving mechanism, in a manner permitting the bolt to be depressed from the first position such that it can be depressed sufficiently to be in the second position.
In a further alternate embodiment (not shown), the alternate lock includes a lock actuating mechanism which is electronically interconnected with the lock case assembly, the lock actuating mechanism includes a code receiving mechanism for entering access codes and the code receiving mechanism is electronically connected with the lock case assembly such that the lock case assembly can function, in response to an electronic signal from the lock actuating mechanism resulting from entering a predetermined access code into the code receiving mechanism, to change the position of the bolt from the first position to the second position by separately mechanically actuating the change of position of the bolt.
Referring now also to FIGS. 9 and 10 , the present invention also includes an enclosure 102 having a plurality of enclosure doors 104 , 106 . In FIG. 9 , the front or first door 104 is secured in a closed position by an electronic lock assembly 2 of the type previously described. The enclosures 102 of the present invention include enclosures of the kind disclosed in U.S. Pat. Nos. 6,515,225 and 6,185,098, the disclosures of which are incorporated by reference.
Referring now also to FIGS. 11-14 , the lock assembly 2 includes a lock bolt assembly 6 secured to an interior surface 107 of the front enclosure door 104 . The enclosure 102 includes a rotary latch assembly 114 . As shown in FIG. 12 , the rotary latch assembly 114 includes a rotary latch 115 in both assembly 116 secured to an alternate mounting plate 8 ′ and a door release 126 that is interconnected with the rotary latch 115 by an actuating cable 134 . The rotary latch assembly is preferably an Eberhardt rotary latch assembly available from Eberhardt Manufacturing Company, Strongsville, Ohio 44149. The preferred door release 126 includes a pivoting release member 128 interconnected with an elongated wire 129 extending through the actuating cable 134 . The wire 129 is interconnected with an actuating arm 139 of the rotary latch 115 and the actuating cable 134 is separately connected to a cable securing member 138 attached to a rotary latch mounting plate 136 . The rotary latch 115 includes a U-shaped catch member 137 that rotates about a bolt 131 when the rotary latch actuating arm 139 is actuated. The bolt assembly 116 includes an L-shaped member 140 secured to the alternate mounting plate 8 ′. A bolt 142 is secured to the L-shaped member 140 and the bolt assembly 116 is secured to the rear or second enclosure door 106 in a manner similar to the way the electronic lock assembly 2 is secured to the front enclosure door 104 . Referring now also to FIGS. 16 and 17 , to secure the bolt assembly 116 to the rear enclosure door 106 , the mounting plate 8 ′ is secured within an opening 120 in the rear enclosure door. The pivoting catch 137 will receive the bolt 142 when the enclosure door 106 is pushed into a closed position as illustrated in FIG. 12 . The cable 134 is secured to the door release 126 and the rotary latch mounting plate 136 in a manner which permits the release member 128 to place leverage upon the elongated wire when the release member 128 is pivoted upward as shown by the arrow in FIG. 14 , thereby placing downward force on the rotary latch actuating arm 139 that will rotate the U-shaped catch member 137 to release the bolt 142 when the release member 128 is raised to actuate the rotary latch 115 and allow the rear enclosure door 106 to be opened when the bolt 142 is released by the pivoting U-shaped latch 137 .
In alternate embodiments, an alternate door release 126 ′ (see FIG. 15 ) may be used in connection with the rotary latch 115 . It will be appreciated, however, that any commonly used door release may be used in the present invention and any commonly used latch mechanism may be employed to secure the rear door. Some of these various latches are disclosed herein below.
It will also be appreciated that the enclosure may have other types of securing mechanism associated with the rear door 106 in alternate embodiments. A number of these securing mechanisms are also disclosed below. In each case, however, the securing mechanism will include a mounting plate of the type described above so that the various securing mechanisms may be interchanged without significant difficulty.
It will be appreciated that an alternate bolt assembly (not shown) where an alternate universal or standard mounting plate to which a further L-shaped bracket is attached, can be secured to the left side of the enclosure 102 when facing the rear enclosure door 106 . In this alternate embodiment (not shown), the L-shaped bracket is secured to the alternate mounting plate when turned the opposite direction from that shown in FIGS. 16 and 17 , so that a further alternate universal mounting plate assembly (not shown) can be assembled for attachment to a right side of the enclosure 102 when facing the rear enclosure door 106 .
The lock assemblies of the present inventions will preferably combine a mounting plate with components of each of the following types of latches, handles and locks:
Compression Latches such as:
Folding T Handle Compression Latch; Lift and Turn Flush Compression Latch; Lift and Turn Handle Compression Latch; Lever Compression Latch; Vise Action Compression Latch; and Multi-point Compression Latch and the like;
Handles such as:
Locking Pawl/Cam Action L-Handle; Non-Locking Pawl/Cam Action L-Handle; Locking L Handle; Non-Locking T Handle; Padlockable L Handle; Tool-Operated L Handle; Locking Push-Button L Handle; Non-Locking Push Button L Handle; D-Ring Handle; Locking D-Ring Handle; Grab Handle; Pull Handle; Finger Pull Handle; Pocket Pull Handle, Flush Mount; Concealed Pull Handle; Recessed Swing Handle; Quarter Turn Handle; Slam Action Handle and the like;
Pawl/Cam Action Latches such as:
Lever Quarter-Turn Latch; Quarter-Turn Latch; Key-Locking Quarter-Turn Latch; Wing Knob Quarter-Turn Latch Padlockable; Wing Knob Quarter-Turn Latch; 1-Point Door Latch; 2-Point Door Latch; 3-Point Door Latch; Rotary Latch; Push to Close Latch; Slam Action Latch and the like; and Locks such as: Cam Lock Cylinders and the like.
It will be appreciated that still other latches, handles and locks may be used to secure the enclosure door of the present inventions without departing from the broad general scope of the present invention.
Several of these securing mechanisms are shown in FIGS. 18-21 .
It is to be understood that, even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts, within the broad principles of the present invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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An enclosure suitable for housing equipment for which controlled access is desirable. The enclosure has at least one, preferably two, enclosure doors secured by securing assemblies selected from a group consisting of a lock cylinder assembly, an electronic lock assembly, a quarter-turn latch assembly, a compression latch assembly, a folding T latch assembly, a lift and turn compression latch assembly, a pawl/cam action latch assembly, a multi-point latch assembly and a bolt assembly for securing to a rotary latch. Each securing assembly is secured to a mounting plate so that the respective securing assemblies may be easily exchanged within a standardized opening in the respective enclosure doors.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a toy or an amusing ornament wherein a doll, a model of a fish, or another figure, is caused to move or dance in a clear liquid inside a transparent container, and wherein that movement can be enjoyed.
[0003] 2. Description of the Related Art
[0004] If a figure is caused to move inside a liquid, then the movement thereof will be a comparatively leisurely, wavering movement, compared to movement over the ground or in the air. A toy of this kind is one that can be enjoyed simply by watching the wavering motion.
[0005] A toy wherein a figure is caused to move in a liquid is described, for example, in the Japanese Utility Model Application No. S59-124909 (Utility Model Laid-open No. S61-39597). In this toy, a fish-shaped object is disposed floatingly in a container filled with water and tied up through a fine string with a weight having a permanent magnet attached thereto. The weight is rotatably set on the bottom of the container filled with water. A coil, which generates alternating lines of magnetic force, is arranged under the bottom on the outer side of the container. Swimming actions are caused to the fish-shaped object by the alternating magnetic force generated by the coil.
[0006] However, the expression of this toy is poor, since it merely causes the weight to rotate in a circle, and it does not provide satisfactory entertainment as a toy.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a toy which is able to create varied and entertaining movements by means of a simple mechanism.
[0008] In order to achieve the aforementioned object, the toy of the present invention comprises: a liquid container section containing a liquid therein; a figure of specific gravity lower than that of the liquid, accommodated inside the liquid container section; a magnetic body accommodated inside the liquid container section and arranged movably in a vertical direction; a line member extended between the figure and the magnetic body; and an electromagnetic mechanism that acts on the magnetic body. Without a magnetic field the magnetic body is pulled up by a buoyant force caused to the figure. Then a descent movement is caused to the figure so as to move against the buoyancy force of the figure by the descent movement of the magnetic body when an electric current is applied through the electromagnetic mechanism. The figure and the magnetic body are caused to return to their original positions by the buoyancy force of the figure, by releasing the passage of current through the electromagnetic mechanism. Thereby, the figure can be caused to make upward and downward movement, and since it returns to its original position by means of the buoyancy force, a natural movement is achieved.
[0009] In the toy described above, desirably, a control device for passing a pulse current through the electromagnetic mechanism is provided. Since the movement of the figure is created by a pulse current, power consumption is reduced and varied movement can be achieved by combining pulse currents or changing periods of pulses.
[0010] In the toy described above, desirably, plural line members and magnetic bodies may be connected to a plurality of positions on the figure, and the plural magnetic bodies can be arranged so as to move at different timings. By causing the magnetic bodies to move simultaneously, or by causing one only to move, or causing each to move alternately, it can provide a more varied movement.
[0011] In the toy described above, desirably, the interval between the line members is greater in the vicinity of the figure than in the vicinity of the magnetic bodies. Thereby, it is possible to cause the figure to move in a horizontal direction, rather than simply the vertical direction, by causing the magnetic body connected to one of the line member to move, or by causing both of the magnetic bodies to move in alternating fashion.
[0012] According to the present invention, it is possible to provide a toy which is able to create varied and entertaining movements by means of a simple mechanism and arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a conceptual diagram showing an example of a toy according to an embodiment of the present invention; and
[0014] [0014]FIG. 2 is a perspective view showing an aspect of the assembly of the toy shown in FIG. 1.
[0015] [0015]FIG. 3 is a conceptual diagram depicting another variation of a toy according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Below, an embodiment of the present invention is described with reference to the drawings.
[0017] (1. Composition of the Toy)
[0018] [0018]FIG. 1 is a conceptual diagram showing an example of the composition of a toy according to an embodiment of the present invention. FIG. 2 is a perspective diagram showing the aspect of the assembly of this toy. This toy comprises a container main body 11 which accommodates a figure object 2 , magnetic members 31 , 32 , and fine line or string members 41 , 42 , and comprises a base section 12 which accommodates coils 51 , 52 forming electromagnetic mechanisms and a drive unit 6 , and the like. The liquid container section according to the present invention is constituted by the container main body 11 and the upper face of the base section 12 .
[0019] (1-1. Liquid Container Section)
[0020] The container main body 11 has a cylindrical shape, one end of which is closed. More specifically, the upper end as illustrated in the diagram is closed in a domed shape, and the lower end as illustrated in the diagram is open. The upper face of the base section 12 is fixed in a watertight fashion, via an O-ring 8 (FIG. 2) to the open end.
[0021] The container main body 11 has a transparent section in such a manner that the movement of the figure object 2 contained therein can be seen, and desirably the whole body thereof is transparent. Desirably, the transparent section has colourless transparency or coloured transparency.
[0022] The liquid accommodated in the liquid accommodating section is desirably a colourless transparent liquid or a coloured transparent liquid, and desirably, it should be chemically stable and not liable to decomposition, such as water containing a preservative, or ethanol, or the like.
[0023] (1-2. Figure Object)
[0024] A figure object 2 may be a doll or an object of adorable characters as depicted in FIG. 1 or a body simulating a fish, or dolphin, or other aquatic creature, or a diver, or the like, is accommodated inside the liquid container section. Desirably, the figure object 2 has a lower specific gravity than the liquid contained in the liquid container section, and is made, for example, from foamed styrene or is made of a hollow figure of an ABS (Acrylonitrile Butadiene Styrene) plastic material. The hollow may be filled with foamed styrene. The figure object 2 may be immersed completely in the liquid, or if it is accommodated inside the liquid container section together with a material of lighter specific gravity (air, or the like,) then it may float on the surface of the liquid.
[0025] The figure object 2 may be provided with a part simulating a tail, fin, or the like, swingably on a main part or on a central body. Even if it is not driven in particular, a tail or fin of this kind can be caused to flutter from side to side, by the movement of the main part through the liquid.
[0026] (1-3. Magnetic Member)
[0027] Swinging plates 33 , 34 are provided on the upper face of the base section 12 , in other words, at the bottom of the liquid container section. The swinging plates 33 , 34 are both flat in shape, and are rotatably supported in the region of one end thereof on the upper face of the base section 12 , in such a manner that they can swing upwards and downwards. Magnetic members 31 , 32 are fixed respectively to the other ends of the swinging plates 33 , 34 , in the vicinity of the free ends thereof, in such a manner that they can move upwards and downwards with the swinging motion of the swinging plates 33 , 34 .
[0028] Desirably, the magnetic members 31 , 32 are flat in shape, and they may be members which are inherently magnetic (for example, permanent magnets), or they may be members which are not inherently magnetic but which are induced to be magnetic (for example, a magnetic metal such as iron, or the like).
[0029] The magnetic members 31 , 32 and the swinging plates 33 , 34 may themselves have a specific gravity that is greater than that of the contained liquid. In this case, when no current is passed through the coils 51 , 52 , the magnetic members 31 , 32 and the swinging plates 33 , 34 can be pulled and raised to a prescribed position, by the buoyancy force caused to the figure object 2 .
[0030] A blind plate 7 is fixed to the base section 12 above the magnetic members 31 , 32 and the swinging plates 33 , 34 . The purpose of the blind plate 7 is to hide the magnetic members 31 , 32 and the swinging plates 33 , 34 , from external view, but desirably, it is provided with gaps or holes in order to pass the line members 41 , 42 . Alternatively, the blind plate 7 itself may be made of a plate-shaped net.
[0031] Although the swinging plates 33 , 34 are able to swing upwards and downwards, the downward movement thereof is restricted by the upper face of th base section 12 , and the upward movement thereof is restricted by the blind plate 7 . The method for limiting the range of swing of the swinging plates 33 , 34 is not limited to this, and it is also possible to provide stoppers on the aforementioned support sections for the base section 12 of the swinging plates.
[0032] (1-4. Fine Line Members)
[0033] The figure object 2 is linked to the magnetic members 31 , 32 by means of respective threads 41 , 42 forming line members. More specifically, it is linked respectively to the aforementioned other end or the movable end of the swinging plate 33 on which the magnetic member 31 is fixed, and the aforementioned other end of the swinging plate 34 on which the magnetic member 32 is fixed. The threads 41 , 42 are connected to different positions on the figure object 2 in particular, if it is possible to define the right-hand side and left-hand side, or the front and back, of the figure object 2 (for example, if the object is simulating a fish, or the like), then the threads 41 , 42 are fixed to approximately symmetrical positions on the right and left-hand sides of the figure object 2 .
[0034] The interval between the threads 41 , 42 is greater in the vicinity of the magnetic members 31 , 32 than in the vicinity of the figure object 2 .
[0035] Desirably, the threads 41 , 42 are made of a material that does not visually stand out in the liquid, such as a transparent material, thin material, or the like, but th material should not be limited in particular, and any material, such as fishing line, or the like, may be used. Here, a material of low expandability is used, but an expandable material may also be used.
[0036] (1-5. Coils)
[0037] Electromagnetic coils 51 , 52 are provided on the inner side of the base section 12 , in other words, on the outer side of the liquid container section. These coils 51 , 52 are able respectively to exercise a magnetic action in the range of movement of the magnetic members 31 , 32 in the liquid container section. For this purpose, desirably, the coils 51 , 52 are fixed to the walls of the liquid container section, from the outer side. In the present embodiment, they are fixed to the upper end of the base section 12 , from the inner side of the base section. The upper face of the base section 12 is made front a non-magnetic material, in such a manner that it does not shield the magnetic force.
[0038] In the present embodiment, the coils 51 , 52 are provided on the outer side of the liquid container section in order to avoid problems of liquid leakage or current leakage, but it is also possible to provide them inside the liquid container section, provided that these problems are prevented. Moreover, the invention is not limited to using coils 51 , 52 , and another magnetic mechanism, such as magnets, with associated moving mechanism which cause the magnets to move for example upwards and downwards so that they engage and disengage with the corresponding magnet members in the liquid container, may also be used.
[0039] The coils 51 , 52 are connected to a control circuit 6 which controls the current flowing through the coils. The control circuit 6 according to the present embodiment is able to pass a pulse current through the coils 51 and 52 , respectively, at any desired timing. In particular, desirably, by means of the control implemented by the control circuit 6 , it is possible to pass pulse currents through the coils 51 and 52 , at separate timings, and it is also possible to pass pulse currents through the coils 51 and 52 , simultaneously. Desirably, a spacer 61 is disposed between the control circuit 6 and the coils 51 , 52 and, in order to maintain a uniform distance of separation of the control circuit 6 from the coils, and to shield out electrical and magnetic effects. Desirably, the spacer 61 is made from an insulating material, such as hardened rubber, for example.
[0040] The control circuit 6 is connected to a power supply, such as a dry cell battery 62 , for example.
[0041] In the present embodiment, the number of magnetic members 31 , 32 , threads 41 , 42 and coils 51 , 52 provided was respectively two each, but the invention is not limited to this, and for example, three or more of each member may be provided. If three of each member is provided, then the position at which the third thread is fixed to the figure object 2 is desirably displaced towards the front or the rear, with respect to the threads 41 and 42 .
[0042] (2. Operation of the Toy)
[0043] Next, the basic operation of the toy shall be described.
[0044] (2-1. When a Pulse Current is Not Supplied)
[0045] If no current is supplied to the coils 51 and 52 , then neither of the coils 51 and 52 is magnetized and hence there is no action on the magnetic bodies 31 , 32 . In this case, the figure object 2 is pushed upwards by the buoyancy force, and the magnetic bodies 31 , 32 and the swinging plates 33 , 34 are pulled and raised to their limit position as determined by the blind plate 7 .
[0046] (2-2. When Pulse Currents are Supplied Simultaneously)
[0047] When currents of the same magnitude are supplied simultaneously to the coils 51 and 52 , then the coils 51 and 52 will be magnetized simultaneously, and the magnetic bodies 31 and 32 will be drawn downwards simultaneously, and with the same degree of force. Thereby, a pulling force is transmitted to the figure object 2 by means of the threads 41 and 42 , and hence the figure object 2 is drawn downwards against the buoyancy force.
[0048] Here, if the pulse width (the length of the time period for which current is passed) is large enough, then the magnetic bodies 31 , 32 and the swinging plates 33 , 34 will be able to move until they reach the lower limit position, as determined by the upper face of the base section 12 . Consequently, the figure object 2 reaches a bottommost point in its range of movement. When the current is released, the figure object 2 returns to its original position, together with the magnetic bodies 31 , 32 , due to the buoyancy force.
[0049] If the pulse width is small, then a magnetizing force of the coils 51 , 52 will attenuate before the magnetic bodies 31 , 32 and the swinging plates 33 , 34 reach their lower limit position, and the figure object 2 will return to its original position, together with the magnetic bodies 31 , 32 , due to the buoyancy force, after having been pulled down to an intermediate position.
[0050] The size of the pulse width required in order for the magnetic bodies 31 , 32 and the swinging plates 33 , 34 to reach their lower limit position varies depending on the resistance of the figure object 2 and the swinging plates 33 , 34 , in the liquid, the buoyancy force of the figure object 2 , and the strength of the coils 51 , 52 , and so on.
[0051] If a current having a short pulse width is passed repeatedly, in a consecutive fashion, then the figure object 2 will move reciprocally, up and down, in short and sharp movements. If the resistance of the figure object 2 in the vertical direction with respect to the liquid differs between the region to the front of the installation positions of the threads 41 , 42 on the figure object 2 and the region to the rear of these positions, then the region where the resistance is lower will perform greater upward and downward movement consequently, for example, if the resistance on the front side is made lower than that on the rear side, by, for instance, making the surface area to the front of the installation positions of the threads 41 , 42 a smaller area, then the front side will move upwards and downwards to a greater degree than the rear side, and hence the whole body of the figure object 2 will oscillate in the vertical direction, and the figure object 2 will appear as if it were nodding up and down. If the interval between pulses is short, then the subsequent pulse will arrive before the figure object 2 has returned to its original position due to the buoyancy force, and it will move further downwards, thus appearing as if it were moving downwards in stages.
[0052] (2-3. When Pulse Currents are Supplied at Different Timings)
[0053] If a pulse current is supplied to one of the coils 51 and 52 only, then only one of the magnetic bodies will be drawn downwards. Accordingly, only one of the left-hand and right-hand threads attached to the figure object 2 will be pulled, whilst the other one of the threads will not be pulled. Here, since the interval between the threads 41 , 42 becomes greater as they proceed in the downward direction, then if, for example, only the right-hand thread is pulled, this will result in the figure object being pulled not only downwards, but also towards the right-hand side. Therefore, the figure object 2 moves in a rightward and downward direction. Moreover, since the threads 41 , 42 are installed in symmetrical positions on the right-hand and left-hand sides of the figure object 2 , and then if only the right-hand thread is pulled, for example, this will also result in the figure object 2 being inclined towards the right-hand side.
[0054] When short pulse currents are supplied alternately to each one of the coils 51 and 52 , then the figure object 2 will repeat a motion of: (1) moving down to the right; (2) returning to its original position; (3) moving down to the left; (4) returning to its original position; and so on. If the interval between pulses is made short, then the figure object 2 will repeat a motion of: (1) moving down to the right; (2) pulled to left whilst returning to original position; (3) pulled to right whilst returning to original position; and so on. In either of these cases, the figure object 2 will perform a rightward and leftward movement. Therefore, it is possible to cause the figure object 2 to perform a movement wherein the whole body thereof. Oscillates towards the right and left, as if it were refusing something.
[0055] Moreover, if a plurality of short pulse currents are supplied repeatedly and consecutively to one of the coils 51 and 52 , whereby only the right-hand thread is pulled a plurality of times, for example, then the figure object 2 will move upwards and downwards, in a state where it moves towards the right and is inclined towards the right-hand side. If the interval between pulses is short, then the subsequent pulse will arrive before the figure object 2 has returned to its original position due to the buoyancy force, and it will move further downwards, thus appearing as it if were moving downwards in stages, in a state where it moves towards the right and is inclined towards the right-hand side.
[0056] (2-4. When the Foregoing Operations are Combined)
[0057] When the operations described above are combined, then it is possible to achieve a rich variety of different movements control of the pulse currents of this kind can be achieved by means of a control device 6 .
[0058] On the toy explained herein above switches operable by a user or watcher, sensors detecting surrounding sounds and lights or other input devices. One example is shown in FIG. 3, The toy shown in FIG. 3 is provided with a pair of switches 71 and 72 each operable by a user. When one of the switches is pressed, the control circuit 6 is triggered starting operation and the figure object 2 starts dancing in accordance with a preset dancing pattern together with a music output from a small speaker 73 installed inside of the base body 12 . Another switch may provide another dancing pattern with another music.
[0059] The toy in FIG. 3 is further provided with a sound sensor which may detect a voice of a user. When the sensor detects a voice or a certain sound, the control circuit 6 starts generating the pulse current and the figure object 2 starts dancing in accordance with a preset moving pattern and outputs music or may be an imitated voice of the figure object 2 from the speaker 73 .
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A floating toy is provided which can achieve varied and entertaining movements by means of a simple composition. The floating toy comprises: a liquid container section ( 11, 12 ) containing liquid therein; a figure ( 2 ) of lower specific gravity than the liquid, accommodated inside the liquid container section; magnetic bodies ( 31, 32 ) accommodated movably inside the liquid container section; line members ( 41, 42 ) extended between the figure and the magnetic bodies; and electromagnetic mechanisms ( 51, 52 ) that act on the magnetic bodies. The magnetic bodies and the figure are caused to move against the buoyancy force of the figure, by passing current through the electromagnetic mechanisms, and are caused to return to their original positions by the buoyancy force of the figure, by releasing the passage of current through the electromagnetic mechanisms.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to memory devices, and in particular to a phase change memory device and fabrication thereof.
[0003] 2. Description of the Related Art
[0004] Phase change memory devices have many advantages, such as high speed, low power consumption, large capacity, endurance, improved process integrity, and lower cost, with resulting suitability for use as independent or embedded memory devices with high integrity. Phase change memory devices can efficiently replace volatile memory devices, such as SRAM and DRAM, or non-volatile memory devices, such as flash memory devices.
[0005] FIG. 1A shows a conventional T shaped phase change memory device. Referring to FIG. 1A , a conventional T-shaped phase change memory device sequentially comprises a bottom electrode 102 , a bottom via 104 , a phase change layer 106 , a top via 108 and a top electrode 110 , wherein the columnar bottom via 104 is a heating electrode, connecting the phase change layer 106 . Contact area of the bottom via 104 and the phase change layer 106 is determined by size of the bottom via 104 . The size of the bottom via 104 , however, is determined according to the limits of photolithography, rendering reduction of dimensions difficult.
[0006] FIG. 1B shows another conventional phase change memory device, in which a heating electrode 112 is disposed horizontally. Contact area of the heating electrode 112 and a phase change materials layer 114 is determined according to thickness of the heating electrode 112 , and is thus not subject to process limits of photolithography. Phase change materials layer 114 of the phase change memory device, however, is formed by gap filling, negatively affecting endurance and uniformity of contact between the phase change materials layer 114 and the heating electrode 112 of the phase change memory device are not good enough. In addition, the heating electrode 112 must comprise highly resistant materials to increase heating efficiency. Due to longer current path of the heating electrode 112 and the phase change material layer 114 , the phase change memory device consumes more power. Further, the horizontal phase change material layer 114 requires more lithography steps than conventional T-shaped phase change memory devices, increasing costs.
[0007] As shown in FIG. IC, U.S. Pat. No. 6,867,425 discloses a lateral phase change memory device. A conductive material is formed on a substrate 150 and then patterned to form two electrodes 152 and 153 , supplying current to a phase change material layer 154 . A dielectric layer 156 is interposed between the phase change material layer 154 and the electrode 152 and 153 , and a protective layer 158 comprising dielectric materials covers the phase change material layer 154 . However, the phase change material layer 154 of the phase change memory device is still formed by gap filling, with accompanying deterioration of endurance and uniformity of contact between the phase change material layer 154 and the heating electrodes 152 and 153 . In addition, filling phase change materials into the gap between the electrodes 152 and 153 becomes more difficult with the reduced distance therebetween. Further, current path in the heating electrode, comprising highly resistant materials to achieve good heating efficiency, is longer than that of the conventional phase change memory device, consuming more power. In addition to the heating electrode, two additional conducing electrodes 152 and 153 are required on both sides of the phase change material layer 154 , increasing area occupied. The lateral phase change memory device, finally, still requires more photolithography steps than conventional T-shaped phase change memory devices, with correspondingly increased cost.
BRIEF SUMMARY OF INVENTION
[0008] A detailed description is given in the following embodiments with reference to the accompanying drawings. According the issues above, Example of the present invention may provide a phase change memory device with shorter current path and fewer defects than conventional phase change memory device with a phase change layer formed in a trench. In addition, example of the present invention may provide a phase change memory device, in which area of a contacting region between a phase change layer and an electrode is determined by a thickness of the phase change layer, such that not limited to photolithography.
[0009] In an embodiment of the invention, a phase change memory device comprises a first columnar electrode and a second columnar electrode, both arranged horizontally. A phase change layer is interposed between the first columnar electrode and the second columnar electrode, electrically connecting both thereof, wherein the entirety of the phase change layer is disposed on a plane. A bottom electrode electrically connects the first columnar electrode. A top electrode electrically connects the second columnar electrode.
[0010] The invention further provides a method for forming a phase change memory device. A substrate comprising a source and a drain is provided. A plurality of interconnects and vias are formed with at least one of the interconnects and vias electrically connecting to the drain. A bottom electrode and a first dielectric layer are formed overlying the interconnects or the vias, wherein the bottom electrode is disposed in the first dielectric layer. Lower portions of a first columnar electrode and a second columnar electrode and a second dielectric layer are formed overlying the bottom electrode and the first dielectric layer, wherein the lower portions of the first columnar electrode and the second columnar electrode are disposed in the second dielectric layer, and the lower portion of the first columnar electrode electrically connects to the bottom electrode. A patterned phase change layer is formed overlying portions of the lower portions of the first columnar electrode and the second columnar electrode, and the second dielectric layer. Upper portions of the first columnar electrode and the second columnar electrode, and a third dielectric layer are formed overlying the lower portions of the first columnar electrode and the second columnar electrode, and a portion of the patterned phase change layer to form entireties of the first columnar electrode and the second columnar electrode, wherein the patterned phase change layer extends into the first columnar electrode and the second columnar electrode. A top electrode is formed to electrically connect a portion of the second columnar electrode.
[0011] The invention provides another method for forming a phase change memory device. A substrate comprising a source and a drain is provided. A plurality of interconnects and vias are formed with at least one of the interconnects and vias electrically connecting the drain. A bottom electrode and a first dielectric layer are formed overlying the interconnects or the vias, wherein the bottom electrode is disposed in the first dielectric layer. A second dielectric layer is formed overlying the bottom electrode and the first dielectric layer. A phase change layer is formed overlying the second dielectric layer. A third dielectric layer is formed overlying the phase change layer and the second dielectric layer. A patterned photoresist layer is formed overlying the third dielectric layer. The second dielectric layer and the third dielectric layer are etched using the patterned photoresist layer as a mask to form at least two openings, wherein the openings penetrate portions of the phase change layer. A conductive material is filled into the openings to form at least two columnar electrodes.
BRIEF DESCRIPTION OF DRAWINGS
[0012] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0013] FIG. 1A shows a conventional T-shaped phase change memory device.
[0014] FIG. 1B shows another conventional phase change memory device.
[0015] FIG. 1C shows yet another phase change memory device.
[0016] FIG. 2A˜FIG . 2 E are intermediate cross sections of fabrications of a phase change memory device of an embodiment of the invention.
[0017] FIG. 3 is a plan view of a phase change memory device of an embodiment of the invention.
[0018] FIG. 4A˜FIG . 4 E are intermediate cross sections of fabrications of a phase change memory device of another embodiment of the invention.
[0019] FIG. 5A˜FIG . 5 E are intermediate cross sections of fabrications of a phase change memory device of further another embodiment of the invention.
[0020] FIG. 6 is a plan view of a phase change memory device of this embodiment.
DETAILED DESCRIPTION OF INVENTION
[0021] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims. Embodiments of the invention, which provides a phase change memory device, will be described in greater detail by referring to the drawings that accompany the invention. It is noted that in the accompanying drawings, like and/or corresponding elements are referred to by like reference numerals.
[0022] FIG. 2A˜FIG . 2 E show intermediate cross sections of fabrications of a phase change memory device of an embodiment of the invention. Referring to FIG. 2A , a substrate 200 comprising an active 202 is provided, wherein a gate 204 is formed on the active area 202 . Source 206 and drain 208 , which both are doped regions, are formed on opposite sides of the gate 204 . The gate 204 , source 206 and drain 208 respectively connects a first interconnect 210 . A second interconnect 212 is connected to the first interconnect 210 through first vias 214 . A third interconnect 216 is connected to the second interconnect 212 through second vias 218 . A plurality of third vias 220 is formed on the third interconnect 216 . The vias 214 , 218 and 220 are disposed in interlayer dielectric layers 222 separating the interconnects 210 , 212 and 216 .
[0023] A first dielectric layer 224 , comprising silicon nitride, silicon oxide, or silicon oxynitride, is formed on the third vias 220 . Next, the first dielectric layer 224 is patterned by a first photolithography step with a first mask to form an opening, and the opening is filled with conductive materials, such as TiN, Tan or TiW, to form a bottom electrode 226 .
[0024] Referring to FIG. 2B , a second dielectric layer 228 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the first dielectric layer 224 and the bottom electrode 226 . Next, the second dielectric layer 228 is patterned by a second photolithography step with a second mask to form at least two openings. Thereafter, refractory metals, such as W or TiAlN, metals with low heat conducting coefficient, phase change materials or chalcogenide are filled into the openings to form lower portions of columnar electrodes 230 .
[0025] Referring to FIG. 2C , a phase change layer (not shown), comprising Ag, In, Te, Sb, Ge or combinations thereof, is blanketly deposited on the lower portions of the columnar electrodes 230 and the second dielectric layer 228 . The phase change layer can be ternary chalcogenide compound, such as GeTe—Sb 2 Te 3 , or binary chalcogenide compound, such as combinations of Sb and Te in various percentages. The chalcogenide compound can comprise Cr, Fe, Ni, or combinations thereof, or Bi, Pb, Sn, As, S, Si, P, O, or combinations thereof.
[0026] Next, the phase change layer is patterned by a photolithography step with a third mask to form a patterned phase change layer 232 , bridging the lower portions of the columnar electrodes 230 .
[0027] Referring to FIG. 2D , a third dielectric layer 234 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the patterned phase change layer 232 , second dielectric layer 228 and the lower portions of the columnar electrodes 230 . Next, the third dielectric layer 234 is patterned by photolithography using the second mask, the same mask used when forming the lower portions of the columnar electrodes 230 , to form at least two openings, each respectively exposing the corresponding lower portion of the columnar electrode 230 . Note that the patterned phase change layer 232 is substantially unaffected during the etching step. Etching ratio between the third dielectric layer 234 and the patterned phase change layer 232 is substantially more than 10 . Further note that deviations between positions of the openings and the corresponding lower portions of the columnar electrodes 230 cannot be too large.
[0028] Next, refractory metals, such as W or TiAlN, metals with low heat conducting coefficient, phase change materials or chalcogenide, are filled into the openings to form upper portions of the columnar electrodes 236 , wherein the lower portions of the columnar electrodes 230 and the upper portions of the columnar electrodes 236 constitute columnar electrodes 240 . The two columnar electrodes 240 are located on the same layer, and the patterned phase change layer 232 extends into both the columnar electrodes 240 .
[0029] Referring to FIG. 2E , a fourth dielectric layer 242 , of silicon nitride, silicon oxide, or silicon oxynitride, is formed on the columnar electrodes 240 . Next, the fourth dielectric layer 242 is patterned by photolithography using a fourth mask to form an opening. A conductive material, such as TiN, TaN or TiW, is deposited into the opening, and then etched back to form a top electrode 244 . Thus, a major portion of the phase change memory device is fabricated. Note that fabrications of the phase change memory of the embodiment may use only four photolithography mask and process steps, one step and mask less than that of conventional planar phase change memory device.
[0030] FIG. 3 is a plan view of a phase change memory device of an embodiment of the invention. Referring to FIG. 2E and FIG. 3 , the patterned phase change layer 232 is formed on a plane, such that the entirety of the pattern phase change layer 232 is planar, having short current path and fewer defects than conventional phase change memory devices. In addition, area of the contact region of the electrode 240 and the patterned phase change layer 232 can be determined by thickness of the patterned phase change layer 232 , not being limited by photolithography technology.
[0031] FIG. 4A˜FIG . 4 E are intermediate cross sections of fabrications of a phase change memory device of another embodiment of the invention, wherein portions of the structure of the device under the bottom electrode are similar to the device of FIG. 2A˜FIG . 2 E. Elements of this portion use the same symbol numbers as the device of FIG. 2A˜FIG . 2 E. Referring to FIG. 4A , a substrate 200 comprising an active area 202 is provided, wherein a gate 204 is formed on the active area 202 . Source 206 and drain 208 , both doped regions, are formed on opposite sides of the gate 204 . The gate 204 , source 206 and drain 208 respectively connect to a first interconnect 210 . A second interconnect. 212 is connected to the first interconnect 210 through first vias 214 . A third interconnect 216 is connected to the second interconnect 212 through second vias 218 . A plurality of third vias 220 is formed on the third interconnect 216 . The vias 214 , 218 and 220 are disposed in interlayer dielectric layers 222 separating the interconnects 210 , 212 and 216 .
[0032] A first dielectric layer 404 , comprising silicon nitride, silicon oxide and silicon oxynitride, is formed on the third vias 220 . Next, the first dielectric layer 404 is patterned by a first photolithography step with a first mask to form an opening. Conductive materials, such as TiN, TaN or TiW, are deposited into the opening to form a bottom electrode 402 .
[0033] Referring to FIG. 4B , a second dielectric layer 406 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the first dielectric layer 404 and the bottom electrode 402 . Next, a phase change layer (not shown), comprising Ag, In, Te, Sb, Ge or combinations thereof, is blanketly deposited on the second dielectric layer 406 . The phase change layer can be ternary chalcogenide compound, such as GeTe—Sb 2 Te 3 , or binary chalcogenide compound, such as combination of Sb and Te in various percentages. The chalcogenide compound can comprise Cr, Fe, Ni or combinations thereof, or Bi, Pb, Sn, As, S. Si, P, O or combinations thereof. Thereafter, the phase change layer is patterned to by photolithography using a second mask to form a patterned phase change layer 408 .
[0034] Referring to FIG. 4C , a third dielectric layer 410 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the patterned phase change layer 408 and the second dielectric layer 406 . Next, a photoresist layer 412 is coated on the third dielectric layer 410 , and then defined by exposure with a third mask.
[0035] Referring to FIG. 4D , the second dielectric layer 406 and the third dielectric layer 410 are etched using the defined photoresist layer 412 as a mask to form at least two openings, each penetrating a portion of the patterned phase change layer 408 at one side, in which the top electrode 402 or the first dielectric layer 404 are exposed. Next, refractory metals, such as W or TiAlN, metals with low heat conducting coefficient, phase change materials or chalcogenide, are filled into the openings to form two columnar electrodes 414 . The two columnar electrodes 414 are on the same level, and the patterned phase change layer 408 contacts sidewalls of the columnar electrodes 414 .
[0036] Referring to FIG. 4E , a fourth dielectric layer 416 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the columnar electrodes 414 . Next, the fourth dielectric layer 416 is patterned by photolithography using a fourth mask to form an opening. A conductive material, such as TiN, TaN or TiW, is deposited into the opening, and then etched back to form a top electrode 418 . Note that fabrication of the phase change memory of the embodiment may use only four masks and three photolithography steps, one mask and two photolithography steps less than a conventional planar phase change memory device.
[0037] FIG. 5A˜FIG . 5 E are intermediate cross sections of fabrication of a phase change memory device of another embodiment of the invention, wherein portions of the structure of the device of this embodiment under the bottom electrode are similar to the device of FIG. 2A˜FIG . 2 E. Elements of this portions use the same symbol numbers as the device of FIG. 2A˜FIG . 2 E. Referring to FIG. 5A , a substrate 200 comprising an active area 202 is provided, wherein a gate 204 is formed on the active area 202 . Source 206 and drain 208 , both doped regions, are formed on opposite sides of the gate 204 . The gate 204 , source 206 and drain 208 respectively connect to a first interconnect 210 . A second interconnect 212 is connected to the first interconnect 210 through first vias 214 . A third interconnect 216 is connected to the second interconnect 212 through second vias 218 . A plurality of third vias 220 are formed on the third interconnect 216 . The vias 214 , 218 and 220 are disposed in interlayer dielectric layers 222 separating the interconnects 210 , 212 and 216 .
[0038] A first dielectric layer 502 , comprising silicon nitride, silicon oxide or silicon oxynitride, is formed on the third vias 220 and patterned by a first photolithography step with a first mask to form an opening. Conductive materials, such as TiN, TaN or TiW, are deposited into the opening to form a bottom electrode 504 .
[0039] Referring to FIG. 5B , a second dielectric layer 506 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the first dielectric layer 502 and the bottom electrode 504 . Next, a phase change layer 508 , comprising Ag, In, Te, Sb, Ge or combinations thereof, is blanlcetly deposited on the second dielectric layer 506 , wherein the phase change layer 508 can be ternary chalcogenide compound, such as GeTe—Sb 2 Te 3 , or binary chalcogenide compound, such as a combination of Sb and Te of various percentages. The chalcogenide compound can comprise Cr, Fe, Ni or combinations thereof, or Bi, Pb, Sn, As, S, Si, P, O or combinations thereof. Thereafter, a third dielectric layer 510 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the phase change layer 508 .
[0040] Referring to FIG. 5C , a photoresist layer 512 is coated on the third dielectric layer and defined by exposure with a third mask. Next, an etching process is utilized using the defined photoresist layer 512 as an etching mask to form at least two openings 514 in the second and third dielectric layers 506 and 510 , the openings 514 penetrating the phase change layer 508 , and the top electrode 504 or the first dielectric layer 502 are exposed.
[0041] Next, referring to FIG. 5D , refractory metals, such as W or TiAlN, metals with low heat conducting coefficient, phase change materials or Chalcogenide, are filled into the openings to form two columnar electrodes 516 . Phase change layer 508 contacts both sidewalls of each columnar electrode 516 .
[0042] Referring to FIG. 5E , a fourth dielectric layer 518 , such as silicon nitride, silicon oxide or silicon oxynitride, is formed on the columnar electrodes 516 . Next, the fourth dielectric layer 518 is patterned by photolithography using a third mask to form an opening. A conductive material, such as TiN, TaN or TiW, is deposited into the opening, and then etched back to fonn a top electrode 520 . FIG. 6 is a plan view of a phase change memory device of this embodiment. Referring to FIG. 6 and FIG. 5E , the entire phase change layer 508 is disposed on a plane, surrounding and contacting the columnar electrodes 516 in their entirety.
[0043] Note that fabrication of the phase change memory of this embodiment may use only three masks and photolithography steps, two mask and photolithography steps less than conventional planar phase change memory device.
[0044] In addition, the phase change memory device can be connected to a driving device, such as a MOSFET device, a BJT device or a diode.
[0045] According to the embodiments, since the patterned phase change layer is formed on a plane, the entirety of the patterned phase change layer can be planar, containing fewer defects and providing shorter current path than conventional phase change memory with phase change layer formed in/on a trench. In addition, area of a contact region between the phase change layer and the electrode can be determined by thickness of the phase change layer, not limited by a photolithography process. Further, fabrication of the phase change memory device of an embodiment of the invention requires fewer photolithography steps and/or masks than that of conventional phase change memory device.
[0046] While the invention has been described by way of example and in terms of the preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A phase change memory device is disclosed. A first columnar electrode and a second columnar electrode are provided, both arranged horizontally. A phase change layer is interposed between the first columnar electrode and the second columnar electrode, electrically connecting both thereof, wherein the entirety of the phase change layer is disposed on a plane. A bottom electrode electrically connects the first columnar electrode. A top electrode electrically connects the second columnar electrode.
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FIELD OF THE INVENTION
The present invention relates to phosphodiesterase (PDE) type 4, phosphodiesterase (PDE) type 7 and dual PDE type 4/PDE type 7 inhibitors.
Compounds disclosed herein can be useful in the treatment, prevention, inhibition or suppression of CNS diseases, for example, multiple sclerosis; various pathological conditions such as diseases affecting the immune system, including AIDS, rejection of transplant, auto-immune disorders such as T-cell related diseases, for example, rheumatoid arthritis; inflammatory diseases such as respiratory inflammation diseases including chronic obstructive pulmonary disease (COPD), asthma, bronchitis, allergic rhinitis, adult respiratory distress syndrome (ARDS) and other inflammatory diseases including but not limited to psoriasis, shock, atopic dermatitis, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis; gastrointestinal inflammation diseases such as Crohn's disease, colitis, pancreatitis as well as different types of cancers including leukaemia; especially in humans.
Processes for the preparation of disclosed compounds, pharmaceutical compositions containing the disclosed compounds and their use as PDE type 4, PDE type 7 and dual PDE type 4/PDE type 7 inhibitors are provided.
BACKGROUND OF THE INVENTION
It is known that cyclic adenosine-3′,5′-monophosphate (cAMP) exhibits an important role of acting as an intracellular secondary messenger ( Pharmacol. Rev. , (1960), 12, 265). Its intracellular hydrolysis to adenosine 5′-monophosphate (AMP) causes number of inflammatory conditions which are not limited to COPD, asthma, arthritis, psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis or colitis. PDE4 inhibitors are designed to inhibit the activity of PDE4, the enzyme which breaks down neuronal cAMP. Studies have shown that administering PDE4 inhibitors can have a restorative effect on memory loss in animal models, including those of Alzheimer's disease ( Expert Opin. Ther. Targets (2005) 9(6):1283-1305; Drug Discovery today, 10, number 22, (2005) 1503-1519). The most important role in the control of cAMP (as well as of cGMP (cyclic guanosine monophosphate)) level is played by cyclic nucleotide phosphodiesterases (PDE) which represent a biochemically and functionally highly variable super family of enzymes. Eleven distinct families of cyclic nucleotide phosphodiesterases with more than 25 gene products are currently recognized. Although PDE1, PDE2, PDE3, PDE4, and PDE7 all use cAMP as a substrate, only PDE4 and PDE7 are highly selective for hydrolysis of cAMP. Inhibitors of PDE, particularly the PDE4 inhibitors, such as rolipram or Ro-1724 are therefore known as cAMP-enhancers. Immune cells contain type 4 and type 3 PDE, the PDE4 type being prevalent in human mononuclear cells. Thus the inhibition of phosphodiesterase type 4 has been a target for modulation and, accordingly, for therapeutic intervention in a range of disease processes.
The initial observation that xanthine derivatives, theophylline and caffeine inhibit the hydrolysis of cAMP led to the discovery of the required hydrolytic activity in the cyclic nucleotide phosphodiesterase (PDE) enzymes. Distinct classes of PDE's have been recognized ( TIPS , (1990), 11, 150), and their selective inhibition has led to improved drug therapy ( TIPS , (1991), 12, 19). Thus it was recognized that inhibition of PDE4 could lead to inhibition of inflammatory mediator release ( J. Mol. Cell. Cardiol . (1989), 12 (Suppl. II), S 61) and airway smooth muscle relaxation.
The current approach of targeting PDE4 for alleviating the chronic inflammation associated with COPD is compromised by the dose limiting side effects that are proving difficult to overcome. Theoretically, an alternate strategy would be to use small molecule inhibitors to target other members of the cAMP dependent PDE family that share a common pulmonary cellular distribution to PDE4. It is hypothesized that such an approach would yield compounds with an improved therapeutic ratio. Of the novel cAMP family of proteins discovered so far, PDE7A offers itself as a promising candidate because of its cellular distribution in almost all pro inflammatory and immune cells ( Curr Pharm Des . (2006); 12:1-14). Additionally, it has been shown to be a prime modulator of human T cell function as well ( Science . (1999) February 5; 283 (5403):848-51).
Thus, dual specificity inhibitors that target both PDE4 and PDE7 would in principle, have an improved spectrum and a wider therapeutic window in the clinics. Compounds with dual PDE4 and PDE7 inhibitory effects have been shown to inhibit T cell function such as cytokine production, proliferation and activation of CD25 expression markers on T cells induced by antigen stimulation ( Eur. J. Pharmacol. 541, 106-114, (2006)). Development of dual PDE4-PDE7 inhibitors would yield a novel class of drugs blocking T cell component of a disease partly through PDE7 inhibition as well as possess anti-inflammatory activity. ( Eur. J. Pharmacol. 550, 166-172, (2006); Eur. J. Pharmacol. 559, 219-226, (2007)). More importantly, such a pharmacophore would be less limited by nausea and vomiting, a major side effect associated with PDE4 inhibition.
WO 2003/047520 discloses substituted aminomethyl compounds and derivatives thereof, which have been described to be useful as inhibitors of factor Xa. WO 2000/59902 discloses aryl sulfonyls, which have been described to be useful as inhibitors of factor Xa. WO 97/48697 discloses substituted azabicyclic compounds and their use as inhibitors of the production of TNF and cyclic AMP phosphodiesterase. WO 98/57951 and U.S. Pat. No. 6,339,099 describe nitrogen containing heteroaromatics and derivatives, which have been said to be the inhibitors of factor Xa. WO 2005/063767 and WO 2006/001894 disclose indoles, 1H-indazoles, 1,2-benzisoxazoles, and 1,2-benzisothiazoles, preparation and uses thereof. WO 2007/031977 discloses substituted pyrazolo[3,4-b]pyridines as phosphodiesterase inhibitors.
SUMMARY OF THE INVENTION
The present invention provides phosphodiesterase (PDE) type 4, PDE type 7 and dual PDE type 4/PDE type 7 inhibitors, which can be used for treatment, prevention, inhibition or suppression of CNS diseases, for example, multiple sclerosis; various pathological conditions such as diseases affecting the immune system, including AIDS, rejection of transplant, auto-immune disorders such as T-cell related diseases, for example, rheumatoid arthritis; inflammatory diseases such as respiratory inflammation diseases including chronic obstructive pulmonary disease (COPD), asthma, bronchitis, allergic rhinitis, adult respiratory distress syndrome (ARDS) and other inflammatory diseases including but not limited to psoriasis, shock, atopic dermatitis, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis; gastrointestinal inflammation diseases such as Crohn's disease, colitis, pancreatitis as well as different types of cancers including leukaemia; especially in humans.
Pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides of these compounds having the same type of activity are also provided.
Pharmaceutical compositions containing the compounds, which may also contain pharmaceutically acceptable carriers or diluents, can be used for treatment, prevention, inhibition or suppression of CNS diseases, for example, multiple sclerosis; various pathological conditions such as diseases affecting the immune system, including AIDS, rejection of transplant, auto-immune disorders such as T-cell related diseases, for example, rheumatoid arthritis; inflammatory diseases such as respiratory inflammation diseases including chronic obstructive pulmonary disease (COPD), asthma, bronchitis, allergic rhinitis, adult respiratory distress syndrome (ARDS) and other inflammatory diseases including but not limited to psoriasis, shock, atopic dermatitis, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis; gastrointestinal inflammation diseases such as Crohn's disease, colitis, pancreatitis as well as different types of cancers including leukaemia; especially in humans.
Other aspects will be set forth in the accompanying description which follows and in part will be apparent from the description or may be learnt by the practice of the invention.
In accordance with one aspect, there are provided compounds having the structure of Formula I:
or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides, wherein
R 1 and R 2 independently can be hydrogen, aryl, heteroaryl, —COR 4 , —S(O) m R 4 (wherein R 4 can be hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl or heterocyclyl and m can be an integer from 0-2),
wherein X can be —O—, S(O) m (wherein m can be an integer from 0-2), C(═O), C═NOH, CR f R q (wherein R f and R q independently can be hydrogen, hydroxy, carboxy or cyano) or NR 5 {wherein R 5 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, heteroaryl, heterocyclyl, —COR 4 , —S(O) m R 4 , —COOR 4 or —CONR 4 R′ 4 (wherein R 4 and R′ 4 independently can be hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl or heterocyclyl and m can be an integer from 0-2)};
R 3 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, aralkyl, aralkenyl, cycloalkylalkyl, heterocyclyl, heteroaryl, heterocyclylalkyl or heteroarylalkyl;
M can be a 3-7 membered saturated, partially saturated or unsaturated ring containing carbon atoms wherein one or more carbon atoms optionally can be replaced by heteroatoms selected from O, S(O) m {wherein m can be an integer from 0-2} or NR 6 {wherein R 6 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, heteroaryl, heterocyclyl, —COR 4 , —S(O) m R 4 , —COOR 4 or —CONR 4 R′ 4 (wherein R 4 and R′ 4 independently can be hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl or heterocyclyl and m can be an integer from 0-2)}, or one or more carbon atoms optionally can be substituted with oxo, halogen, spino-attached heterocyclyl, hydroxy, cyano, alkyl, heteroaryl, heteroarylalkyl, —(CH 2 ) m NR 4 R′ 4 , —(CH 2 ) m OR 4 , —(CH 2 ) m CONR 4 R′ 4 , —(CH 2 ) m NR 4 COR 4 or —(CH 2 ) m COOR 4 (wherein m, R 4 and R′ 4 can be the same as defined earlier).
In accordance with another aspect, there are provided methods for treating, preventing, inhibiting or suppressing inflammatory diseases, CNS diseases or autoimmune diseases, in a mammal, comprising administering a therapeutically effective amount of a PDE type 7 inhibitor or dual PDE type 4/PDE type 7 inhibitor having the structure of Formula Ia,
or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides, wherein
R′ 1a can be hydrogen, alkyl, alkenyl, alkynyl, acyl, aryl, aralkenyl, aralkyl, cycloalkyl alkyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, cycloalkyl or heterocyclyl;
R′ 2a can be cyclopropyl, cyclopentyl, alkyl, alkenyl, alkynyl, acyl, aralkenyl, aralkyl, cycloalkylalkyl, heterocyclylalkyl, heteroarylalkyl or heterocyclyl;
R 3 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, aralkyl, aralkenyl, cycloalkylalkyl, heterocyclyl, heteroaryl, heterocyclylalkyl or heteroarylalkyl;
M a can be a 3-7 membered saturated, partially saturated or unsaturated ring containing carbon atoms wherein one or more carbon atoms optionally can be replaced by heteroatoms selected from O, S(O) m {wherein m can be an integer from 0-2} or NR 7 {wherein R 7 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl or heterocyclyl}.
In accordance with another aspect, there are provided methods for the treatment, prevention, inhibition or suppression of multiple sclerosis, AIDS, rejection of transplant, rheumatoid arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), asthma, psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, colitis, pancreatitis, and cancer in a mammal comprising administering a therapeutically effective amount of a PDE type 7 inhibitor or dual PDE type 4/PDE type 7 inhibitor having the structure of Formula Ia.
In accordance with another aspect, there are provided intermediates having the structure of Formula Ib:
or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides, wherein
R 1 and R 2 independently can be hydrogen, aryl, aralkyl, heteroaryl, —COR 4 , —S(O) m R 4 (wherein R 4 can be hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl or
heterocyclyl and m can be an integer from 0-2),
wherein X can be —O—, S(O) m (wherein m can be an integer from 0-2), C(═O), C═NOH, CR f R q (wherein R f and R q independently can be hydrogen, hydroxy, carboxy or cyano) or NR 5 {wherein R 5 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, aryl, heteroaryl, heterocyclyl, —COR 4 , —S(O) m R 4 , —COOR 4 or —CONR 4 R′ 4 (wherein R 4 and R′ 4 independently can be hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl or heterocyclyl and m can be an integer from 0-2)};
R 3 can be hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aryl, aralkyl, aralkenyl, cycloalkylalkyl, heterocyclyl, heteroaryl, heterocyclylalkyl or heteroarylalkyl;
R 8 can be
(wherein R 1a can be alkyl), —CHO or —CH═NOR x (wherein R x can be hydrogen, alkyl or cycloalkyl).
The following definitions apply to terms as used herein.
The term “alkyl,” unless otherwise specified, refers to a monoradical branched or unbranched saturated hydrocarbon chain having from 1 to 20 carbon atoms. Alkyl groups can be optionally interrupted by atom(s) or group(s) independently selected from oxygen, sulfur, a phenylene, sulphinyl, sulphonyl group or —N(R α )—, wherein R α , can be hydrogen, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, acyl, aralkyl, —C(═O)OR λ , SO m R ψ (wherein m is an integer from 0-2 and R ψ is hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heterocyclyl, heteroaryl, heteroarylalkyl or heterocyclylalkyl) or —C(═O)NR λ R π {wherein R λ and R π are independently selected from hydrogen, halogen, hydroxy, alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, aryl, aralkyl, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or carboxy}. This term can be exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-decyl, tetradecyl, and the like. Alkyl groups may be substituted further with one or more substituents selected from alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, aryl, heterocyclyl, heteroaryl, heterocyclylalkyl, cycloalkoxy, —CH═N—O(C 1-6 alkyl), —CH═N—NH(C 1-6 alkyl), —CH═N—N(C 1-6 alkyl)C 1-6 alkyl, arylthio, thiol, alkylthio, aryloxy, nitro, aminosulfonyl, aminocarbonylamino, —NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —C(═O)heteroaryl, C(═O)heterocyclyl, —O—C(═O)NR λ R π , nitro or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, alkyl substituents may be further substituted by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, —NR λ R π , —C(═O)NR λ R π , —OC(═O)NR λ R π , —NHC(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ . Unless otherwise constrained by the definition, all substituents may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π , hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier); or an alkyl group as defined above that has substituents as defined above and is also interrupted by 1-5 atoms or groups as defined above.
The term “alkenyl,” unless otherwise specified, refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group having from 2 to 20 carbon atoms with cis, trans or geminal geometry. Alkenyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —N(R α )— (wherein R α is the same as defined earlier). In the event that alkenyl is attached to a heteroatom, the double bond cannot be alpha to the heteroatom. Alkenyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, —NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, keto, carboxyalkyl, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, aminosulfonyl, amino carbonyl amino, alkoxyamino, hydroxyamino, alkoxyamino, nitro or SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Unless otherwise constrained by the definition, alkenyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, —CF 3 , cyano, —NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π and —SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier). Groups, such as ethenyl or vinyl (CH═CH 2 ), 1-propylene or allyl (—CH 2 CH═CH 2 ), iso-propylene (—C(CH 3 )═CH 2 ), and the like, exemplify this term.
The term “alkynyl,” unless otherwise specified, refers to a monoradical of an unsaturated hydrocarbon, having from 2 to 20 carbon atoms. Alkynyl groups can be optionally interrupted by atom(s) or group(s) independently chosen from oxygen, sulfur, phenylene, sulphinyl, sulphonyl and —N(R α )— (wherein R α is the same as defined earlier). In the event that alkynyl groups are attached to a heteroatom, the triple bond cannot be alpha to the heteroatom. Alkynyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, keto, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, hydroxyamino, alkoxyamino, nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, —NHC(═O)R λ , —NR λ R π , —NHC(═O)NR λ R π , —C(═O)NR λ R π , —O—C(═O)NR λ R π or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Unless otherwise constrained by the definition, alkynyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, carboxyalkyl, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier).
The term “cycloalkyl,” unless otherwise specified, refers to cyclic alkyl groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings, which may optionally contain one or more olefinic bonds, unless otherwise constrained by the definition. Such cycloalkyl groups can include, for example, single ring structures, including cyclopropyl, cyclobutyl, cyclooctyl, cyclopentyl, cyclohexyl and the like or multiple ring structures, including adamantanyl, and bicyclo [2.2.1] heptane or cyclic alkyl groups to which is fused an aryl group, for example, indane, and the like. Spiro and fused ring structures can also be included. Cycloalkyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, ═NOR x (wherein R x is hydrogen, alkyl or cycloalkyl), —NR λ R π , —NHC(═O)NR λ R π , —NHC(═O)R λ , —C(═O)NR λ R π , —O—C(═O)NR λ R π , nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier). Carbonyl or sulfonyl group can replace carbon atom(s) of cycloalkyl. Unless otherwise constrained by the definition, cycloalkyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, alkenyl, alkynyl, carboxy, hydroxy, alkoxy, halogen, CF 3 , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —OC(═O)NR λ R π , cyano or —SO m R ψ (wherein R λ , R π , m and R ψ are the same as defined earlier).
The term “cycloalkylalkyl” refers to alkyl-cycloalkyl group linked through alkyl portion, wherein the alkyl and cycloalkyl are as defined earlier.
The term “alkoxy” denotes the group O-alkyl wherein alkyl is the same as defined above.
The term “aryl,” unless otherwise specified, refers to aromatic system having 6 to 14 carbon atoms, wherein the ring system can be mono-, bi- or tricyclic and carbocyclic aromatic groups. For example, aryl groups include, but are not limited to, phenyl, biphenyl, anthryl or naphthyl ring and the like, optionally substituted with 1 to 3 substituents selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, acyl, aryloxy, CF 3 , cyano, nitro, COOR ψ , NHC(═O)R λ , —NR λ R π , —C(═O)NR λ R π , —NHC(═O)NR λ R π , —O—C(═O)NR λ R π , —SO m R ψ , carboxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, amino carbonyl amino, mercapto, haloalkyl, optionally substituted aryl, optionally substituted heterocyclylalkyl, thioalkyl, —CONHR π , —OCOR π , —COR π , —NHSO 2 R π or —SO 2 NHR π (wherein R λ , R π , m and R ψ are the same as defined earlier). Aryl groups optionally may be fused with a cycloalkyl group, wherein the cycloalkyl group may optionally contain heteroatoms selected from O, N or S.
The term “aralkyl,” unless otherwise specified, refers to alkyl-aryl linked through an alkyl portion (wherein alkyl and aryl are as defined above). Examples of aralkyl groups include benzyl, ethylphenyl, propylphenyl, naphthylmethyl and the like.
The term “aralkenyl,” unless otherwise specified, refers to alkenyl-aryl linked through alkenyl portion (wherein alkenyl and aryl are as defined above).
The term “aryloxy” denotes the group O-aryl, wherein aryl is as defined above.
The term “cycloalkoxy” denotes the group O-cycloalkyl, wherein cycloalkyl is as defined above.
The term “carboxy,” as defined herein, refers to —C(═O)OR ψ wherein R ψ is the same as defined above.
The term “heteroaryl,” unless otherwise specified, refers to a monocyclic aromatic ring structure containing 5 or 6 ring atoms or a bicyclic or tricyclic aromatic group having from 8 to 10 ring atoms, with one or more heteroatom(s) independently selected from N, O or S and optionally substituted with 1 to 4 substituent(s) selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, carboxy, aryl, alkoxy, aralkyl, cyano, nitro, heterocyclyl, heteroaryl, —NR λ R π , CH═NOH, —(CH 2 ) w C(═O)R η {wherein w is an integer from 0-4 and R η is hydrogen, hydroxy, OR λ , NR λ R π , —NHOR ω , or —NHOH}, —C(═O)NR λ R π —NHC(═O)NR λ R π , —SO m R ψ , —O—C(═O)NR λ R π , —O—C(═O)R λ , or —O—C(═O)OR λ (wherein m, R ψ , R λ , and R π are as defined earlier and R ω is alkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, the substituents are attached to a ring atom, i.e., carbon or heteroatom in the ring. Examples of heteroaryl groups include oxazolyl, imidazolyl, pyrrolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, tetrazolyl, thiazolyl, oxadiazolyl, benzoimidazolyl, thiadiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, thienyl, isoxazolyl, triazinyl, furanyl, benzofuranyl, indolyl, benzthiazinyl, benzthiazinonyl, benzoxazinyl, benzoxazinonyl, quinazonyl, carbazolyl phenothiazinyl, phenoxazinyl, benzothiazolyl or benzoxazolyl, and the like.
The term “heterocyclyl,” unless otherwise specified, refers to a non-aromatic cycloalkyl group having 5 to 10 atoms wherein 1 to 4 carbon atoms in a ring are replaced by heteroatoms selected from O, S(O) m (wherein m is an integer from 0-2) or N, and optionally are benzofused or fused heteroaryl having 5-6 ring members and/or optionally are substituted, wherein the substituents are selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, optionally substituted aryl, alkoxy, alkaryl, cyano, nitro, oxo, carboxy, optionally substituted heterocyclyl, optionally substituted heterocyclylalkyl, optionally substituted heteroaryl, —O—C(═O)R λ , —O—C(═O)OR λ , —C(═O)NR λ R π , SO m R ψ , —O—C(═O)NR λ R π , —NHC(═O)NR λ R π , —NR λ R π , mercapto, haloalkyl, thioalkyl, —COOR ψ , —COONHR λ , —COR λ , —NHSO 2 R λ , or SO 2 NHR λ (wherein m, R ψ , R λ and R π are as defined earlier) or guanidine. Such ring systems can be mono-, bi- or tricyclic. Carbonyl or sulfonyl group can replace carbon atom(s) of heterocyclyl. Unless otherwise constrained by the definition, the substituents are attached to the ring atom, i.e., carbon or heteroatom in the ring. Also, unless otherwise constrained by the definition, the heterocyclyl ring optionally may contain one or more olefinic bond(s). Examples of heterocyclyl groups include tetrahydropyranyl, oxazolidinyl, tetrahydrofuranyl, dihydrofuranyl, benzoxazinyl, benzthiazinyl, imidazolyl, benzimidazolyl, tetrazolyl, carbaxolyl, indolyl, phenoxazinyl, phenothiazinyl, dihydropyridinyl, dihydroisoxazolyl, dihydrobenzofuryl, azabicyclohexyl, thiazolidinyl, dihydroindolyl, isoindole 1,3-dione, piperidinyl, piperazinyl, 3H-imidazo[4,5-b]pyridine, isoquinolinyl, dioxolanyl, 1H-pyrrolo[2,3-b]pyridine or piperazinyl and the like.
“Spiro-attached heterocyclyl” refers to heterocyclyl group attached to ring M of Formula I via one carbon atom common to both rings, i.e. ring M and heterocyclyl ring.
“Heteroarylalkyl” refers to alkyl-heteroaryl group linked through alkyl portion, wherein the alkyl and heteroaryl are as defined earlier.
“Heterocyclylalkyl” refers to alkyl-heterocyclyl group linked through alkyl portion, wherein the alkyl and heterocyclyl are as defined earlier.
“Acyl” refers to —C(═O)R z (wherein R z is alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl).
“Amine,” unless otherwise specified, refers to —NH 2 . “Substituted amine” unless otherwise specified, refers to a group —N(R k ) 2 wherein each R k is independently selected from the group hydrogen provided that both R k groups are not hydrogen (defined as “amine”), alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl, heteroarylalkyl, acyl, S(O) m R ψ (wherein m and R ψ are the same as defined above), —C(═R v )NR λ R π (wherein R v is O or S and R λ and R π are the same as defined earlier) or NHC(═R v )NR π R λ (wherein R v , R π and R λ , are the same as defined earlier). Unless otherwise constrained by the definition, all amine substituents may optionally be further substituted by 1-3 substituents chosen from alkyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, carboxy, —COOR ψ , hydroxy, alkoxy, halogen, CF 3 , cyano, —C(═R v )NR λ R π , —O(C═O)NR λ R π , —OC(═R v )NR λ R y (wherein R λ , R π and R v are the same as defined earlier), —S(O) m R ψ (wherein R ψ and m are the same as defined above).
“Thiocarbonyl” refers to —C(═S)H. Thiocarbonyl may be substituted and “Substituted thiocarbonyl” refers to —C(═S)R″′, wherein R″′ is selected from alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl, heterocyclylalkyl, amine or substituted amine. Unless otherwise constrained by the definition, all substituents optionally may be substituted further by 1-3 substituents selected from alkyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, carboxy, hydroxy, alkoxy, halogen, CF 3 , cyano, —C(═O)NR λ R π , —O—C(═O)NR λ R π and —SO m R ψ (wherein R λ , R π , m and R ψ are as defined earlier).
The term “oxo” means “═O”. Oxo is attached at a carbon atom unless otherwise noted. Oxo, together with the carbon atom to which it is attached forms a carbonyl group (i.e., C═O).
The term “halogen” refers to fluorine, chlorine, bromine or iodine.
The compounds of the present invention can be used for treatment, prevention, inhibition or suppression of CNS diseases, for example, multiple sclerosis; various pathological conditions such as diseases affecting the immune system, including AIDS, rejection of transplant, auto-immune disorders such as T-cell related diseases, for example, rheumatoid arthritis; inflammatory diseases such as respiratory inflammation diseases including chronic obstructive pulmonary disease (COPD), asthma, bronchitis, allergic rhinitis, adult respiratory distress syndrome (ARDS) and other inflammatory diseases including but not limited to psoriasis, shock, atopic dermatitis, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis; gastrointestinal inflammation diseases such as Crohn's disease, colitis, pancreatitis as well as different types of cancers including leukaemia; especially in humans.
In accordance with yet another aspect, there are provided processes for the preparation of the compounds as described herein.
DETAILED DESCRIPTION OF THE INVENTION
The compounds described herein may be prepared by techniques well known in the art and familiar to the average synthetic organic chemist. In addition, the compounds of present invention may be prepared by the following reaction sequences as depicted in Schemes I, II, III, IV, V, VI, VII, VIII, IX, X, XI, XI a, XII, XIII, XIV and XV.
The compounds of Formula I can be prepared by following Scheme I. Accordingly, compounds of Formula II are reacted with compounds of Formula III to give compounds of Formula IV (wherein R 1a is alkyl), which on heating give compounds of Formula V(a), which on reaction with phosphorous oxy halide give compounds of Formula V (wherein X is a halogen) or compounds of Formula IV are reacted with phosphorous oxy halide to give compounds of Formula V (wherein X is same as defined earlier), which on reaction with compounds of Formula VI give compounds of Formula VII (wherein R 1 and R 2 are the same as defined earlier), which on ester hydrolysis give compounds of Formula VIII, or compounds of Formula V on ester hydrolysis give compounds of Formula VII (a), which on reaction with compounds of Formula VI give compounds of Formula VIII (wherein R 1 and R 2 are the same as defined earlier), which on reaction with compounds of Formula I×give compounds of Formula X (wherein R 1a is alkyl), which on reduction give compounds of Formula XI, which on reaction with hydroxylamine hydrochloride give compounds of Formula XII, which are finally reacted with compounds of Formula XIII to give compounds of Formula I (wherein R 3 and M are the same as defined earlier).
The compounds of Formula IV can be prepared by the reaction of compounds of Formula II with compounds of Formula III on heating.
The compounds of Formula V (a) can be prepared by the heating of compounds of Formula IV in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol in the presence of a high boiling medium, for example, diphenyl ether, dimethylsulfoxide or mixture(s) thereof.
The compounds of Formula V can be prepared by the reaction of compounds of Formula V a with phosphorous oxy halide on heating.
The compounds of Formula V can also be prepared by the reaction of compounds of Formula IV with phosphorous oxy halide on heating.
The ester hydrolysis of compounds of Formula V to give compounds of Formula VII (a) can be carried out in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, dioxane or tetrahydrofuran; or an alcohol and water mixture.
The ester hydrolysis of compounds of Formula V can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The reaction of compounds of Formula VII (a) with compounds of Formula VI to give compounds of Formula VIII can be carried out in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reaction of compounds of Formula VII (a) with compounds of Formula VI can be carried out in the optional presence of one or more bases, for example, triethylamine, pyridine, potassium tert-butoxide, sodium hydride or mixture(s) thereof.
The reaction of compounds of Formula V with compounds of Formula VI to give compounds of Formula VII can be carried out in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reaction of compounds of Formula V with compounds of Formula VI can be carried out in the optional presence of one or more bases, for example, triethylamine, pyridine, potassium tert-butoxide, sodium hydride or mixture(s) thereof.
The ester hydrolysis of compounds of Formula VII to give compounds of Formula VIII can be carried out in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or an alcohol and water mixture.
The ester hydrolysis of compounds of Formula VII to give compounds of Formula VIII can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The reaction of compounds of Formula VIII with compounds of Formula IX to give compounds of Formula X can be carried out in the presence of one or more activating reagents, for example, hydroxybenzotriazole, acetone oxime, 2-hydroxypyridine or mixture(s) thereof, and one or more coupling reagents, for example, 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride, 1,3-dicyclohexyl carbodiimide or mixture(s) thereof in one or more solvents, for example, ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; or mixture(s) thereof.
The reaction of compounds of Formula VIII with compounds of Formula IX can be carried out in the presence of one or more bases, for example, N-methylmorpholine; N-ethyldiisopropylamine; 4-dialkylaminopyridines, for example, 4-dimethylaminopyridine; or mixture(s) thereof.
The reduction of compounds of Formula X to give compounds of Formula XI can be carried out in one or more solvents, for example, ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reduction of compounds of Formula X to give compounds of Formula XI can be carried out in the presence of one or more reducing agents, for example, sodium bis(2-methoxyethoxy)aluminium hydride (vitride), lithium aluminium hydride or mixture(s) thereof.
The reaction of compounds of Formula XI with hydroxylamine hydrochloride to give compounds of Formula XII can be carried out in the presence of sodium acetate in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or mixture(s) thereof.
The reaction of compounds of Formula XII with compounds of Formula XIII to give compounds of Formula I can be carried out in the presence of one or more halogenating agents, for example, sodium hypochlorite, N-chlorosuccinimide, N-bromosuccinimide or mixture(s) thereof in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XII with compounds of Formula XIII can be carried out in the optional presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The compounds of Formulae XVI (a), XVIII, XIX and XX can be prepared by following Scheme II. Accordingly, compounds of Formula XII are reacted with compounds of Formula XIV to give compounds of Formula XV (wherein R 1a is alkyl), which on reduction give compounds of Formula XVI or compounds of Formula XII are reacted with compounds of Formula XIV (a) to give compounds of Formula XVI, which on
(i) cyclization give compounds of Formula XVI (a) (wherein R 1 , R 2 , R 3 are the same as defined earlier and m is an integer from 0-2). (ii) mesylation give compounds of Formula XVII, which on cyclization give compounds of Formula XVIII, which are oxidized to give compounds of Formula XIX (wherein R 1 , R 2 , R 3 are the same as defined earlier and m is an integer from 0-2) or compounds of Formula XX (wherein R 1 , R 2 , R 3 are the same as defined earlier and m is an integer from 0-2).
The reaction of compounds of Formula XII with compounds of Formula XIV or compounds of Formula XIV (a) to give compounds of Formula XV or compounds of Formula XVI can be carried out, for example, by 1,3-dipolar cycloaddition reaction in the presence of one or more halogenating agents, for example, sodium hypochlorite, N-bromosuccinimide, N-chlorosuccinimide or mixture(s) thereof in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XII with compounds of Formula XIV or compounds of Formula XIV (a) to give compounds of Formula XV or compounds of Formula XVI can be carried out in the optional presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The reduction of compounds of Formula XV to give compounds of Formula XVI can be carried out in the presence of one or more reducing agents, for example, sodium borohydride, lithium aluminium hydride, borane dimethyl sulphide in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; esters, for example, ethyl acetate; or mixture(s) thereof.
The cyclization of compounds of Formula XVI to give compounds of Formula XVI (a) can be carried out in Mitsunobu fashion with triaryl phosphines, for example, triphenylphosphine; dialkyl azodicarboxylates, for example, diisopropyl azodicarboxylate; and succinimide in one or more solvents, for example, ethers, for example, tetrahydrofuran or diethyl ether; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The mesylation of compounds of Formula XVI to give compounds of Formula XVII can be carried out in the presence of one or more mesylating agents, for example, methanesulfonyl chloride, methanesulfonic anhydride, trifluoromethanesulfonic anhydride or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; ethers, for example, tetrahydrofuran or diethyl ether; nitriles, for example, acetonitrile; or mixture(s) thereof.
The mesylation of compounds of Formula XVI to give compounds of Formula XVII can be carried out in the presence of one or more bases, for example, triethylamine, pyridine, 2,6-lutidene, diisopropyl ethylamine or mixture(s) thereof.
The cyclization of compounds of Formula XVII to give compounds of Formula XVIII can be carried out in the presence of one or more hydrated or anhydrous alkali metal sulphides, for example, sodium sulphide in one or more solvents, for example, ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The oxidation of compounds of Formula XVIII to give compounds of Formula XIX or compounds of Formula XX can be carried out in the presence of one or more oxidizing agents, for example, sodium periodate, m-chloroperbenzoic acid, tert-butyl hydroperoxide or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; water or mixture(s) thereof
The compounds of Formulae XXII and XXIII can be prepared by following Scheme III. Accordingly, compounds of Formula XXI are oxidized to give compounds of Formula XXII, which are finally reacted with hydroxylamine hydrochloride to give compounds of Formula XXIII (wherein R 3 and M are the same as defined earlier).
The compounds of Formula XXI can be oxidized to give compounds of Formula XXII in the presence of one or more oxidizing agents, for example, pyridinium chlorochromate, pyridinium dichromate, dess martin periodinane or mixture(s) thereof in the presence of one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide or mixture(s) thereof.
The reaction of compounds of Formula XXII with hydroxylamine hydrochloride to give compounds of Formula XXIII can be carried out in the presence of one or more bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal acetates, for example, sodium acetate or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; ethers, for example, tetrahydrofuran or diethyl ether; nitriles, for example, acetonitrile; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The compounds of Formula XXVII can be prepared by following Scheme IV. Accordingly, compounds of Formula XII are reacted with compounds of Formula XXIV to give compounds of Formula XXV (wherein R 1a is alkyl and X is halogen), which on reduction give compounds of Formula XXVI, which on cyclization give compounds of Formula XXVII (wherein R 1 , R 2 and R 3 are the same as defined earlier).
The reaction of compounds of Formula XII with compounds of Formula XXIV to give compounds of Formula XXV can be carried out, for example, by 1,3-dipolar cycloaddition reaction in the presence of one or more reagents, for example, sodium hypochlorite, N-bromosuccinimide, N-chlorosuccinimide or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XII with compounds of Formula XXIV to give compounds of Formula XXV can be carried out in the optional presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The reduction of compounds of Formula XXV to give compounds of Formula XXVI can be carried out in the presence of one or more reducing agents, for example, sodium borohydride, lithium aluminium hydride, borane dimethyl sulphide or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; esters, for example, ethyl acetate; or mixture(s) thereof.
The cyclization of compounds of Formula XXVI to give compounds of Formula XXVII can be carried out in the presence of one or more alkali metal hydroxides, for example, sodium hydroxide, potassium hydroxide or lithium hydroxide, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal alkoxides, for example, potassium t-butoxide, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; water; or mixture(s) thereof.
The compounds of Formulae XXIX and XXXI can be prepared by following Scheme V. Accordingly, deprotection of compounds of Formula XXVIII (wherein R 1a is alkyl) give compounds of Formula XXIX, which on reaction with compounds of Formula XXX (wherein X is halogen) give compounds of Formula XXXI (wherein R 1 , R 2 , R 3 are the same as defined earlier and R is alkyl, cycloalkyl, cycloalkylalkyl, —COR 4 or —SO 2 R 4 and R 4 is the same as defined earlier).
The deprotection of compounds of Formula XXVIII to give compounds of Formula XXIX can be carried out in the presence of one or more acids, for example, hydrochloric acid, trifluoroacetic acid, p-toluene sulphonic acid or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XXIX with compounds of Formula XXX to give compounds of Formula XXXI can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The compounds of Formulae XXXIII, XXXIII (a), and XXXIII (c) can be prepared by following Scheme VI. Accordingly, hydrolysis of compounds of Formula XXXII give compounds of Formula XXXIII, which on
(a) reduction give compounds of Formula XXXIII (a) (wherein R 1 , R 2 and R 3 are the same as defined earlier and A is a 3-7 membered saturated, partially saturated or unsaturated ring containing carbon atoms). (b) reaction with chloroacetonitrile give compounds of XXXIII (b), which are hydrolysed to give compounds of Formula XXXIII (c) (wherein R 1 , R 2 and R 3 are the same as defined earlier and A is a 3-7 membered saturated, partially saturated or unsaturated ring containing carbon atoms).
The hydrolysis of compounds of Formula XXXII to give compounds of Formula XXXIII can be carried out in the presence of one or more acids, for example trifluoroacetic acid, p-toluene sulphonic acid or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; water or mixture(s) thereof.
The reduction of compounds of Formula XXXIII to give compounds of Formula XXXIII (a) can be carried out in the presence of reducing reagents, for example, sodium borohyride in combination with one or more lewis acid catalysts, for example cerium chloride, sodium triacetoxy borohydride or sodium cyanoborohydride or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XXXIII with chloroacetonitrile to give compounds of Formula XXXIII (b) can be carried out in the presence of one or more phase transfer catalysts, for example, benzyltriethyl ammonium chloride, benzyltriethyl ammonium iodide or 18-crown-6 in one or more solvents, for example, ethers, for example, tetrahydrofuran or diethyl ether; nitriles, for example, acetonitrile; or mixture(s) thereof.
The reaction of compounds of Formula XXXIII with chloroacetonitrile can be carried out in the presence of one or more bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide, or mixture(s) thereof.
The hydrolysis of compounds of Formula XXXIII (b) to give compounds of Formula XXXIII (c) can be carried out in the presence of lewis acid reagents, for example, lithum bromide, magnesium bromide or mixture(s) thereof in one or more solvents, for example, water; nitriles, for example, acetonitrile; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The compounds of Formulae XXXIV and XXXVI can be prepared by following Scheme VII. Accordingly, compounds of Formula XXXIV (a) (wherein Pr is a protecting group, for example, p-methoxy benzyl, benzyl or 2-furanylmethyl) are deprotected to give compounds of Formula XXXIV, which are reacted with compounds of Formula XXXV (wherein X is halogen) to give compounds of Formula XXXVI (wherein R′ is alkyl, cycloalkyl or cycloalkylalkyl and R 1 , R 2 , R 3 and M are the same as defined earlier).
The deprotection of compounds of Formula XXXIV (a) to give compounds of Formula XXXIV can be carried out in the presence of ceric ammonium nitrate; or one or more oxidizing agents, for example, selenium dioxide; or one or more organic acids, for example, trifluoroacetic acid; or under hydrogenation conditions using hydrogen over palladium/carbon; in the optional presence of one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; alcohols, for example, methanol, ethanol, propanol or butanol; esters, for example, ethyl acetate; or mixture(s) thereof.
The reaction of compounds of Formula XXXIV with compounds of Formula XXXV to give compounds of Formula XXXVI can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof
The compounds of Formulae XXXVIII and XXXIX can be prepared by following Scheme VIII. Accordingly, compounds of Formula XXXVII (wherein R 1a is alkyl) are deprotected to give compounds of Formula XXXVIII, which are reacted with compounds of Formula XXX (wherein X is halogen) to give compounds of Formula XXXIX (wherein R is alkyl, cycloalkyl, cycloalkylalkyl, —COR 4 or —SO 2 R 4 and R 4 is the same as defined earlier and R 3 and M are the same as defined earlier).
The deprotection of compounds of Formula XXXVII to give compounds of Formula XXXVIII can be carried out in the presence of one or more acids, for example, hydrochloric acid, trifluoroacetic acid, p-toluene sulphonic acid or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XXXVIII with compounds of Formula XXX to give compounds of Formula XXXIX can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, nitriles, for example, acetonitrile; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The compounds of Formulae XLI, XLII and XLIIII can be prepared by following Scheme IX. Accordingly, compounds of Formula XL (wherein Pr is a protecting group, for example, p-methoxy benzyl, benzyl or 2-furanylmethyl) are deprotected to give compounds of Formula XLI, which are reacted with compounds of Formula XXXV (wherein X is as defined earlier) to give compounds of Formula XLII, which are finally debenzylated to give compounds of Formula XLIII (wherein R′ is alkyl, cycloalkyl or cycloalkylalkyl and R 1 , R 2 , R 3 , M and m are the same as defined earlier).
The deprotection of compounds of Formula XL to give compounds of Formula XLI can be carried out in the presence of eerie ammonium nitrate; or one or more oxidizing agents, for example, selenium dioxide; or one or more organic acids, for example, trifluoroacetic acid; or under hydrogenation conditions using hydrogen over palladium/carbon; in the optional presence of one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; alcohols, for example, for example, methanol, ethanol, propanol or butanol; esters, for example, esters, for example, ethyl acetate; or mixture(s) thereof.
The reaction of compounds of Formula XLI with compounds of Formula XXXV to give compounds of Formula XLII can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The debenzylation of a compounds of Formula XLII to give compounds of Formula XLIII can be carried out in the presence of one or more debenzylating agents, for example, palladium on carbon/hydrogen, palladium on carbon with ammonium formate, palladium hydroxide or mixture(s) thereof, in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or mixture(s) thereof.
The compounds of Formula L can be prepared by following Scheme X. Accordingly, compounds of Formula V (wherein X is halogen and R 1a is alkyl) are reacted with compounds of Formula VI (a) to give compounds of Formula XLIV, which on oxidation give compounds of Formula XLV, which on ester hydrolysis give compounds of Formula XLVI, which on reaction with compounds of Formula IX (wherein R 1a is alkyl) give compounds of Formula XLVII, which on reduction give compounds of Formula XLVIII, which on reaction with hydroxylamine hydrochloride give compounds of Formula XLIX, which are reacted with compounds of Formula XIII to give compounds of Formula L (wherein R 3 and M are the same as defined earlier).
The reaction of compounds of Formula V with compounds of Formula VI (a) to give compounds of Formula XLIV can be carried out in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reaction of compounds of Formula V with compounds of Formula VI (a) can be carried out in the optional presence of one or more bases, for example, triethylamine, pyridine, potassium tert-butoxide, sodium hydride or mixture(s) thereof.
The oxidation of compounds of Formula XLIV to give compounds of Formula XLV can be carried out in the presence of one or more oxidizing agents, for example, m-chloroperbenzoic acid, oxone or hydrogen peroxide in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The ester hydrolysis of compounds of Formula XLV to give compounds of Formula XLVI can be carried out in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or an alcohol and water mixture.
The ester hydrolysis of compounds of Formula XLV can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The reaction of compounds of Formula XLVI with compounds of Formula IX to give compounds of Formula XLVII can be carried out in the presence of one or more activating reagents, for example, hydroxybenzotriazole, acetone oxime, 2-hydroxypyridine or mixture(s) thereof, and one or more coupling reagents, for example, 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride, 1,3-dicyclohexyl carbodiimide or mixture(s) thereof in one or more solvents, for example, ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; or mixture(s) thereof.
The reaction of compounds of Formula XLVI with compounds of Formula IX can be carried out in the presence of one or more bases, for example, N-methylmorpholine; N-ethyldiisopropylamine; 4-dialkylaminopyridines, for example, 4-dimethylaminopyridine; or mixture(s) thereof.
The reduction of compounds of Formula XLVII to give compounds of Formula XLVIII can be carried out in one or more solvents, for example, ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reduction of compounds of Formula XLVII can be carried out in the presence of one or more reducing agents, for example, sodium bis(2-methoxyethoxy)aluminum hydride (vitride), lithium aluminium hydride or mixture(s) thereof.
The reaction of compounds of Formula XLVIII with hydroxylamine hydrochloride to give compounds of Formula XLIX can be carried out in the presence of sodium acetate in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol, butanol or mixture(s) thereof.
The reaction of compounds of Formula XLIX with compounds of Formula XIII to give compounds of Formula L can be carried out in the presence of one or more halogenating agents, for example, sodium hypochlorite, N-chlorosuccinimide, N-bromosuccinimide or mixture(s) thereof, in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula XLIX with compounds of Formula XIII can be carried out in the optional presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The compounds of Formula LXVI can be prepared by following Scheme XI. Accordingly, compounds of Formula LI (wherein R 1a is alkyl and Pr is a protecting group, for example, p-methoxy benzyl, benzyl or 2-furanylmethyl) on heating give compounds of Formula LII, which on reaction with phosphorous oxy halide give compounds of Formula LIII (wherein X is a halogen), which on reaction with compounds of Formula LIV give compounds of Formula LV, which on ester hydrolysis give compounds of Formula LVI, which on reaction with compounds of Formula IX (wherein R 1a is the same as defined earlier) give compounds of Formula LVII, which on deprotection give compounds of Formula LVIII, which on reaction with compounds of Formula LIX (wherein X is halogen) give compounds of Formula LX, which on reduction give compounds of Formula LXI, which on reaction with hydroxylamine hydrochloride give compounds of Formula LXII, which on reaction with compounds of Formula XIII give compounds of Formula LXIII, which on deprotection give compounds of Formula LXIV, which are finally reacted with compounds of Formula LXV (wherein X is halogen) to give compounds of Formula LXVI (wherein R 3b is alkyl or cycloalkyl, R 3c is aryl or heteroaryl and R 3 and M are the same as defined earlier).
The compounds of Formula LXIII (a) can be prepared by following Scheme XI a. Accordingly, compounds of Formula LIII (wherein X is halogen, R 1a is alkyl and Pr is a protecting group, for example, p-methoxy benzyl, benzyl or 2-furanylmethyl) on reaction with compounds of Formula VI give compounds of Formula LV (a), which on ester hydrolysis give compounds of Formula LVI (a), which on reaction with compounds of Formula IX (wherein R 1a is the same as defined earlier) give compounds of Formula LVII (a), which on deprotection give compounds of Formula LVIII (a), which on reaction with compounds of Formula LIX (wherein X is halogen) give compounds of Formula LX (a), which on reduction give compounds of Formula LXI (a), which on reaction with hydroxylamine hydrochloride give compounds of Formula LXII (a), which are finally reacted with compounds of Formula XIII to give compounds of Formula LXIII (a) (wherein R 3b is alkyl or cycloalkyl and R 1 , R 2 , R 3 and M are the same as defined earlier).
The compounds of Formula LII can be prepared by heating of compounds of Formula LI in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol in the presence of a high boiling medium, for example, diphenyl ether, dimethylsulfoxide or mixture(s) thereof.
The compounds of Formula LIII can be prepared by the reaction of compounds of LII with phosphorous oxy halide on heating.
The reaction of compounds of Formula LIII with compounds of Formula LIV or compounds of Formula VI to give compounds of Formula LV or compounds of Formula LV (a), respectively can be carried out in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reaction of compounds of Formula LIII with compounds of Formula LIV or compounds of Formula VI can be carried out in the optional presence of one or more bases, for example, triethylamine, pyridine, potassium tert-butoxide, sodium hydride or mixture(s) thereof.
The ester hydrolysis of compounds of Formula LV or compounds of Formula LV (a) to give compounds of Formula LVI or compounds of Formula LVI (a), respectively can be carried out in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or an alcohol and water mixture.
The ester hydrolysis of compounds of Formula LV or compounds of Formula LV (a) can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The reaction of compounds of Formula LVI or compounds of Formula LVI (a) with compounds of Formula IX to give compounds of Formula LVII or compounds of Formula LVII (a), respectively can be carried out in the presence of one or more activating reagents, for example, hydroxybenzotriazole, acetone oxime, 2-hydroxypyridine or mixture(s) thereof, and one or more coupling reagents, for example, 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride, 1,3-dicyclohexyl carbodiimide or mixture(s) thereof in one or more solvents, for example, ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; or mixture(s) thereof.
The reaction of compounds of Formula LVI or compounds of Formula LVI (a) with compounds of Formula IX can be carried out in the presence of one or more bases, for example, N-methylmorpholine; N-ethyldiisopropylamine; 4-dialkylaminopyridines, for example, 4-dimethylaminopyridine; or mixture(s) thereof.
The deprotection of compounds of Formula LVII or compounds of Formula LVII (a) to give compounds of Formula LVIII or compounds of Formula LVIII (a), respectively can be carried out in the presence of one or more acids, for example, hydrochloric acid, trifluoroacetic acid, p-toluene sulphonic acid or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula LVIII or compounds of Formula LVIII (a) with compounds of Formula LIX to give compounds of Formula LX or compounds of Formula LX (a), respectively can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate or potassium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, nitriles, for example, acetonitrile; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The reduction of compounds of Formula LX or compounds of Formula LX (a) to give compounds of Formula LXI or compounds of Formula LXI (a), respectively can be carried out in one or more solvents, for example, ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reduction of compounds of Formula LX or compounds of Formula LX (a) can be carried out in the presence of one or more reducing agents, for example, sodium bis(2-methoxyethoxy)aluminum hydride (vitride), lithium aluminium hydride or mixture(s) thereof.
The reaction of compounds of Formula LXI or compounds of Formula LXI (a) with hydroxylamine hydrochloride to give compounds of Formula LXII or compounds of Formula LXII a, respectively can be carried out in the presence of sodium acetate in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol, butanol or mixture(s) thereof.
The reaction of compounds of Formula LXII or compounds of Formula LXII (a) with compounds of Formula XIII to give compounds of Formula LXIII or compounds of Formula LXIII (a), respectively can be carried out in the presence of one or more halogenating agents, for example, sodium hypochlorite, N-chlorosuccinimide, N-bromosuccinimide or mixture(s) thereof, in one or more solvents, for example, nitriles, for example, acetonitrile; ketones, for example, acetone; alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula LXII or compounds of Formula LXII (a) with compounds of Formula XIII can be carried out in the optional presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The deprotection of compounds of Formula LXIII to give compounds of Formula LXIV can be carried out in the presence of palladium on carbon/hydrogen, palladium hydroxide/carbon with hydrogen, ammonium formate/palladium on carbon, in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof.
The reaction of compounds of Formula LXIV with compounds of Formula LXV to give compounds of Formula LXVI can be carried out in the presence of one or more transition metal catalysts, for example, tris(dibenzylidineacetone)dipalladium(0), palladium(II) acetate, tetrakis(triphenylphosphine)palladium(0), tetrakis(methyldiphenylphosphine) palladium(0), trans-dichlorobis(methyldiphenylphosphine)palladium(II), dichlorobis (triphenylphosphine)palladium(II), bis[1,2-bis(diphenylphosphino)ethane]palladium(0), copper (I) iodide, cuprous oxide, cuprous bromide, cuprous chloride or mixture(s) thereof.
The reaction of compounds of Formula LXIV with compounds of Formula LXV can be carried out in the presence of one or more phosphine ligands, for example, xantphos, 1,1′-bis(di-tert-butylphosphino)ferrocene, 2,2′-bis(diphenylphosphino)diphenyl ether (DPEphos), bis(triethylphosphine)nickel (II) chloride, (R,S)-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl, (S)-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl, (R)-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl or mixture(s) thereof.
The reaction of compounds of Formula LXIV with compounds of Formula LXV can be carried out in the presence of one or more bases, for example, amines, for example, N-ethyldiisopropylamine, triethyl amine or dimethylamino pyridine, alkali metal alkoxides, for example, sodium tert-butoxide, potassium tert-butoxide, sodium methoxide, lithium methoxide, potassium methoxide or cesium methoxide, alkali metal hydroxides, for example, sodium hydroxide, lithium hydroxide, potassium hydroxide or cesium hydroxide, alkali metal halides, for example, potassium fluoride, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate or mixture(s) thereof.
The reaction of compounds of Formula LXIV with compounds of Formula LXV can be carried out in one or more solvents, for example, ethers, for example, dioxane or tetrahydrofuran, amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof
The compounds of Formula LXVII can be prepared by following Scheme XII. Accordingly, ester hydrolysis of compounds of Formula LXVII (a) (wherein R 1a is alkyl) gives compounds of Formula LXVII (wherein R 3 and M are the same as defined earlier and ring D is cyclobutyl or cyclohexyl ring).
The ester hydrolysis of compounds of Formula LXVII (a) to give compounds of Formula LXVII can be carried out in the presence of one or more acids, for example, hydrochloric acid, trifluoroacetic acid, p-toluene sulphonic acid or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; or mixture(s) thereof
The compounds of Formulae LXX, LXXI, LXXII and LXXIV can be prepared by following Scheme XIII. Accordingly, compounds of Formula LXVIII are
(a) protected to give compounds of Formula LXIX (wherein Pr 1 is a protecting group, for example, tosylate, mesylate or triflate) which on reaction with sodium cyanide give compounds of Formula LXX, which on
(i) hydrolysis give compounds of Formula LXXI (wherein R 1 , R 2 , R 3 , m and M are the same as defined earlier). (ii) cyclization give compounds of Formula LXXII (wherein R 1 , R 2 , R 3 , m and M are the same as defined earlier).
(b) reacted with compounds of Formula LXXIII (wherein X is halogen) to give compounds of Formula LXXIV (wherein R 1 , R 2 , R 3 , R 4 , m and M are the same as defined earlier).
The protection of compounds of Formula LXVIII to give compounds of Formula LXIX
can be carried out with one or more protecting reagents, for example, p-toluene sulphonyl chloride, methyl sulphonyl chloride or trifluoromethanesulfonyl chloride in one or more solvents, for example, ethers, for example, dioxane, tetrahydrofuran or diethyl ether; halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The protection of compounds of Formula LXVIII to give compounds of Formula LXIX
can be carried out in the presence of one or more bases, for example, triethyl amine, trimethyl amine or mixture(s) thereof.
The reaction of compounds of Formula LXIX with sodium cyanide to give compounds of Formula LXX can be carried out in the presence of one or more solvents, for example, amides, for example, dimethylformamide, dimethylacetamide or mixture(s) thereof.
The hydrolysis of compounds of Formula LXX to give compounds of Formula LXXI can be carried out in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; or an alcohol and water mixture.
The hydrolysis of compounds of Formula LXX can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The cyclization of compounds of Formula LXX to give compounds of Formula LXXII can be carried out in the presence of sodium azide and triethyl amine hydrochloride in one or more solvents, for example, amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide; hydrocarbons, for example, hexane or toluene; or mixture(s) thereof.
The reaction of compounds of Formula LXVIII with compounds of Formula LXXIII to give compounds of Formula LXXIV can be carried out in the presence of one or more alkali metal hydroxides, for example, sodium hydroxide, potassium hydroxide or lithium hydroxide, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal alkoxides, for example, potassium t-butoxide, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof in one or more solvents, for example, alcohols, for example, methanol, ethanol, propanol or butanol; ethers, for example, tetrahydrofuran or diethyl ether; amides, for example, dimethylformamide or dimethylacetamide; water; or mixture(s) thereof.
The compounds of Formulae LXXI, LXXV (a) and LXXV (b) can be prepared by following Scheme XIV. Accordingly, compounds of Formula LXXVI (wherein R 1a is alkyl) on ester hydrolysis give compounds of Formula LXXI, which are reacted with ammonium carbonate or compounds of Formula LXXV to give compounds of Formula LXXV (a) (wherein R 1 , R 2 , R 3 , m and M are the same as defined earlier) or compounds of Formula LXXV (b) (wherein R 1 , R 2 , R 3 , R 4 , R′ 4 , m and M are the same as defined earlier) respectively.
The ester hydrolysis of compounds of Formula LXXVI to give compounds of Formula LXXI can be carried out in one or more solvents, for example, water; ethers, for example, diethyl ether or tetrahydrofuran; alcohols, for example, methanol, ethanol, propanol or butanol; or mixture(s) thereof.
The ester hydrolysis of compounds of Formula LXXVI can be carried out in the presence of one or more inorganic bases, for example, alkali metal hydroxides, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide or mixture(s) thereof.
The reaction of compounds of Formula LXXI with ammonium carbonate or compounds of Formula LXXV to give compounds of Formula LXXV (a) or compounds of Formula LXXV (b), respectively can be carried out in the presence of one or more activating reagents, for example, hydroxybenzotriazole, acetone oxime, 2-hydroxypyridine or mixture(s) thereof, and one or more coupling reagents, for example, 1-ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride, 1,3-dicyclohexyl carbodiimide or mixture(s) thereof in one or more solvents, for example, ethers, for example, diethyl ether or tetrahydrofuran; amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide or mixture(s) thereof.
The reaction of compounds of Formula LXXI with ammonium carbonate or compounds of Formula LXXV can be carried out in the presence of one or more bases, for example, N-methylmorpholine; N-ethyldiisopropylamine; 4-dialkylaminopyridines, for example, 4-dimethylaminopyridine; or mixture(s) thereof
The compounds of Formulae LXXVIII, LXXX and LXXXI can be prepared by following Scheme XV. Accordingly, compounds of Formula LXIX (wherein Pr 1 is a protecting group, for example, tosylate, mesylate or triflate) on reaction with sodium azide give compounds of Formula LXXVII, which on reduction give compounds of Formula LXXVIII, which on reaction with
(a) compounds of Formula LXXIX (wherein X is halogen) give compounds of Formula LXXX (wherein R 1 , R 2 , R 3 , R 4 , m and M are the same as defined earlier). (b) compounds of Formula LXXIII (wherein X is halogen) give compounds of Formula LXXXI (wherein R 1 , R 2 , R 3 , R 4 , m and M are the same as defined earlier).
The reaction of compounds of Formula LXIX with sodium azide to give compounds of Formula LXXVII can be carried out in the one or more solvents, for example, amides, for example, dimethylformamide or dimethylacetamide; sulfoxides, for example, dimethylsulfoxide or mixture(s) thereof.
The reduction of compounds of Formula LXXVII to give compounds of Formula LXXVIII can be carried out in the presence of one or more reducing agents, for example, sodium borohydride, lithium boro hydride, lithium aluminium hydride or hydrogen in the presence of palladium/carbon in one or more solvents, for example, ethers, for example, diethyl ether, dioxane or tetrahydrofuran; alcohols, for example, methanol, ethanol, propanol or butanol; or mixture(s) thereof.
The reaction of compounds of Formula LXXVIII with compounds of Formula LXXIX or Formula LXXIII to give compounds of Formula LXXX or compounds of Formula LXXXI, respectively can be carried out in the presence of one or more inorganic bases, for example, alkali metal carbonates, for example, sodium carbonate, potassium carbonate or cesium carbonate, alkali metal hydrides, for example, sodium hydride or mixture(s) thereof or one or more organic bases, for example, triethyl amine, N-ethyldiisopropyl amine or mixture(s) thereof in one or more solvents, for example, halogenated hydrocarbons, for example, dichloromethane, dichloroethane or chloroform; amides, for example, dimethylformamide or dimethylacetamide; or mixture(s) thereof.
The compounds of Formula Ia can be prepared by following the methods disclosed in WO 2007/031977.
In the above schemes, where the specific solvents, bases, acids, reducing agents, oxidizing agents, activating reagents, coupling reagents, halogenating agents, transition metal catalysts, phosphine ligands, mesylating agents, lewis acid catalysts, debenzylating agents, protecting reagents etc., are mentioned, it is to be understood that other solvents, bases, acids, reducing agents, oxidizing agents, activating reagents, coupling reagents, halogenating agents, transition metal catalysts, phosphine ligands, mesylating agents, lewis acid catalysts, debenzylating agents, protecting reagents etc., known to those skilled in the art may be used. Similarly, the reaction temperature and duration may be adjusted according to the desired needs.
An illustrative list of intermediates includes these listed below:
4-(Cyclohexylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 1), 1-Ethyl-N-methoxy-N-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 2), 1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 3), 4-(Cyclopropylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 4), 4-(Cyclopropylamino)-N-methoxy-N-1,3-trimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 5), 4-(Cyclopentylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 6), 4-(Cyclopentylamino)-N-methoxy-N-1,3-trimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 7), 4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 8), 1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 9), 1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 10), 4-Cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 11), 4-Cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 12), 4-(Cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 13), 4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 14), 4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 15), 1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 16), 1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 17), 4-Cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 18), 4-(Cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 19), 4-(Cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 20), 4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 21), tert-Butyl 4-({1-ethyl-5-[methoxy(methyl)carbamoyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)piperidine-1-carboxylate ((Intermediate No. 22), 1-Ethyl-N-methoxy-4-[(3-methoxyphenyl)amino]-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 23), 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 24), 4-(Benzylamino)-1-ethyl-N-Methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 25), 1-Ethyl-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 26), tert-Butyl 4-[(1-ethyl-5-formyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]piperidine-1-carboxylate (Intermediate No. 27), 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 28), 4-(Benzylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 29), 1-Ethyl-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 30), 4-(Benzylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyden oxime (Intermediate No. 31), tert-Butyl 4-[(1-ethyl-5-[(E)-(hydroxyimino)methyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]piperidine-1-carboxylate (Intermediate No. 32), 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 33),
An illustrative list of compounds includes these listed below:
N-cyclohexyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 1), N-cyclohexyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 2), N-cyclohexyl-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 3), N-cyclohexyl-1-ethyl-5-(1-oxa-7-thia-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 4), N-cyclohexyl-1-ethyl-5-(7-oxido-1-oxa-7-thia-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 5), N-cyclohexyl-1-ethyl-5-(5-oxa-2-thia-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 6), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 7), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 8), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 9), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 10), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 11), N-cyclohexyl-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 12), 4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 13), N-cyclohexyl-5-(2,2-dioxido-5-oxa-2-thia-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 14), tert-Butyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 15), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 16), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone oxime (Compound No. 17), N-cyclohexyl-1-ethyl-5-(1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine hydrochloride salt (Compound No. 18), 4-{[1-Ethyl-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 19), 4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 20), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 21), 3-{1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 22), N-cyclohexyl-5-[8-(2,2-dimethylpropanoyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 23), N-cyclohexyl-1-ethyl-5-{8-[(trifluoromethyl)sulfonyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl}-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 24), N-cyclohexyl-1-ethyl-5-[8-(ethylsulfonyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 25), N-cyclohexyl-5-[8-(cyclopropylmethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 26), 5-(8-Acetyl-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 27), N-cyclohexyl-5-(2,5-dioxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 28), N-cyclopropyl-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 29), N-cyclopropyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 30), N-cyclopropyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 31), N-cyclopentyl-1,3-dimethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 32), N-cyclopentyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 33), N-cyclopentyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 34), N-cyclopropyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 35), N-cyclopropyl-1,3-dimethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 36), N-cyclopropyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 37), N-cyclopentyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 38), N-cyclopentyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 39), N-cyclopentyl-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 40), 1-(4-Methoxybenzyl)-N-(3-methoxyphenyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 41), (cis or trans) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 42), (trans or cis) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 43), 5-[2-(Benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 44), (cis or trans) 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 45), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 46), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 47), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 48), 5-(5-Oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 49), 1-Methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 50), 5-(1-Oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoroethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 51), 1-Ethyl-N-[1-(methylsulfonyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 52), N-(1-acetylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 53), N-(1-acetylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 54), 1-(4-Methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 55), 5-(5-Oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoroethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 56), 7-[1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 57), 1-(Cyclopropylmethyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 58), 1-Butyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 59), 1-(1-Methylethyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 60), 5-(5-Oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 61), 5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoroethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 62), N-(1-Cyclopentylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 63), N-(1-butylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 64), 2-(4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidin-1-yl)ethanol (Compound No. 65), N-[1-(cyclopropylmethyl)piperidin-4-yl]-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 66), 1-Ethyl-N-[1-(1-methylethyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 67), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(1-propylpiperidin-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 68), N-(1-cyclopentylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 69), 1-Ethyl-N-[1-(1-methylethyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 70), 1-Cyclopentyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 71), 1-(Cyclopropylmethyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 72), 1-(1-Methylethyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 73), 5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 74), 1-Cyclopentyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 75), 1-(Cyclopropylmethyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 76), 1-(1-Methylethyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 77), 5-(1-Oxa-2-azaspiro[4.4]non-2-en-3-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 78), 1-Methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 79), N-Cyclohexyl-1-ethyl-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 80), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 81), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-piperidin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 82), Tert-butyl 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidine-1-carboxylate (Compound No. 83), 1-Ethyl-N-(1-ethylpiperidin-4-yl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 84), 1-Ethyl-N-(1-methylpiperidin-4-yl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 85), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-piperidin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 86), Tert-butyl 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidine-1-carboxylate (Compound No. 87), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(1-propylpiperidin-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 88), N-[1-(cyclopropylmethyl)piperidin-4-yl]-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 89), 2-(4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidin-1-yl)ethanol (Compound No. 90), N-cyclohexyl-1-(4-methoxybenzyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 91), 3-[1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 92), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 93), 1-Ethyl-N-(3-methoxyphenyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 94), (cis or trans) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 95), (trans or cis) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 96), 5-{2-[(Benzyloxy)methyl]-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl}-1-(4-methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 97), (trans or cis) 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 98), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 99), 1-(4-Methoxybenzyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 100), 5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 101), 1-(4-Methoxybenzyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 102), 5-{2-[(Benzyloxy)methyl]-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl}-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 103), {7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methanol (Compound No. 104), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 105), cis or trans 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 106), (trans or cis) 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 107), (cis or trans) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 108), (trans or cis) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 109), 1-(4-Methoxybenzyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 110), 5-[2-(Benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-(4-methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 111), Ethyl (cis or trans) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 112), Ethyl (trans or cis) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 113), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine ((Compound No. 114), 3-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 115), 3-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 116), 3-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 117), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 118), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 119), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 120), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 121), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 122), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 123), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 124), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 125), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-ethyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 126), N-Ethyl-7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 127), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 128), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 129), N-{7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}acetamide (Compound No. 130), N-{7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}acetamide (Compound No. 131), 4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 132), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 133), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 134), 4-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 135), 1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 136), 1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 137), 1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 138), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 139), N-Cyclohexyl-1-ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 140), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 141), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-amine (Compound No. 142), 4-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 143), 4-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 144), 4-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 145), 4-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 146), 4-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 147), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 148), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 149), 4-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 150), 3-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 151), 3-{1-Ethyl-4-[(3-hydroxycyclobutyl)amino]-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 152), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 153), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 154), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 155), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 156), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 157), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 158), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 159), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 160), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 161), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 162), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 163), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 164), 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 165), 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 166), 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 167), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 168), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 169), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 170), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 171), 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 172), 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 173), 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 174), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 175), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 176), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 177), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-cyclohexyl-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 178), 4-{[1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 179), 4-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 180), 3-{[1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 181), 3-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 182), 3-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 183), 3-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 184), 3-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 185), 3-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 186), 3-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 187), 3-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 188), 3-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 189), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 190), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 191), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)acetamide (Compound No. 192), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)acetamide (Compound No. 193), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)propanamide (Compound No. 194), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)propanamide (Compound No. 195), 3-{[5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 196), 3-{[5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 197), 3-({5-[2-(Acetylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 198), 3-({5-[2-(Acetylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 199), 3-({1-Ethyl-5-[2-(propanoylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 200), 3-({1-Ethyl-3-methyl-5-[2-(propanoylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 201), N-ethyl-7-[1-ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 202), N-{7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 203), N-{7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 204), N-{7-[1-ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 205), 4-{[5-(8-Amino-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 206), 4-{[5-(8-Amino-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 207), 4-({5-[8-(Acetylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 208), 4-({5-[8-(Acetylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 209), 4-({1-Ethyl-3-methyl-5-[8-(propanoylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 210), 4-({1-Ethyl-5-[8-(propanoylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 211), 7-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 212), 7-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 213), 4-{[5-(2-Carbamoyl-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 214), 4-{[5-(2-Carbamoyl-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 215), 4-({1-Ethyl-3-methyl-5-[2-(methylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 216), 4-({1-Ethyl-5-[2-(methylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 217), 4-({1-Ethyl-5-[2-(ethylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 218), 4-({1-Ethyl-5-[2-(ethylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 219), 3-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 220), 3-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 221), 4-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 222), 4-({1-Ethyl-5-[8-(methylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 223), 4-({1-Ethyl-3-methyl-5-[8-(methylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 224), 4-({1-Ethyl-5-[8-(ethylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 225), 4-({1-Ethyl-5-[8-(ethylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 226), 4-{[1-Ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 227), 4-{[5-(8-Ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 228), 4-({1-Ethyl-5-[8-(2-hydroxyethoxy)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 229), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 230), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 231), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 232), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 233), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 234), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 235), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 236), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 237), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 238), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 239), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 240), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 241), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 242), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 243), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 244), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 245), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 246), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 247), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 248), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 249), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 250), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 251), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 252), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 253), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 254), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 255), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 256), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 257), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 258), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 259), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 260), 1-Ethyl-N-furan-3-yl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 261), 1-Ethyl-N-furan-3-yl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 262), 1-Ethyl-N-furan-3-yl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 263), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 264), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 265), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 266), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 267), Methyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 268), Ethyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 269), tert-Butyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 270), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 271), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-ethyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 272), N-cyclopropyl-7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 273), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 274), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-cyclopropyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 275), N-cyclopropyl-7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 276), 1-Ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 277), 5-(8-Ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 278), N-cyclohexyl-5-(8-ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 279), N-cyclohexyl-1-ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 280), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-ethyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 281), N-cyclopropyl-3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 282), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-cyclopropyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 283), N-cyclopropyl-3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 284), N-ethyl-3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 285), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-ethyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 286), Ethyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 287), Methyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 288), tert-Butyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 289), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 290), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-(8-ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 291), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 292), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 293), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 294), 1-Ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 295), N-cyclohexyl-1-ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 296), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 297), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-(2-ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 298), N-cyclohexyl-5-(2-ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 299), 5-(2-Ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 300), {7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methanol (Compound No. 301), (7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methanol (Compound No. 302), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 303), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-[2-(ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 304), N-cyclohexyl-5-[2-(ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 305), 5-[2-(Ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 306), 1-Ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 307), N-cyclohexyl-1-ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 308), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 309), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 310), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 311), N-[(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methyl]acetamide (Compound No. 312), N-[(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methyl]propanamide (Compound No. 313), N-({7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)propanamide (Compound No. 314), N-({7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)propanamide (Compound No. 315), N-({7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)acetamide (Compound No. 316), N-({7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)acetamide (Compound No. 317), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 318), N-cyclohexyl-1-ethyl-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 319), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 320), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 321), N-cyclohexyl-1-ethyl-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 322), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 323), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 324), N-cyclohexyl-1-ethyl-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 325), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 326), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 327), N-cyclohexyl-1-ethyl-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 328), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 329), Ethyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 330), Ethyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 331), Methyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 332), Methyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 333), tert-Butyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 334), tert-Butyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 335), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 336), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 337), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-amine (Compound No. 338),
or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides, thereof.
The term “pharmaceutically acceptable” means approved by regulatory agency of the federal or a state government or listed in the U.S. Pharmacopoeia or other generally recognized pharmacopoeia for use in mammals, and more particularly in humans.
The term “pharmaceutically acceptable salts” refers to derivatives of compounds that can be modified by forming their corresponding acid or base salts. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acids salts of basic residues (such as amines), or alkali or organic salts of acidic residues (such as carboxylic acids), and the like.
The term “pharmaceutically acceptable solvates” refers to solvates with water such as hydrates, hemihydrate or sesquihydrate or pharmaceutically acceptable solvents, for example solvates with common organic solvents as ethanol and the like. Such solvates are also encompassed within the scope of the disclosure.
The present invention also includes within its scope prodrugs of these agents. In general, such prodrugs will be functional derivatives of these compounds, which are readily convertible in vivo into the required compound. Conventional procedures for the selection and preparation of prodrugs are known.
The disclosed compounds may get metabolized in vivo and these metabolites are also encompassed within the scope of this invention.
The term “polymorphs” includes all crystalline form as well as amorphous form for compounds described herein and as such are intended to be included in the present invention.
All stereoisomers of the compounds of the invention are contemplated, either in admixture or in pure or substantially pure form. The compounds of the present invention can have asymmetric centers at any of the carbon atoms including all the substituents. Consequently, compounds of present invention can exist in enantiomeric or diastereomeric forms or in mixture thereof. The processes for the preparation can utilize racemates, enantiomers, or diastereomers as starting materials. When diastereomeric or enantiomeric products are prepared, they can be separated by conventional methods, for example, chromatographic or fractional crystallization.
The term “tautomer” includes one of two or more structural isomers that exist in equilibrium and are readily converted from one isomeric form to another. Certain compounds of the general Formula (I) may furthermore be present in tautomeric forms.
The term, “geometric isomers”, refers to compounds, having the same molecular formula as another but a different geometric configuration, as when atoms or groups of atoms are attached in different spatial arrangements on either side of a double bond or other rigid bond.
The term “regioisomers” refers to compounds, which have the same molecular formula but differ in the connectivity of the atoms.
The term “racemate” includes a mixture of equal amounts of left- and right-handed stereoisomers of chiral molecules.
When a bond to a substituent is shown to cross a bond connecting two atoms in a ring, then such substituent may be bonded to any atom on the ring.
In another aspect, the present invention includes pharmaceutical compositions comprising, as an active ingredient, at least one of the disclosed compound or a pharmaceutically acceptable salt, a pharmaceutically acceptable solvate, stereoisomer, tautomer, geometric isomer, racemate, regioisomer, prodrug, metabolite, polymorph or N-oxide, together with a pharmaceutically acceptable carrier, excipient or diluent. Compounds disclosed herein may be administered to mammal for treatment by any route, which effectively transports the active compound to the appropriate or desired site of action such as oral, nasal, pulmonary, transdermal or parenteral (rectal, subcutaneous, intravenous, intraurethral, intramuscular, intranasal). The pharmaceutical composition of the present invention comprises a pharmaceutically effective amount of a compound of the present invention formulated together with one or more pharmaceutically acceptable carriers, excipients or diluents. The choice of pharmaceutical carrier, excipient or diluent can be made with regard to the intended route of administration and standard pharmaceutical practice.
Where desired, the compounds of the invention and/or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides may be advantageously used in combination with one or more other compounds. Examples of other compounds, which may be used in combination with compounds of this invention and/or their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, stereoisomers, tautomers, geometric isomers, racemates, regioisomers, prodrugs, metabolites, polymorphs or N-oxides include β2-agonists, corticosteroids, leukotriene antagonists, 5-lipoxygenase inhibitors, chemokine inhibitors, p38 kinase inhibitors, anticholinergics, antiallergics, PAF (platelet activating factor) antagonists, EGFR (epidermal growth factor receptor) kinase inhibitors, muscarinic receptor antagonists or combinations thereof.
The one or more β2-agonist as described herein may be chosen from those described in the art. The β2-agonists may include one or more compounds described in U.S. Pat. Nos. 3,705,233; 3,644,353; 3,642,896; 3,700,681; 4,579,985; 3,994,974; 3,937,838; 4,419,364; 5,126,375; 5,243,076; 4,992,474; and 4,011,258.
β2-agonists include, for example, one or more of albuterol, salbutamol, biltolterol, pirbuterol, levosalbutamol, tulobuterol, terbutaline, bambuterol, metaproterenol, fenoterol, salmeterol, carmoterol, arformoterol, formoterol, and their pharmaceutically acceptable salts or solvates thereof.
Corticosteroids as described herein may be chosen from those described in the art. Corticosteroids may include one or more compounds described in U.S. Pat. Nos. 3,312,590; 3,983,233; 3,929,768; 3,721,687; 3,436,389; 3,506,694; 3,639,434; 3,992,534; 3,928,326; 3,980,778; 3,780,177; 3,652,554; 3,947,478; 4,076,708; 4,124,707; 4,158,055; 4,298,604; 4,335,121; 4,081,541; 4,226,862; 4,290,962; 4,587,236; 4,472,392; 4,472,393; 4,242,334; 4,014,909; 4,098,803; 4,619,921; 5,482,934; 5,837,699; 5,889,015; 5,278,156; 5,015,746; 5,976,573; 6,337,324; 6,057,307; 6,723,713; 6,127,353; and 6,180,781.
Corticosteroids may include, for example, one or more of alclometasone, amcinonide, amelometasone, beclometasone, betamethasone, budesonide, ciclesonide, clobetasol, cloticasone, cyclomethasone, deflazacort, deprodone, dexbudesonide, diflorasone, difluprednate, fluticasone, flunisolide, halometasone, halopredone, hydrocortisone, hydrocortisone, methylprednisolone, mometasone, prednicarbate, prednisolone, rimexolone, tixocortol, triamcinolone, ulobetasol, rofleponide, GW 215864, KSR 592, ST-126, dexamethasone and pharmaceutically acceptable salts, solvates thereof. Preferred corticosteroids include, for example, flunisolide, beclomethasone, triamcinolone, budesonide, fluticasone, mometasone, ciclesonide, and dexamethasone. Examples of possible salts or derivatives include: sodium salts, sulfobenzoates, phosphates, isonicotinates, acetates, propionates, dihydrogen phosphates, palmitates, pivalates, or furoates. In some cases, the corticosteroids may also occur in the form of their hydrates.
The leukotriene antagonist can be selected from compounds, for example, those described in U.S. Pat. Nos. 5,565,473, 5,583,152, 4,859,692 or U.S. Pat. No. 4,780,469.
Examples of leukotriene antagonist include, but are not limited to, montelukast, zafirlukast, pranlukast and pharmaceutically acceptable salts thereof.
5-Lipoxygenase inhibitors can be selected from for example, compounds in U.S. Pat. Nos. 4,826,868, or 4,873,259, or European Patent Nos. EP 419049, EP 542356 or EP 542355. Examples may include, but are not limited to, atreleuton, zyflo (zileuton), ABT-761, fenleuton or tepoxalin.
Examples of the chemokine inhibitors include, but are not limited to, endogenous ligands of chemokine receptors or derivatives thereof, and non-peptidic low molecular compounds or antibodies for chemokine receptors.
Examples of the endogenous ligands of chemokine receptors include, but are not limited to, MIP-1α, MIP-1β, Rantes, SDF-1α, SDF-1β, MCP-1, MCP-2, MCP4, Eotaxin, MDC. Examples of the derivatives of endogenous ligands include, but are not limited to, AOP-RANTES, Met-SDF-1α, Met-SDF-1β.
Examples of the antibodies for chemokine receptors include, but are not limited to, Pro-140.
Examples of the non-peptidic low molecular compounds include, but are not limited to, antagonists and agonists for CCR1, CCR2, CCR3, CCR4, CCR5, CXCR1, CXCR2, CXCR3 and CXCR4 receptors.
p38 kinase inhibitors include compounds disclosed in WO06021848, WO06016237, WO06056863, WO06117657 and WO06082492. Any reference to the above mentioned p38 kinase inhibitors also includes any pharmacologically acceptable salts thereof which may exist.
Anticholinergics include, for example, tiotropium salts, ipratropium salts, oxitropium salts, salts of the compounds known from WO 02/32899: tropenol N-methyl-2,2-diphenylpropionate, scopine N-methyl-2,2-diphenylpropionate, scopine N-methyl-2-fluoro-2,2-diphenylacetate and tropenol N-methyl-2-fluoro-2,2-diphenylacetate; as well as salts of the compounds known from WO 02/32898: tropenol N-methyl-3,3′,4,4′-tetrafluorobenzilate, scopine N-methyl-3,3′,4,4′-tetrafluorobenzilate, scopine N-methyl-4,4′-dichlorobenzilate, scopine N-methyl-4,4′-difluorobenzilate, tropenol N-methyl-3,3′-difluorobenzilate, scopine N-methyl-3,3′-difluorobenzilate, and tropenol N-ethyl-4,4′-difluorobenzilate, optionally in the form of their hydrates and solvates. By salts are meant those compounds which contain, in addition to the above mentioned cations, as counter-ion, an anion with a single negative charge selected from among the chloride, bromide, and methanesulfonate.
Preferred anticholinergics include, for example, tiotropium bromide, ipratropium bromide, oxitropium bromide, tropenol 2,2-diphenylpropionate methobromide, scopine 2,2-diphenylpropionate methobromide, scopine 2-fluoro-2,2-diphenylacetate methobromide, tropenol 2-fluoro-2,2-diphenylacetate methobromide, tropenol 3,3′,4,4′-tetrafluorobenzilate methobromide, scopine 3,3′,4,4′-tetrafluorobenzilate methobromide, scopine 4,4′-dichlorobenzilate methobromide, scopine 4,4′-difluorobenzilate methobromide, tropenol 3,3′-difluorobenzilate methobromide, scopine 3,3′-difluorobenzilate methobromide, and tropenol 4,4′-difluorobenzilate ethylbromide.
Antiallergics include, for example, epinastine, cetirizine, azelastine, fexofenadine, levocabastine, loratadine, mizolastine, ketotifene, emedastine, dimetindene, clemastine, bamipine, hexachloropheniramine, pheniramine, doxylamine, chlorophenoxamine, dimenhydrinate, diphenhydramine, promethazine, ebastine, desloratadine, and meclizine. Preferred antiallergic agents include, for example, epinastine, cetirizine, azelastine, fexofenadine, levocabastine, loratadine, ebastine, desloratadine, and mizolastine. Any reference to the above-mentioned antiallergic agents also includes any pharmacologically acceptable salts thereof, which may exist.
PAF antagonists include, for example, 4-(2-chlorophenyl)-9-methyl-2-[3-(4-morpholinyl)-3-propanon-1-yl]-6H-thieno[3,2-f][1,2,4]triazolo[4,3-a][1,4]diazepine and 6-(2-chlorophenyl)-8,9-dihydro-1-methyl-8-[(4-morpholinyl)carbonyl]-4H,7H-cyclopenta[4.5]thieno[3,2-f][1,2,4]triazolo[4,3-a][1,4]diazepine.
EGFR kinase inhibitors include, for example, 4-[(3-chloro-4-fluorophenyl)amino]-7-(2-{4-[(S)-(2-oxotetrahydro furan-5-yl)carbonyl]piperazin-1-yl}-ethoxy)-6-[(vinylcarbonyl)amino]quinazoline, 4-[(3-chloro-4-fluorophenyl)amino]-7-[4-((S)-6-methyl-2-oxomorpholin-4-yl)butyloxy]-6-[(vinylcarbonyl)amino]quinazoline, 4-[(3-chloro-4-fluorophenyl)amino]-7-[4-((R)-6-methyl-2-oxomorpholin-4-yl)butyloxy]-6-[(vinylcarbonyl)amino]quinazoline, 4-[(3-chloro-4-fluorophenyl)amino]-7-[2-((S)-6-methyl-2-oxomorpholin-4-yl)ethoxy]-6-[(vinylcarbonyl)amino]quinazoline, 4-[(3-chloro-4-fluorophenyl)amino]-6-[(4-{N-[2-(ethoxycarbonyl)ethyl]-N-[(ethoxycarbonyl)methyl]-amino}-1-oxo-2-buten-1-yl)amino]-7-cyclopropylmethoxyquinazoline, 4-[(R)-(1-phenylethyl)amino]-6-{[4-(morpholin-4-yl)-1-oxo-2-buten-1-yl]amino}-7-cyclopropyl-methoxyquinazoline, and 4-[(3-chloro-4-fluorophenyl)amino]-6-[3-(morpholin-4-yl)propyloxy]-7-methoxyquinazoline. Any reference to the above-mentioned EGFR kinase inhibitors also includes any pharmacologically acceptable salts thereof which may exist.
Muscarinic receptor antagonists include substances that directly or indirectly block activation of muscarinic cholinergic receptors. Examples include, but are not limited to, quaternary amines (e.g., methantheline, ipratropium, propantheline), tertiary amines (e.g., dicyclomine, scopolamine) and tricyclic amines (e.g., telenzepine). Other muscarinic receptor antagonists include benztropine, hexahydro-sila-difenidol hydrochloride (HHSID hydrochloride), (+/−)-3-quinuclidinyl xanthene-9-carboxylate hemioxalate (QNX-hemioxalate), telenzepine dihydrochloride and tolterodine, oxybutynin, and atropine.
Examples set forth below demonstrate the synthetic procedures for the preparation of the representative compounds. The examples are provided to illustrate particular aspect of the disclosure and do not constrain the scope of the present invention as defined by the claims.
EXPERIMENTAL DETAILS
Example 1a
Preparation of 1-(4-methoxybenzyl)-1H-pyrazol-5-amine
This compound was synthesized according to procedure reported in Bioorganic and medicinal chemistry letters, 13, 1133-1136 (2003).
Example 1b
Preparation of 1-ethyl-3-methyl-1H-pyrazol-5-amine
This compound was synthesized according to procedure reported in Chem. Pharm. Bull. 52(9), 1098-1104 (2004).
Example 1c
Preparation of tetrahydro-2H-pyran-4-amine hydrochloride
This compound was synthesized according to the procedure reported in Tetrahedron letters, 42, 4257-4259, (2001).
Example 1d
Preparation of tetrahydro-2H-thiopyran-4-amine
Step a: Tetrahydro-4H-thiopyran-4-one (15 gm, 0.129 mole), hydroxylamine hydrochloride (15.27 gm, 0.219 mole) and sodium acetate trihydrate (30 gm, 0.219 mole) were taken together in a mixture of water (150 ml) and ethanol (60 ml). The reaction mixture was refluxed for about 4 hours. The solvent was evaporated under reduced pressure. Solid compound, which separated out, was filtered and dried under vacuum.
Yield: 15 gm (99%)
Step b: Lithium aluminum hydride (6.96 gm, 0.183 mole) was taken in tetrahydrofuran (80 ml) and solution of tetrahydro-4H-thiopyran-4-one oxime (8 gm, 0.0610 mole) (step a) in tetrahydrofuran (20 ml) was added to it drop wise at 0° C. The reaction mixture was refluxed for about 4 hours and quenched with saturated ammonium chloride solution. Extraction was done using ethyl acetate, organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 8 gm (crude) (100%)
Example 2
Preparation of diethyl {[(1-ethyl-1H-pyrazol-5-yl)amino]methylidene}propanedioate
A mixture of 5-amino-1-ethylpyrazole (5 gm, 0.0448 mole) and diethylethoxy methylenemalonate (10.35 ml, 0.0448 mole) was stirred at 120° C. for about 1 hour. The reaction mixture was poured into water and extraction was done with ethyl acetate. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to give viscous oil.
Yield: 15 gm (crude) (124%)
The following compounds were prepared similarly
Diethyl {[(1,3-dimethyl-1H-pyrazol-5-yl)amino]methylidene}propanedioate Diethyl ({[1-(4-methoxybenzyl)-1H-pyrazol-5-yl]amino}methylidene)propanedioate
The following compound can be prepared similarly
Diethyl {[(1-ethyl-3-methyl-1H-pyrazol-5-yl)amino]methylidene}propanedioate
Example 2a
Preparation of ethyl 4-hydroxy-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Diphenyl ether (180 ml) was heated to about 230° C. (Internal temperature 200-210° C.) under inert atmosphere in a round bottom flask fitted with distillation set and a solution of diethyl ({[1-(4-methoxybenzyl)-1H-pyrazol-5-yl]amino}methylidene)propanedioate (85 gm, 0.227 mol) (example 2) in absolute ethanol (130 ml) was added dropwise. The reaction mixture was heated for about 2 hours. Volatile solubles were distilled out. The mixture was cooled to 45° C. and methanol (150 ml) was added dropwise. Solid, which precipitated out was filtered and washed with methanol and hexane and dried under vacuum.
Yield: 33 gm (crude) (45%)
m/z: (M + +1) 328.10
Example 3
Preparation of ethyl 4-chloro-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
A mixture of diethyl {[(1-ethyl-1H-pyrazol-5-yl)amino]methylidene}propanedioate (15 gm, 0.0533 mole) (example 2) and phosphorous oxy chloride (76.64 ml, 0.7998 mole) was heated at 110-120° C. under stirring for about 4 hours under argon atmosphere. The reaction mixture was cooled and then poured drop wise into ice water. A pale yellow solid separated which was filtered. The solid was first washed twice with ice cold water and then finally with hexane and dried over vacuum.
Yield: 10 gm (70%)
m/z: (M + +1) 254.2
The following compound was prepared similarly
Ethyl 4-chloro-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
The following compound can be prepared similarly
Ethyl 4-chloro-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Example 3a
Preparation of ethyl 4-chloro-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
The title compound was prepared by following the procedure of example 3 using ethyl 4-hydroxy-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (example 2a).
m/z: (M + +1) 346.09
Example 4
Preparation of ethyl 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Cyclohexyl amine (9.07 ml, 0.7905 mole) was added to a mixture of ethyl 4-chloro-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (10 gm, 0.0395 mole) (example 3) in acetonitrile. After stirring for about 2 h at 110° C., acetonitrile was removed under reduced pressure. Water was added and the reaction mixture was extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo to give brownish solid.
Yield: 9.6 gm (78%)
m/z: (M + +1) 317.22
The following compounds were prepared similarly
Ethyl 1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 319.26
Ethyl 1-ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 333.06
Ethyl 4-cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 275.0
Ethyl 4-(cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate Ethyl 4-(cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate Ethyl 4-(cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate Ethyl 1-(4-methoxybenzyl)-4-(tetrahydro-2H-thiopyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 427.14
Ethyl 4-(cyclohexylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 409.22
Ethyl 4-{[1-(tert-butoxycarbonyl)piperidin-4-yl]amino}-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 418.39
Ethyl 1-(4-methoxybenzyl)-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 433.63
Ethyl 1-(4-methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 411.14
Ethyl 4-(benzylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
m/z: (M + +1) 417.14
Ethyl 1-ethyl-4-(tetrahydro-2H-thiopyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Example 4a
Preparation of 4-chloro-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
A solution of ethyl 4-chloro-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (0.013 mol) (example 3) in dioxane is treated with potassium hydroxide (0.13 mol in 30 ml water) solution. The reaction mixture is stirred for about 3-4 hrs and concentrated under reduced pressure. It is acidified with hydrochloric acid to pH of about 3-4, extracted with ethyl acetate, washed with brine and dried under vacuo
Example 4b
Preparation of 4-{[4-(tert-butoxycarbonyl)cyclohexyl]amino}-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
A solution of 4-chloro-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid (0.0088 mol) (example 4a) in acetonitrile is treated with tert-butyl 4-aminocyclohexanecarboxylate (0.026 mol). The reaction mixture is refluxed for about 3-4 hrs. Solvent is evaporated off and water is added and extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography.
The following compound can be prepared similarly
4-{[3-(tert-Butoxycarbonyl)cyclobutyl]amino}-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
Example 4c
Preparation of ethyl 4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Ethyl 1-(4-methoxybenzyl)-4-(tetrahydro-2H-thiopyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (500 mg, 0.00117 mole) (example 4) was taken in dichloromethane (5 ml). At 0° C., m-chloroperbenzoic acid (600 mg, 0.00352 mole) was added and the mixture was stirred overnight. Water was added and extraction was done using dichloromethane. The organic layer was washed with saturated ammonium bicarbonate and then with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 500 mg (93%)
m/z: (M + +1) 495.16
The following compound can be prepared similarly
Ethyl 4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate
Example 5
Preparation of 4-cyclohexylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
Sodium hydroxide solution (4.09 gm in 20 ml water) was added to a solution of ethyl 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylate (9.32 gm, 0.0294 mole) (example 4) in ethanol. The reaction mixture was stirred for about 14 h at room temperature and then warmed for about 1 h at 60° C. Water was added and the reaction mixture was extracted with ethyl acetate. Aqueous layer was acidified by using hydrochloric acid (2N) to pH of about 4-5. White solid, which was obtained, was filtered and dried in vacuo.
Yield: 9 gm crude (100%)
m/z: (M + +1) 289.22
The following compounds were prepared similarly
1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 291.36
1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 305.10
4-Cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 274.2
4-(Cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid 4-(Cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid 4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 383.28
4-(Benzylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 389.08
4-(Cyclohexylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid 4-{[1-(tert-Butoxycarbonyl)piperidin-4-yl]amino}-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 390.40
1-(4-Methoxybenzyl)-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 405.05
1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid
m/z: (M + +1) 383.28
Example 6
Preparation of 4-(cyclohexylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 1)
4-Cyclohexylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxylic acid (0.200 gm, 0.0006 mole) (example 5) and N,O-dimethylhydroxylamine hydrochloride (0.102 gm, 0.0010 mole) were taken in dimethylformamide. At 0° C., hydroxybenzotriazole (0.162 gm, 0.0012 mole) and N-methylmorpholine (0.30 ml, 0.0027 mole) were added and the reaction mixture was stirred for about 1 h. 1-Ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride (0.266 gm, 0.0012 mole) was added and the reaction mixture was stirred for about 14 h. Water was added and extraction was carried out with ethyl acetate. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo. The compound was purified over preparative thin layer chromatography.
Yield: 136 mg (59%)
m/z: (M + +1) 332.26
The following intermediates were prepared similarly
1-Ethyl-N-methoxy-N-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 2)
m/z: (M + +1) 334.11
1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 3)
m/z: (M + +1) 348.05
4-(Cyclopropylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 4)
m/z: (M + +1) 290.2
4-(Cyclopropylamino)-N-methoxy-N-1,3-trimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 5) 4-(Cyclopentylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 6) 4-(Cyclopentylamino)-N-methoxy-N-1,3-trimethyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 7) 4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide ((Intermediate No. 24),
m/z: (M + +1) 382.10
4-(Benzylamino)-N-methoxy-1-(4-methoxybenzyl)-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 432.10
4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-N-methoxy-1-(4-methoxybenzyl)-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 474.06
4-(Cyclohexylamino)-N-methoxy-1-(4-methoxybenzyl)-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 332.26
1-Ethyl-N-methoxy-4-[(3-methoxyphenyl)amino]-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 23), tert-Butyl 4-({1-ethyl-5-[methoxy(methyl)carbamoyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)piperidine-1-carboxylate (Intermediate No. 22),
m/z: (M + +1) 433.36
N-methoxy-1-(4-methoxybenzyl)-4-[(3-methoxyphenyl)amino]-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 448.15
N-methoxy-1-(4-methoxybenzyl)-N-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 426.38
The following compounds can be prepared similarly
tert-Butyl 3-({1-ethyl-5-[methoxy(methyl)carbamoyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylate tert-Butyl 4-({1-ethyl-5-[methoxy(methyl)carbamoyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylate
Example 6a
Preparation of 4-(benzylamino)-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
Trifluoroacetic acid (5.35 ml, 69.6 mmol) was added to the solution of 4-(benzylamino)-N-methoxy-1-(4-methoxybenzyl)-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (3 gm, 6.96 mmol) (example 6) in dichloroethane (20 ml) and the reaction mixture was refluxed for about 2 hours under inert atmosphere. It was cooled, diluted with ethyl acetate, washed with saturated sodium bicarbonate, water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 2 gm (92%)
The following compound was prepared similarly
4-(Cyclohexylamino)-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide
m/z: (M + +1) 304.12
Example 6b
Preparation of 4-(benzylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (Intermediate No. 25)
Ethyl iodide (1.52 gm, 9.63 mmol) and potassium carbonate (2.214 gm, 16.05 mmol) were added to the solution 4-(benzylamino)-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (1 gm, 3.21 mmol) (example 6a) in dimethylformamide and the reaction mixture was stirred at 60° C. for about 5 hours. It was cooled, diluted with water and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude product was purified over silica gel column.
Yield: 0.800 gm (73%)
m/z: (M + +1) 340.22
Example 7
Preparation of 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 8)
Toluene was cooled to −30 to −35° C. and vitride (0.12 ml, 0.0006 mole) was added. After about 10 min., 4-(cyclohexylamino)-1-ethyl-N-methoxy-N-methyl-1H-pyrazolo[3,4-b]pyridine-5-carboxamide (0.10 gm, 0.0003 mole) (example 6) was added and the reaction mixture was stirred for about 4 h. Citric acid (10%) solution was added dropwise to quench the reaction and the reaction mixture was extracted with ethyl acetate. The organic layer was washed with brine and dried over anhydrous sodium sulphate and concentrated in vacuo. The compound was purified over preparative thin layer chromatography.
Yield: 54 mg (65%)
m/z: 273.23
The following intermediates were prepared similarly
1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 9)
m/z: (M + +1) 275.06
1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 10)
m/z: (M + +1) 289.06
4-Cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 11)
m/z: (M + +1) 231.1
4-Cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 12) 4-(Cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 13) 4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 14) 1-Ethyl-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 26), 1-(4-Methoxybenzyl)-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde
m/z: (M + +1) 389.08
tert-Butyl 4-[(1-ethyl-5-formyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]piperidine-1-carboxylate (Intermediate No. 27),
m/z: (M + +1) 374.35
4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 28),
m/z: (M + +1) 323.19
4-(Benzylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (Intermediate No. 29),
m/z: (M + +1) 281.11
4-(Cyclohexylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde
m/z: (M + +1) 365.31
1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde
m/z: (M + +1) 367.10
The following compounds can be prepared similarly
tert-Butyl 4-[(1-ethyl-5-formyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]cyclohexane carboxylate tert-Butyl 3-[(1-ethyl-5-formyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]cyclobutane carboxylate
Example 8
Preparation of 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 15)
Hydroxylamine hydrochloride (0.255 gm, 0.0036 mole) and sodium acetate (0.301 gm, 0.0036 mole) were added to a stirred solution of 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde (0.250 gm, 0.0009 mole) (example 7) in ethanol. The reaction mixture was allowed to stir at room temperature for about 2 h. Ethanol was removed under reduced pressure and residue was poured in water. The title compound was then filtered and washed with water twice and finally with hexane.
Yield: 0.202 gm (77%)
m/z: (M + +1) 288.31
The following intermediates were prepared similarly:
1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 16)
m/z: (M + +1) 290.13
1-Ethyl-4-[(4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 17)
m/z: (M + +1) 304.11
4-Cyclopropylamino-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 18)
m/z: (M + +1) 246.1
4-(Cyclopropylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 19) 4-(Cyclopentylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 20) 4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (Intermediate No. 21) 1-Ethyl-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (intermediate No. 30) tert-Butyl 4-[(1-ethyl-5-[(E)-(hydroxyimino)methyl-1H-pyrazolo[3,4-b]pyridin-4-yl)amino]piperidine-1-carboxylate (intermediate No. 32)
m/z: (M + +1) 389.22
4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (intermediate No. 33)
m/z: (M + +1) 338.22
4-(Benzylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carb aldehyde oxime (intermediate No. 31) 4-(Cyclohexylamino)-1-(4-methoxybenzyl)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime 1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime
m/z: (M + +1) 382.21
1-(4-Methoxybenzyl)-4-[(3-methoxyphenyl)amino]-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime
m/z: (M + +1) 404.11
The following compounds can be prepared similarly
tert-butyl 3-({1-ethyl-5-[(Z)-(hydroxyimino)methyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylate tert-butyl 4-({1-ethyl-5-[(E)-(hydroxyimino)methyl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylate
Example 8(a)
Preparation of 8-methylene-1,4-dioxaspiro[4.5]decane
Potassium tert-butoxide (3.230 gm, 28.812 mmol) and triphenylphosphine methyl iodide (10.286 gm, 28.812 mmol) were dissolved in dry tetrahydrofuran (30 ml). The mixture was cooled to −78° C. and stirred at the same temperature for about 15 minutes. 1,4-Dioxaspiro[4.5]decan-8-one (3.0 gm, 19.208 mmol) in tetrahydrofuran was added drop wise and the mixture was stirred at the same temperature for about 30 minutes and then it was warmed to room temperature and stirred overnight, extaction was done with ethyl acetate and water. The organic layer was dried over sodium sulphate and concentrated. Purification was done by column chromatography.
Yield: 2.0 gm (67%)
m/z: (M + +1) 155
NMR: (6, CDCl 3 ): 4.66 (s, 2H), 3.95 (s, 4H), 2.29-2.26 (t, 4H), 1.71-1.67 (t, 4H).
The following compound was prepared similarly
{[(3-Methylidenecyclobutyl)methoxy]methyl}benzene
Example 8(b)
Preparation of 2-methylidene-5,8-dioxaspiro[3.4]octane
Step a: Preparation of 3-[(benzyloxy)methyl]-2,2-dichlorocyclobutanone
The title compound was synthesized by following the procedure disclosed in WO 2006/092691.
Step b: Preparation of 3-[(benzyloxy)methyl]cyclobutanone
The title compound was synthesized by following the procedure disclosed in WO 2006/092691.
Step c: Preparation of 2-[(benzyloxy)methyl]-5,8-dioxaspiro[3.4]octane
p-Toluene sulphonic acid (2.0 gm) was added to a solution of 3-[(benzyloxy)methyl]cyclobutanone (25.0 gm, 131.6 mmol) (step b) and 1,2-ethanediol (8.98 gm, 144.7 mmol) in benzene and the reaction mixture was refluxed with removal of water through dean-stark apparatus. After about 6 hours, the reaction mixture was cooled to room temperature and washed with saturated sodium bicarbonate solution, followed by water and brine. The organic layer was dried over sodium sulphate and concentrated under reduced pressure to get a crude product, which was purified by column chromatography.
Yield: 22.0 gm (71%)
Step d: Preparation of 5,8-dioxaspiro[3.4]oct-2-ylmethanol
Palladium/carbon (10%) was added to a solution of 2-[(benzyloxy)methyl]-5,8-dioxaspiro[3.4]octane (22.0 gm, 94.0 mmol) (step c) in methanol and the mixture was stirred at room temperature under hydrogen balloon for about 4 hours. It was filtered through celite bed and residue was washed with methanol. The combined filtrate was concentrated under reduced pressure.
Yield: 14.0 gm (97%)
Step e: Preparation of 2-(bromomethyl)-5,8-dioxaspiro[3.4]octane
Triphenylphosphine (6.28 gm, 24 mmol) in dichloromethane was added drop wise to a solution of 5,8-dioxaspiro[3.4]oct-2-ylmethanol (2.3 gm, 16 mmol) (step d) and tetrabromomethane (6.62 gm, 20 mmol) in dichloromethane. The reaction mixture was stirred at room temperature for about 6 hours. The solvent was removed under reduced pressure and the residue was extracted with diethyl ether. The organic layer was concentrated under reduced pressure to get a crude product, which was purified by column chromatography.
Yield: 1.3 gm (39.4%)
Step f: Preparation of 2-methylidene-5,8-dioxaspiro[3.4]octane
A mixture of 2-(bromomethyl)-5,8-dioxaspiro[3.4]octane (1.3 gm, 6.28 mmol) (step e), polyethylene glycol (PEG-600) (0.5 gm), 50% aqueous sodium hydroxide solution (5 ml) and benzene was refluxed for about 12 hours. The reaction mixture was cooled, diluted with water and extracted with diethyl ether. The organic layer was washed with brine, dried over sodium sulphate and concentrated under reduced pressure to get a crude product, which was purified by column chromatography.
Yield: 0.26 gm (33%)
Example 9
Preparation of N-cyclohexyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 1)
Methylene cyclopentane (0.073 ml, 0.0006 mole) was added to 4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (0.1 gm, 0.0003 mole) (example 8) in tetrahydrofuran. The reaction mixture was stirred at room temperature for about 5 minutes. Sodium hypochlorite (5 ml) was added slowly to the reaction mixture over a period of about 5 minutes and the mixture was allowed to stir at room temperature for about 5 h. The organic solvent was evaporated and the residue was extracted in ethyl acetate. The organic layer was concentrated and the title compound obtained was purified by preparative thin layer chromatography.
Yield: 40%
m/z: (M + +1) 368.36
NMR: (δ, CDCl 3 ): 8.93-8.91 (d, 1H), 8.11 (s, 1H), 7.97 (s, 1H), 4.49-4.44 (q, 2H), 3.92-3.89 (m, 1H), 3.44 (s, 2H), 2.20-1.66 (m, 14H), 1.51-1.48 (t, 3H).
The following compounds were prepared similarly
N-cyclohexyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 2),
Yield: 30%
m/z: (M + +1) 354.38
N-cyclohexyl-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 3),
Yield: 28%
m/z: (M + +1) 382.41
1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 7),
Yield: 28.5%
m/z: (M + +1) 356.10
1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 8),
Yield: 25.6%
m/z: (M + +1) 370.10
1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 9),
Yield: 26.1%
m/z: (M + +1) 384.12
4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 10),
Yield: 32.6%
m/z: (M + +1) 384.08
4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 11),
Yield: 33.4%
m/z: (M + +1) 398.09
4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 13),
Yield: 35.3%
m/z: (M + +1) 370.08
tert-Butyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 15),
Yield: 56%
m/z: (M + -OC(CH 3 ) 3 ) 410
4-{[1-Ethyl-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (Compound No. 19),
Yield: 6.0%
m/z: (M + +1) 456.05
N-cyclopropyl-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 29),
Yield: 21.68%
m/z: (M + +1) 340.2
N-cyclopropyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 30),
Yield: 28.6%
m/z: (M + +1) 326.2
N-cyclopropyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 31),
Yield: 15.87%
m/z: (M + +1) 312.2
N-cyclopentyl-1,3-dimethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 32),
Yield: 28.6%
m/z: (M + +1) 340.1
N-cyclopentyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 33),
Yield: 22%
m/z: (M + +1) 354.2
N-cyclopentyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 34),
Yield: 23.29%
m/z: (M + +1) 368.1
N-cyclopropyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 35),
Yield: 23.44%
m/z: (M + +1) 326.1
N-cyclopropyl-1,3-dimethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 36),
Yield: 15.74%
m/z: (M + +1) 312.1
N-cyclopropyl-1,3-dimethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 37),
Yield: 18.11%
m/z: (M + +1) 340.1
N-cyclopentyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 38),
Yield: 32.3%
m/z: (M + +1) 340.1
N-cyclopentyl-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 39),
Yield: 31%
m/z: (M + +1) 354.2
1-(4-Methoxybenzyl)-N-(3-methoxyphenyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 41),
Yield: 21%
m/z: (M + +1) 484.06
7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 47),
Yield: 19%
m/z: (M + +1) 381.16
7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 48),
Yield: 65%
m/z: (M + +1) 379.23
1-(4-Methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 55),
Yield: 59%
m/z: (M + +1) 534.19
7-[1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 57),
Yield: 48%
m/z: (M + +1) 473.22
N-Cyclohexyl-1-ethyl-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 80),
Yield: 65%
m/z: (M + +1) 420.21
Tert-butyl 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidine-1-carboxylate (Compound No. 83),
Yield: 37%
m/z: (M + +1) 469.42
Tert-butyl 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidine-1-carboxylate (Compound No. 87),
Yield: 26%
m/z: (M + +1) 483.39
N-cyclohexyl-1-(4-methoxybenzyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 91),
Yield: 72%
m/z: (M + +1) 460.35
1-Ethyl-N-(3-methoxyphenyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 94),
Yield: 16%
m/z: (M + +1) 392.17
5-{2-[(Benzyloxy)methyl]-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl}-1-(4-methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 97),
Yield: 47%
m/z: 568.19 (M + +1)
1-(4-Methoxybenzyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 100),
Yield: 37%
m/z: (M + +1) 476.34
1-(4-Methoxybenzyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 102),
Yield: 42%
m/z: (M + +1) 462.17
1-(4-Methoxybenzyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 110),
Yield: 38%
Ethyl (cis or trans) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 112),
Yield: 20%
m/z (M + +1) 454.2
Ethyl (trans or cis) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate Compound No. 113)
Yield: 19%
m/z (M + +1) 454.2
The following compounds can be prepared similarly
N-cyclohexyl-1-ethyl-5-(1,8,11-trioxa-2-azadispiro[4.1.4.1]dodec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine, N-benzyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine, tert-Butyl 3-{[1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylate, N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine ((Compound No. 114), 1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 136), 1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 137), 1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 138), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 139), N-cyclohexyl-1-ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 140), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 141), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 157), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 158), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 159), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (Compound No. 266), Methyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 268), Ethyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 269), tert-Butyl 7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylate (Compound No. 270), Ethyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 287), Methyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 288), tert-Butyl 3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 289), Ethyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 330), Ethyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 331), Methyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 332), Methyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 333), tert-Butyl 3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 334), tert-Butyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (Compound No. 335), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 336), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 337).
Example 10
Preparation of methyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(2-methoxy-2-oxoethyl)-4,5-dihydroisoxazole-5-carboxylate
The title compound was prepared by following the procedure of example 9.
Yield: 54%
m/z: (M + +1) 444.45
The following compounds were prepared similarly
Methyl 3-[4-(cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(2-methoxy-2-oxo ethyl)-4,5-dihydroisoxazole-5-carboxylate {3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazole-5,5-diyl}dimethanol
Example 11
Preparation of 2-{3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl}ethanol
Sodium borohydride (14 mg, 0.00036 mole) was added to methyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(2-methoxy-2-oxoethyl)-4,5-dihydroisoxazole-5-carboxylate (80 mg, 0.00018 mole) (example 10) in tetrahydrofuran (5 ml). Methanol (2 drops) was added and the reaction mixture was stirred at room temperature overnight. It was quenched with saturated ammonium chloride solution, diluted with ethyl acetate and extracted with brine. The organic layer was dried over anhydrous sodium sulphate and concentrated in vacuo. The crude product was purified by column chromatography.
Yield: 70 mg (98%)
m/z: (M + +1) 388.28
NMR (δ, CDCl 3 ): 8.77-8.75 (d, 1H), 8.13 (s, 1H), 7.97 (s, 1H), 4.47-4.44 (q, 2H), 3.95-3.74 (m, 5H), 3.60-3.37 (m, 2H), 2.11-1.36 (m, 15H)
The following compound was prepared similarly
2-{3-[4-(Cyclopentylamino)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl}ethanol
Example 12
Preparation of (3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-{2-[(methylsulfonyl)oxy]ethyl}-4,5-dihydroisoxazol-5-yl)methyl methanesulfonate
2-{3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl}ethanol (150 mg, 0.00038 mole) (example 11) was taken in a mixture of dichloromethane and chloroform (10 ml: 10 ml). At 0° C., triethylamine (0.153 g, 0.001513 mole) and methane sulphonyl chloride (0.173 g, 0.001513 mole) were added. The reaction mixture was stirred at 0° C. for about 2 h. The mixture was diluted with dichloromethane and washed with sodium bicarbonate solution. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo.
Yield: 280 mg (crude)
The following compound was prepared similarly
{3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazole-5,5-diyl}bis(methyl) dimethanesulfonate
Example 13
Preparation of N-cyclohexyl-1-ethyl-5-(1-oxa-7-thia-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 4)
(3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-{2-[(methylsulfonyl)oxy]ethyl}-4,5-dihydroisoxazol-5-yl)methyl methanesulfonate (280 mg, 0.00051 mole) (example 12) was taken in dimethylformamide (5 ml). Sodium sulphide nanohydrate (372 mg, 0.0015 mole) was added. The reaction mixture was refluxed at 90-100° C. overnight. Water was added, extraction was done with ethyl acetate, the organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuum. Purification was done by preparative thin layer chromatography by using ethyl acetate (40%) in hexane solvent.
Yield: 100 mg (65%)
m/z: (M + +1) 386.32
NMR (δ, CDCl 3 ): 8.84-8.83 (d, 1H), 8.09 (s, 1H), 7.98 (s, 1H), 4.90-4.44 (q, 2H), 3.96 (m, 1H), 3.56-2.97 (m, 6H), 2.42-1.25 (m, 14H).
The following compound was prepared similarly
N-cyclohexyl-1-ethyl-5-(5-oxa-2-thia-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 6),
Yield: 14.6%
m/z: (M + +1) 372.16
Example 14
Preparation of N-cyclohexyl-1-ethyl-5-(7-oxido-1-oxa-7-thia-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 5)
N-cyclohexyl-1-ethyl-5-(1-oxa-7-thia-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (70 mg, 0.00018 mole) (example 13) was taken in methanol and stirring was done for about five minutes. Water (1 ml) was added. Sodium periodate (38 mg, 0.00018 mole) was added. The reaction mixture was stirred at room temperature for about 5 h. Filtration was done and the residue was washed with dichloromethane. The organic layer was dried over anhydrous sodium sulphate and concentrated in vacuo. Purification was done by preparative thin layer chromatography using ethyl acetate (60%) in hexane.
Yield: 68.5%
m/z: (M + +1) 402.26
NMR (δ, CDCl 3 ) 8.69-8.67 (d, 1H), 8.05 (s, 1H), 7.98 (s, 1H), 4.48-4.45 (q, 2H), 3.98-3.92 (m, 1H), 3.78-3.74 (m, 3H), 3.15-3.11 (m, 3H), 3.04-3.01 (m, 1H), 2.8-2.7 (m, 1H), 2.14-1.46 (m, 13H).
Example 15
Preparation of N-cyclohexyl-5-(2,2-dioxido-5-oxa-2-thia-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 14)
N-cyclohexyl-1-ethyl-5-(5-oxa-2-thia-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (70 mg, 0.00018 mole) (example 13) was taken in dichloromethane. m-Chloroperbenzoic acid (48 mg, 0.00028 mole) was added at 0° C. The reaction mixture was stirred at room temperature overnight. Extraction was done with water. The organic layer was washed with sodium hydroxide solution (1N, 10 ml) and brine. It was concentrated in vacuo. The title compound obtained was purified by preparative thin layer chromatography.
Yield: 28%
m/z: (M + +1) 403.98
NMR (δ, CDCl 3 ): 8.96 (s, 1H), 8.12 (s, 1H), 8.02 (s, 1H), 4.68-4.64 (d, 2H), 4.60-4.55 (q, 2H), 4.45-4.42 (d, 2H), 3.97-3.93 (m, 3H), 2.15-1.45 (m, 10H), 1.42-1.08 (m, 3H).
Example 16
Preparation of N-cyclohexyl-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 12)
2-{3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-(hydroxymethyl)-4,5-dihydroisoxazol-5-yl}ethanol (150 mg, 0.00038 mole) (example 11), triphenylphosphine (132 mg, 0.00050 mole) and succinimide (42 mg, 0.00042 mole) were taken in dry tetrahydrofuran. Diisopropyl azodicarboxylate (0.115 ml, 0.00058 mole) was added dropwise. The reaction mixture was stirred at room temperature overnight. The solvent was removed under reduced pressure. The crude product obtained was purified by column chromatography.
Yield: 42%
m/z: (M + +1) 370.06
NMR (δ, CDCl 3 ): 10.03 (s, 1H), 8.10-8.03 (d, 2H), 4.83-4.13 (q, 2H), 4.10-3.99 (m, 3H), 3.82-3.80 (d, 1H), 3.55-3.53 (d, 2H), 2.66-2.11 (m, 2H), 1.7-1.25 (m, 10H), 0.89-0.82 (m, 3H).
The following compound was prepared similarly
N-cyclopentyl-5-(1,7-dioxa-2-azaspiro[4.4]non-2-en-3-yl)-1,3-dimethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 40),
Yield: 26%
m/z: (M + +1). 356.1
Example 17
Preparation of 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 16)
4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (100 mg, 0.251 mmol) (example 9) was dissolved in dichloromethane and the reaction mixture was cooled up to 5° C. Pyridinium chlorochromate (108 mg, 0.502 mmol) was added and the reaction mixture was stirred for about 5 minutes at the same temperature. It was warmed to room temperature and stirred at room temperature for about 16 h. Dilution was done with dichloromethane and filtration was done using celite. The organic layers were combined, concentrated and purified by preparative thin layer chromatography by using ethyl acetate.
Yield: 50 mg (50%)
m/z: (M + +1) 396.00
NMR (δ, CDCl 3 ): 8.15 (s, 1H), 8.07 (s, 1H), 4.60-4.57 (q, 2H), 4.46-4.44 (m, 1H), 3.22 (s, 2H), 2.64-2.40 (m, 6H), 2.17-2.12 (m, 2H), 1.85-1.81 (m, 4H), 1.71-1.69 (m, 2H), 1.69-1.42 (m, 5H).
The following compounds were prepared similarly
4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 20),
Yield: 5.0%
m/z: (M + +1) 367.97
4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (Compound No. 21),
Yield: 9.6%
m/z: (M + +1) 381.95
Example 18
Preparation of 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone oxime (Compound No. 17)
4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanone (0.025 gm, 0.063 mmol) (example 17), hydroxylamine hydrochloride (0.008 gm, 0.126 mmol) and potassium carbonate (0.043 gm, 0.315 mmol) were taken in acetonitrile and the reaction mixture was stirred at room temperature for about 6 h. Excess of solvent was removed under reduced pressure and solid separated was washed with hexane and dried in vacuum.
Yield: 60%
m/z: (M + +1) 411.15
NMR (δ, CDCl 3 ): 8.25 (s, 1H), 8.23 (s, 1H), 4.41-4.32 (q, 2H), 4.31-4.30 (m, 1H), 3.20-3.17 (m, 2H), 2.94-2.90 (m, 1H), 2.39-2.31 (m, 3H), 2.17-2.13 (m, 2H), 1.77-1.39 (m, 15H).
Example 19
Preparation of ethyl 5-(bromomethyl)-3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazole-5-carboxylate
4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridine-5-carbaldehyde oxime (200 mg, 0.0006 mole) (example 8) was taken in dichloromethane: chloroform mixture (10 ml: 5 ml). Ethyl 2-(bromomethyl)acrylate (0.2 ml, 0.00103 mole) was added. Sodium hypochlorite (2.5 ml) was added drop wise. The reaction mixture was stirred overnight. Water was added, the mixture was extracted with chloroform, washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo. The crude compound obtained was purified by column chromatography.
Yield: 66%
m/z: (M + +1) 479.97
Example 20
Preparation of {5-(bromomethyl)-3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazol-5-yl}methanol
Ethyl 5-(bromomethyl)-3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazole-5-carboxylate (200 mg, 0.0004 mole) (example 19) was taken in tetrahydrofuran (15 ml). Sodium borohydride (31 mg, 0.0008 mole) was added portion wise. The reaction mixture was stirred overnight. It was quenched with saturated ammonium chloride solution. The organic solvent was removed, water was added and the mixture was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo. The crude product obtained was purified by column chromatography.
Yield: 65.7%
m/z: (M + +1) 437.94
Example 21
Preparation of N-cyclohexyl-5-(2,5-dioxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 28)
{5-(Bromomethyl)-3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-4,5-dihydroisoxazol-5-yl}methanol (110 mg, 0.00025 mole) (example 20) was dissolved in ethanol (10 ml). Water (2 ml) was added followed by potassium hydroxide (20 mg, 0.00050 mole). The reaction mixture was stirred at refluxing temperature overnight. The solvent was removed under reduced pressure. Water was added and the mixture was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo. The crude product obtained was purified by column chromatography.
Yield: 28%
m/z: (M + +1) 356.07
NMR (δ, CDCl 3 ): 8.85 (s, 1H), 8.12 (s, 1H), 7.99 (s, 1H), 5.06-5.04 (d, 2H), 4.80-4.78 (d, 2H), 4.55-4.49 (q, 2H), 3.95-3.93 (m, 1H), 3.84 (s, 2H), 2.15-1.26 (m, 13H).
Example 22
Preparation of N-cyclohexyl-1-ethyl-5-(1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine hydrochloride salt (Compound No. 18)
Ethanolic hydrochloric acid (25 ml) was added to tert-butyl 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2,8-diazaspiro[4.5]dec-2-ene-8-carboxylate (700 mg, 0.00148 mole) (example 9) The reaction mixture was stirred at room temperature overnight. The solvent was removed under reduced pressure. White solid precipitated, which was dried under vacuum.
Yield: 96%
m/z: (M + +1) 383.02
NMR (δ, D 2 O): 8.18 (s, 1H), 7.99 (s, 1H), 4.33-4.27 (q, 2H), 4.05 (s, 1H), 3.40 (s, 2H), 3.34-3.22 (m, 4H), 2.11-1.41-(m, 14H), 1.36-1.32 (m, 3H).
Example 23
Preparation of N-cyclohexyl-5-[8-(2,2-dimethylpropanoyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 23)
N-Cyclohexyl-1-ethyl-5-(1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine hydrochloride salt (70 mg, 0.00016 mole) (example 22) was taken in dichloromethane (10 ml). Triethyl amine (0.07 ml, 0.00050 mole) and pivaloyl chloride (0.030 ml, 0.00025 mole) were added at 0° C. The reaction mixture was stirred at room temperature overnight. It was diluted with dichloromethane, washed with sodium bicarbonate solution, extracted with brine, dried over anhydrous sodium sulphate and concentrated in vacuo. The crude product obtained was purified by preparative thin layer chromatography.
Yield: 66%
m/z: (M + +1) 467.15
NMR (δ, CDCl 3 ): 9.1 (s, 1H), 8.0 (s, 1H), 7.9 (s, 1H), 4.56-4.50 (q, 2H), 4.11-4.08 (d, 2H), 3.9 (s, 1H), 3.53-3.4 (m, 2H), 3.2 (s, 2H), 2.14-1.7 (m, 4H) 1.6-1.5 (m, 13H), 1.51-1.2 (m, 9H).
The following compounds were prepared similarly
N-cyclohexyl-1-ethyl-5-{8-[(trifluoromethyl)sulfonyl]-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl}-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 24),
Yield: 29%
m/z: (M + +1) 515.02
N-cyclohexyl-1-ethyl-5-[8-(ethylsulfonyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 25),
Yield: 50%
m/z: (M + +1) 475.12
5-(8-Acetyl-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 27),
Yield: 70%
m/z: (M + +1) 425.11
Example 24
Preparation of N-cyclohexyl-5-[8-(cyclopropylmethyl)-1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 26)
N-cyclohexyl-1-ethyl-5-(1-oxa-2,8-diazaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine hydrochloride salt (70 mg, 0.00016 mole) (example 22) was taken in dimethylformamide (5 ml). Potassium carbonate (69 mg, 0.00050 mole) and cyclopropane methyl chloride (0.20 ml, 0.000021 mole) were added. The reaction mixture was stirred at 70-80° C. overnight. Water was added and the mixture was extracted with ethyl acetate, washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuum. The crude product obtained was purified by preparative thin layer chromatography.
Yield: 27%
m/z: (M + +1) 437.16
NMR (δ, CDCl 3 ): 8.72 (s, 1H), 8.1 (s, 1H), 7.9 (s, 1H), 4.50-4.44 (q, 2H), 3.9 (s, 1H), 3.34-3.31 (d, 2H), 3.0 (bs, 2H), 2.7 (bs, 2H), 2.25-1.25 (m, 20H), 0.72 (s, 2H), 0.34 (s, 2H).
Example 25
Preparation of 3-{1-ethyl-4-[4-hydroxycyclohexyl)amino]-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 22)
4-{[1-Ethyl-5-(1,9,12-trioxa-2-azadispiro[4.2.4.2]tetradec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanol (0.040 g, 0.087 mole) (example 9) was dissolved in dichloromethane and the mixture was cooled to 5° C. Trifluoroacetic acid (0.050 g, 0.439 mmol) was added drop wise in about 1 h. Water (0.1 ml) was added and the mixture was stirred vigorously for about 6 h at room temperature. It was diluted with dichloromethane and washed with sodium bicarbonate, dried over sodium sulphate, concentrated and purified by column chromatography.
Yield: 57.5%
m/z: (M + +1) 411.98
NMR (δ, CDCl 3 ): 9.47 (bs, 1H), 8.13 (s, 1H), 8.05 (s, 1H), 4.58-4.52 (m, 2H) 4.00 (s, 1H), 3.84-3.83 (d, 1H), 3.64 (s, 1H), 3.37 (s, 2H), 2.86-2.77 (m, 2H), 2.44-2.40 (d, 2H), 2.33-2.29 (d, 4H), 2.15-2.08 (m, 5H), 168-1.53 (m, 6H).
The following compounds were prepared similarly
3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 46),
Yield: 28%
m/z: (M + +1) 398.14
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 81),
Yield: 69%
m/z: (M + +1) 396.24
3-[1-(4-Methoxybenzyl)-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (Compound No. 92),
Yield: 48%
m/z: (M + +1) 490.10
Example 26
Preparation of (cis or trans)) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 42) and (trans or cis) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 43)
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (100 mg, 0.000253 mole) (example 25) in methanol was cooled to −78° C. and cerium chloride (187 mg, 0.00075 mole) and sodium borohydride (28 mg, 0.00075 mole) were added sequentially. The reaction mixture was stirred at −78° C. for about 2-3 hours. It was quenched with 5% hydrochloric acid and brine. The reaction mixture was extracted with ethyl acetate, organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to get crude product. The title compounds were separated by preparative thin layer chromatography.
Compound No. 42, Yield: 15%, HPLC purity-97.81%
Compound No. 43, Yield: 10%, HPLC purity-93.86%
m/z: (M + +1) 398.21
Compound No. 42, NMR (δ, CDCl 3 ) 8.90-8.88 (d, 1H), 8.09 (s, 1H), 7.98 (s, 1H), 4.49-4.44 (m, 2H), 3.92-3.90 (m, 1H), 3.79-3.73 (m, 1H), 3.24 (s, 2H), 2.26-1.42 (m, 21H)
Compound No. 43, NMR (δ, CDCl 3 ) 8.91-8.90 (d, 1H), 8.12 (s, 1H), 7.97 (s, 1H), 4.50-4.44 (m, 2H), 4.00-3.89 (m, 1H) 3.89-3.64 (m, 1H), 3.28 (s, 2H), 2.16-1.25 (m, 21H)
The following compounds were prepared similarly
(cis or trans) 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 45)
Yield: 28%
HPLC purity: 99.59%
m/z: (M + +1) 400.22
(trans or cis) 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 98)
Yield: 35%
HPLC purity: 96.94
m/z: (M + +1) 400.22
The following compounds can be prepared similarly
3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 148) 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 160) 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 165) 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (Compound No. 172)
Example 27
Preparation of 9-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1,7-dioxa-8-azadispiro[2.2.4.2]dodec-8-ene-2-carbonitrile
Benzyltriethyl ammonium chloride (23 mg, 0.00001 mole) was added to a mixture of 50% potassium hydroxide solution and tetrahydrofuran (10 ml) and the mixture was cooled to 0° C. Chloroacetonitrile (0.020 ml, 0.00026 mole) and 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-one (100 mg, 0.00025 mole) (example 25) in tetrahydrofuran were added to the reaction mixture. It was stirred for about 4 hours at room temperature and water was added. The reaction mixture was extracted with ethyl acetate, organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude product was purified by preparative thin layer chromatography.
Yield: 80 mg (72%)
m/z: (M + +1) 435.12
Example 28
Preparation of (cis or trans) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 95) and (trans or cis) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 96)
Lithium bromide (23 mg, 0.0002 mole) was added to a mixture of dimethylformamide (0.17 ml), acetonitrile (0.17 ml) and water (1.2 ml). 9-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1,7-dioxa-8-azadispiro[2.2.4.2]dodec-8-ene-2-carbonitrile (80 mg, 0.00018 mole) (example 27) was added after about 15 minutes and the reaction mixture was heated at 90° C. for about 10-12 hours. Acetonitrile was evaporated, water was added and the reaction mixture was extracted with ethyl acetate. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure to get crude product. The title compounds were separated by preparative thin layer chromatography.
Compound No. 95 Yield: 10.25% Chiral purity 99.69%
Compound No. 96 Yield: 13% Chiral purity 99.81%
m/z: (M + +1) 426.20
Compound No. 95 (δ, CDCl 3 ) NMR 8.95-8.94 (d, 1H), 8.17 (s, 1H), 7.98 (s, 1H), 4.51-4.45 (q, 2H), 3.93-3.92 (m, 1H), 3.31 (s, 2H), 2.56 (m, 1H), 2.20-2.13 (m, 4H), 1.95-1.89 (m, 2H), 1.84-1.7 (m, 6H), 1.70-1.55 (m, 6H), 1.51-1.48 (t, 3H)
Compound No. 96 (δ, CDCl 3 ) NMR 8.91-8.89 (d, 1H), 8.11 (s, 1H), 7.97 (s, 1H), 4.49-4.439 (q, 2H), 3.92 (m, 1H), 3.25 (s, 1H), 2.42 (m, 1H), 2.17-2.66 (m, 4H), 1.85-1.82 (m, 2H), 1.68-1.61 (m, 6H), 1.54-1.49 (m, 6H), 1.47-1.41 (t, 3H)
Example 29
Preparation of 5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 49)
1-(4-Methoxybenzyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (1.8 gm, 4 mmol) (example 9) was dissolved in trifluoroacetic acid (4.56 gm, 40 mmol) and the reaction mixture was stirred for about 4 hours at room temperature under nitrogen atmosphere. The reaction mixture was diluted with ethyl acetate and sodium bicarbonate solution was added drop wise. It was extracted with ethyl acetate, organic layer was washed with water, brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude product was purified by column chromatography.
Yield: 1.5 gm (87%)
m/z: (M + +1) 328.56
NMR: (δ, CDCl 3 ) 9.14 (d, 1H), 8.24 (s, 1H), 8.06 (s, 1H), 4.22 (s, 1H), 3.68-3.65 (t, 2H), 3.61 (s, 2H), 2.63-2.55 (m, 2H), 2.19-2.16 (m, 2H), 1.92-1.89 (d, 1H), 1.65-115 (m, 8H)
The following compound was prepared similarly
5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 101)
Yield: 32%
m/z: 356.14 (M + +1)
Example 30
Preparation of 5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoro ethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 56)
1,1,1-Trifluoro-2-iodoethane (0.07 gm, 0.33 mmol) and potassium carbonate (0.125 gm, 0.9 mmol) were added to the solution of 5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (0.1 gm, 0.3 mmol) (example 29) in dimethylformamide and the reaction mixture was heated at 80° C. for about 3 hours. It was diluted with water and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude product was purified by column chromatography.
Yield: 0.046 gm (37%)
m/z: (M + +1) 410.18
NMR (δ, CDCl 3 ) 9.11 (s, 1H), 8.11 (s, 1H), 8.05 (s, 1H), 5.07-5.01 (m, 2H), 4.15 (s, 1H), 4.05-4.02 (d, 2H), 3.66-3.63 (d, 2H), 3.61-3.58 (d, 2H), 2.60-2.54 (m, 2H), 2.28-2.23 (m, 2H), 1.89-1.25 (m, 6H).
The following compounds were prepared similarly
1-Methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 50),
Yield: 21%
m/z: (M + +1) 342.18
5-(1-Oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoroethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 51),
Yield: 26%
m/z: (M + +1) 424.56
1-(Cyclopropylmethyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 58),
Yield: 22%
m/z: (M + +1) 382.18
1-Butyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 59),
Yield: 20%
m/z: (M + +1) 384.20
1-(1-Methylethyl)-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 60),
Yield: 24%
m/z: (M + +1) 370.17
5-(5-Oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 61),
Yield: 20%
m/z: (M + +1) 370.17
5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1-(2,2,2-trifluoroethyl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 62),
Yield: 38%
m/z: (M + +1) 438.17
1-Cyclopentyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 71),
Yield: 17%
m/z: (M + +1) 424.23
1-(Cyclopropylmethyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 72),
Yield: 18%
m/z: (M + +1) 410.20
1-(1-Methylethyl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 73),
Yield: 20%
m/z: (M + +1) 398.25
5-(1-Oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 74),
Yield: 20%
m/z: (M + +1) 398.18
1-Cyclopentyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 75),
Yield: 28%
m/z: (M + +1) 410.20
1-(Cyclopropylmethyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 76),
Yield: 32%
m/z: (M + +1) 396.17
1-(1-Methylethyl)-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 77),
Yield: 25%
m/z: (M + +1) 384.22
5-(1-Oxa-2-azaspiro[4.4]non-2-en-3-yl)-1-propyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 78),
Yield: 28%
m/z: (M + +1) 384.22
1-Methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 79),
Yield: 17%
m/z: (M + +1) 356.16
5-{2-[(Benzyloxy)methyl]-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl}-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 103),
Yield: 52%
m/z: 476.14 (M + +1).
Example 31
Preparation of 1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-piperidin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 82)
Tert-butyl 4-{[1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidine-1-carboxylate (950 mg, 0.00196 mole) (example 9) was taken in dichloromethane. At 0° C., trifluoroacetic acid (10 ml) was added and the reaction mixture was stirred at room temperature for about 2 hours. It was diluted with dichloromethane and basified with saturated sodium bicarbonate solution. The organic layer was separated, washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 550 mg (74%)
m/z: (M + +1) 369.18
NMR (δ, CDCl 3 ) 9.03-9.015 (d, 1H), 8.13 (s, 1H), 7.966 (s, 1H), 4.50-4.45 (q, 2H), 4.12 (s, 1H), 3.45 (s, 2H), 3.24-3.21 (2H, d), 2.93-1.72 (m, 14H), 1.52-1.48 (t, 3H)
The following compound was prepared similarly 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-piperidin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 86)
Yield: 65%
m/z: (M + +1) 383.35
Example 32
Preparation of N-(1-cyclopentylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 63)
1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-piperidin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (70 mg, 0.0018 mole) (example 31) was taken in acetonitrile and potassium carbonate (126 mg, 0.0009 mole) and cyclopentyl bromide (0.020 ml, 0.0002 mole) were added. The reaction mixture was stirred at refluxing temperature overnight. Acetonitrile was removed and water was added to the residue. Extraction was done with ethyl acetate and washings were done with brine. The organic layer was dried over anhydrous sodium sulphate and concentrated under reduced pressure and the crude product was purified by preparative thin layer chromatography.
Yield: 25 mg (32%)
m/z: (M + +1) 437.23
NMR (δ, CDCl 3 ) 9.06 (d, 1H), 8.13 (1H, s), 7.95 (s, 1H), 4.50-4.45 (q, 2H), 3.22 (s, 2H), 3.01 (m, 1H), 1.97-1.25 (m, 27H), 1.51-1.48 (t, 3H)
The following compounds were prepared similarly
1-Ethyl-N-[1-(methylsulfonyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 52)
Yield: 24%
m/z: (M + +1) 447.17
N-(1-acetylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 53)
Yield: 28%
m/z: (M + +1) 425.21
N-(1-acetylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 54)
Yield: 28%
m/z: (M + +1) 411.18
N-(1-butylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 64)
Yield: 32%
m/z: (M + +1) 425.28
2-(4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidin-1-yl)ethanol (Compound No. 65)
Yield: 22%
m/z: (M + +1) 413.20
N-[1-(cyclopropylmethyl)piperidin-4-yl]-1-ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 66)
Yield: 38%
m/z: (M + +1) 423.20
1-Ethyl-N-[1-(1-methylethyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 67)
Yield: 34%
m/z: (M + +1) 411.25
1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-(1-propylpiperidin-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 68)
Yield: 34%
m/z: (M + +1) 411.25
N-(1-cyclopentylpiperidin-4-yl)-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 69)
Yield: 30%
m/z: (M + +1) 451.27
1-Ethyl-N-[1-(1-methylethyl)piperidin-4-yl]-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 70)
Yield: 32%
m/z: (M + +1) 425.21
1-Ethyl-N-(1-ethylpiperidin-4-yl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 84)
Yield: 9%
m/z: (M + +1) 411.41
1-Ethyl-N-(1-methylpiperidin-4-yl)-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 85)
Yield: 7%
m/z: (M + +1) 397.24
1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(1-propylpiperidin-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 88)
Yield: 32%
m/z: (M + +1) 425.24
N-[1-(cyclopropylmethyl)piperidin-4-yl]-1-ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 89)
Yield: 37%
m/z: (M + +1) 437.26
2-(4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}piperidin-1-yl)ethanol (Compound No. 90)
Yield: 38%
m/z: (M + +1) 427.25
Example 33
Preparation of Benzyl 3-methylidenecyclobutyl ether
Step a: Preparation of [3-(benzyloxy)cyclobutyl]methanol
A tetrahydrofuran solution of 3-(benzyloxy)cyclobutanecarboxylic acid (2.5 gm, 11.36 mmol) was added to a solution of sodium borohydride (0.52 gm, 13.63 mmol) in tetrahydrofuran. Iodine (1.44 gm, 5.68 mmol) in tetrahydrofuran solution was added to solution at 0° C., after about 15 minutes, and the mixture was stirred at room temperature for about 2 hours. It was quenched with dilute hydrochloric acid and extracted with ethyl acetate. The organic layer was washed with dilute sodium hydroxide solution and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 1.1 gm (50%)
Step b: Preparation of [3-(benzyloxy)cyclobutyl]methyl methanesulfonate
Methane sulphonyl chloride (0.16 gm, 1.1 mmol) and triethylamine (0.26 gm, 2.6 mmol) were added to a solution of [3-(benzyloxy)cyclobutyl]methanol (0.25 gm, 1.3 mmol) (step a) in dichloromethane at 0° C. and the reaction mixture was stirred at room temperature for about 2 hours. It was diluted with dichloromethane, washed with water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 0.27 gm (14%)
Step c: Preparation of Benzyl 3-methylidenecyclobutyl ether
Sodium iodide (0.45 gm, 3 mmol) and 1,8-diazabicyclo (5.4.0)undec-7-ene (0.304 gm, 2 mmol) were added to a stirred solution of [3-(benzyloxy)cyclobutyl]methyl methanesulfonate (0.27 gm, 1 mmol) (step b) in dimethoxyethane and the reaction mixture was refluxed for about 2 hours. It was allowed to come to room temperature and then was stirred with diethyl ether and water for about 10 minutes. The ether layer was separated and aqueous layer was washed with ether. The combined organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude compound was purified over silica gel.
Yield: 0.050 gm (39.6%)
Example 34
Preparation of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 44)
Step a: Preparation of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-(4-methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 111)
The title compound was prepared by following the procedure of example 9.
Yield: 0.40 gm (75%)
m/z: (M + +1) 554.0
Step b: Preparation of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine
Trifluoroacetic acid (0.41 gm, 3.61 mmol) was added to the solution of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-(4-methoxybenzyl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (0.4 gm, 0.72 mmol) (step a) in dichloroethane (5 ml) and the reaction mixture was refluxed for about 2 hours under inert atmosphere. It was cooled, diluted with ethyl acetate, washed with saturated sodium bicarbonate, water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
Yield: 0.21 gm (45%)
Step c: Preparation of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 44)
Ethyl iodide (0.227 gm, 1.45 mmol) and potassium carbonate (0.2 gm, 1.45 mmol) were added to the solution of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (0.21 gm, 0.48 mmol) (step b) in dimethylformamide and the reaction mixture was stirred at 60° C. for about 5 hours. It was cooled, diluted with water and extracted with ethyl acetate. The organic layer was washed with brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure. The crude product was purified over silica gel column.
Yield: 0.055 gm (25%)
m/z: (M + +1) 462.18
NMR: (δ, CDCl 3 ) 8.30 (s, 1H), 8.13 (s, 1H), 7.96 (d, 1H), 7.37-7.29 (m, 5H), 4.52-4.48 (m, 4H), 4.3-4.03 (m, 1H), 4.17 (s, 1H), 4.07-4.01 (m, 2H), 3.63-3.58 (m, 4H), 1.50-1.28 (m, 11H)
Example 35
Preparation of 7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 93)
Palladium/carbon (10%, 0.010 gm) was added to a solution of 5-[2-(benzyloxy)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (0.055 gm, 0.12 mmol) (example 34) in methanol and the reaction mixture was stirred under hydrogen balloon for about 12 hours. It was filtered through a bed of celite and residue was washed with methanol. The combined filtrate was concentrated under reduced pressure to get the title compound.
Yield: 0.021 gm (47%)
m/z: (M + +1) 372.10.
NMR: (δ, CDCl 3 ) 8.14 (s, 1H), 7.96 (s, 1H), 7.88 (s, 1H), 4.63-4.49 (m, 3H), 4.03-4.01 (m, 4H), 3.63-3.61 (m, 4H), 2.15-2.03 (m, 4H), 1.79-1.28 (m, 7H).
The following compound was prepared similarly
{7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methanol (Compound No. 104)
Yield: 39%
m/z: 387.13 (M + +1)
The following compounds can be prepared similarly
7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 121), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 122), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 169), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-ol (Compound No. 176), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methanol (Compound No. 301), (7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methanol (Compound No. 302),
Example 36
Preparation of 1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine
Palladium hydroxide/carbon (1 gm) is added to a solution of N-benzyl-1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (1 gm, 0.0022 mole) (example 9) in methanol and the reaction mixture is stirred under hydrogen balloon for about 12 hours. It is filtered through a bed of celite and residue is washed with methanol. The combined filtrate is concentrated under reduced pressure to get the title compound.
Example 37
Preparation of 1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 230)
2,2′-Bis(diphenylphosphino)-1,1′-binaphthyl (0.3 equivalent), palladium acetate (0.09 equivalent) and cesium carbonate (1.5 equivalent) is added to 4-bromo pyridine (1 equivalent) in anhydrous dioxane under inert atmosphere. 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (1.3 equivalent) (example 36) is added and the reaction mixture is stirred at reflux for about 10-12 hours. It is cooled to room temperature and filtered through celite. The reaction mixture is extracted with ethyl acetate. The organic layer is washed with water, dried over anhydrous sodium sulphate and concentrated in vacuo. The crude compound is purified by column chromatography.
The following compounds can be prepared similarly
1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 231), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 232), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 233), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 234), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 235), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 236), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 237), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 238), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 239), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 240), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 241), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 242), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 243), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 244), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 245), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 246), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 247), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 248), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 249), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 250), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 251), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 252), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyridin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 253), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrimidin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 254), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrimidin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 255), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,2,4-triazin-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 256), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 257), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-2H-tetrazol-5-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 258), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-4H-1,2,4-triazol-4-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 259), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,3-thiazol-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 260), 1-Ethyl-N-furan-3-yl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 261), 1-Ethyl-N-furan-3-yl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 262), 1-Ethyl-N-furan-3-yl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 263), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 264), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-pyrazin-2-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 265), 1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 292), 1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 293), 1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-1,2,4-triazin-3-yl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 294).
Example 38
Preparation of 3-{[1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 115)
Trifluoroacetic acid (4 equivalent) is added to the solution of tert-butyl 3-{[1-ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylate (1 equivalent) (example 9) in dichloroethane and the reaction mixture is stirred at room temperature for about 2 hours under inert atmosphere. It is cooled and diluted with ethyl acetate. The organic layer is washed with saturated sodium bicarbonate, water and brine, dried over anhydrous sodium sulphate and concentrated under reduced pressure to get the title compound.
The following compounds can be prepared similarly
3-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutane carboxylic acid (Compound No. 116), 3-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutane carboxylic acid (Compound No. 117), 4-{[1-Ethyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 132), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 133), 4-{[1-Ethyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 134), 4-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 135), 4-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 143), 4-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 144), 4-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 145), 4-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 146), 4-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 147), 4-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 150), 3-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 151), 4-{[1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 179), 4-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 180), 3-{[1-Ethyl-3-methyl-5-(5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 181), 3-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.4]non-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 182), 3-{[1-Ethyl-3-methyl-5-(1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 183), 3-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 184), 3-{[5-(2-Cyano-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 185), 3-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 186), 3-{[1-Ethyl-5-(8-hydroxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 187), 3-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 188), 3-{[1-Ethyl-5-(2-hydroxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 189), 3-{[5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 196), 3-{[5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclobutanecarboxylic acid (Compound No. 197), 3-({5-[2-(Acetylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 198), 3-({5-[2-(Acetylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 199), 3-({1-Ethyl-5-[2-(propanoylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 200), 3-({1-Ethyl-3-methyl-5-[2-(propanoylamino)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclobutanecarboxylic acid (Compound No. 201), 4-{[5-(8-Amino-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 206), 4-{[5-(8-Amino-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 207), 4-({5-[8-(Acetylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 208), 4-({5-[8-(Acetylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 209), 4-({1-Ethyl-3-methyl-5-[8-(propanoylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 210), 4-({1-Ethyl-5-[8-(propanoylamino)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 211), 7-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 212), 7-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 213), 4-{[5-(2-Carbamoyl-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 214), 4-{[5-(2-Carbamoyl-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 215), 4-({1-Ethyl-3-methyl-5-[2-(methylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 216), 4-({1-Ethyl-5-[2-(methylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 217), 4-({1-Ethyl-5-[2-(ethylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 218), 4-({1-Ethyl-5-[2-(ethylcarbamoyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 219), 3-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 220), 3-{4-[(4-Carboxycyclohexyl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 221), 4-{[5-(8-Carbamoyl-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 222), 4-({1-Ethyl-5-[8-(methylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 223), 4-({1-Ethyl-3-methyl-5-[8-(methylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 224), 4-({1-Ethyl-5-[8-(ethylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 225), 4-({1-Ethyl-5-[8-(ethylcarbamoyl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 226), 4-{[1-Ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 227), 4-{[5-(8-Ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-yl]amino}cyclohexanecarboxylic acid (Compound No. 228), 4-({1-Ethyl-5-[8-(2-hydroxyethoxy)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-yl}amino)cyclohexanecarboxylic acid (Compound No. 229).
Example 39
Preparation of 3-[4-(cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl 4-methylbenzenesulfonate
3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (0.0025 mole) (example 26) is dissolved in dichloromethane. Triethyl amine (0.0050 mol) is added at 0° and p-toluene sulphonyl chloride (0.0050 mole) is added. The reaction mixture is stirred for about 5 hrs. Water is added and extraction is done with dichloromethane. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude product, which is purified by column chromatography.
The following compound can be prepared similarly
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl 4-methylbenzenesulfonate
Example 40
Preparation of 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 173)
3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl 4-methylbenzenesulfonate (0.0018 mole) (example 39) is taken in dimethylformamide. Sodium cyanide (0.0036 mole) is added and the reaction mixture is stirred at 60-65° C. overnight. Water is added and extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography.
The following compounds can be prepared similarly
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 118), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 120), 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (Compound No. 167).
Example 41
Preparation of N-cyclohexyl-1-ethyl-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 322)
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carbonitrile (0.00098 mole) (example 40), sodium azide (0.00147 mole) and triethyl amine hydrochloride (0.00147 mol) is taken in toluene. The reaction mixture is refluxed overnight. Toluene is removed and water is added. The extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography
The following compounds can be prepared similarly
1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 318), N-cyclohexyl-1-ethyl-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 319), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(1H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 320), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 321), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[8-(1H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 323), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 324), N-cyclohexyl-1-ethyl-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 325), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[8-(2H-tetrazol-5-yl)-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 326), 1-Ethyl-N-(tetrahydro-2H-pyran-4-yl)-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 327), N-cyclohexyl-1-ethyl-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 328), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(2H-tetrazol-5-yl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 329).
Example 42
Preparation of N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 290)
3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-en-8-ol (0.00025 mole) (example 26) and potassium carbonate (0.00050 mole) is taken in dimethylformamide and methyl iodide (0.0010 mole) is added. The reaction mixture is stirred at room temperature overnight. Water is added and the extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography.
The following compounds can be prepared similarly
1-Ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 277), 5-(8-Ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 278) N-cyclohexyl-5-(8-ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 279) N-cyclohexyl-1-ethyl-5-(8-methoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 280), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-(8-ethoxy-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 291), 1-Ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 295), N-cyclohexyl-1-ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 296), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-(2-methoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 297), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-(2-ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 298), N-cyclohexyl-5-(2-ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 299), 5-(2-Ethoxy-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 300), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 303), N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-5-[2-(ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 304), N-cyclohexyl-5-[2-(ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 305), 5-[2-(Ethoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 306), 1-Ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 307), N-cyclohexyl-1-ethyl-5-[2-(methoxymethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 308).
Example 43
Preparation of 7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 105)
7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carbonitrile (300 mg, 0.00079 mole) (example 9) was dissolved in ethanol (10 ml). Aqueous potassium hydroxide (178 mg, 0.0031 mole) was added and reaction mixture was refluxed for about 3-4 hrs. Ethanol was evaporated off and reaction mixture was diluted with water, acidifed with dilute hydrochloric acid to pH of about 6. It was extracted with ethyl acetate. The organic layer was washed with brine, dried and concentrated under reduced pressure to give crude compound. The title compound was purified by preparative thin layer chromatography.
Yield: 2%
m/z: (M + +1) 398.14
NMR: NMR: (δ, CDCl 3 ) 9.05-9.03 (d, 1H), 8.67 (s, 1H), 7.9 (s, 1H), 4.44-4.39 (m, 2H), 4.03 (s, 2H), 3.95 (s, 1H), 3.17-3.12 (m, 1H), 2.90 (m, 2H), 2.6-2.68 (m, 2H), 2.15-2.11 (m, 4H), 1.70-1.57 (m, 6H), 1.52-1.35 (m, 3H).
The following compound was prepared similarly
7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 99)
Yield: 50%
m/z: (M + +1) 400.09
The following compounds can be prepared similarly
7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 168) 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 175) 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxylic acid (Compound No. 267)
Example 44
Preparation of (cis or trans) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 95)
Ethyl (cis or trans) 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylate (130 mg, 0.000286 mole) (example 9) was taken in tetrahydrofuran (5 ml). Aqueous lithium hydroxide (48 mg, 0.00147 mole) in 2 ml water was added to it. The reaction mixture was stirred at room temperature overnight. The solvent was removed under reduced pressure. The mixture was acidified with 3N hydrochloric acid to about pH of 6. The extraction was done with ethyl acetate. The organic layer was washed with water and brine, dried and concentrated under reduced pressure to get crude product. The title compound was purified by preparative thin layer chromatography.
Yield: 53%
m/z: (M+1) 426.20
The following compound was prepared similarly
(trans or cis) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 96)
Yield 62%
m/z: (M+1) 426.20
The following compounds can be prepared similarly
3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 119), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 161), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 162), 3-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 166), 3-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (Compound No. 174).
Example 45
Preparation of cis or trans 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 108)
(cis or trans) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxylic acid (70 mg, 0.00016 mole) (example 44), ammonium carbonate (47 mg, 0.00049 mg), hydroxybenzotriazole (24 mg, 0.00018 mole) were taken in dimethylformamide. N-methylmorpholine (0.03 ml, 0.00032 mole) was added at 0° C. The reaction mixture was stirred for about an hour at this temperature. 1-Ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride (34 mg, 0.00018 mole) was added and the mixture was stirred at room temperature overnight. Water was added and extraction was done with ethyl acetate. The organic layer was washed with brine, dried and concentrated under reduced pressure to give crude compound, which was purified by column chromatography.
Yield 28.9%
m/z: M+1 425.15
NMR: (δ, CDCl 3 ) 8.82-8.80 (m 1H), 8.03 (s, 1H), 7.90 (s, 1H), 5.45 (s, 2H), 4.43-4.37 (m, 2H), 3.86 (s, 1H), 3.23 (s, 2H), 2.25 (s, 1H), 2.20-1.59 (m 18H)
Chiral purity: 99.73%
(trans or cis) 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 109)
Yield 43.4%
m/z: M+1 425.15
NMR: (δ, CDCl 3 ) 8.79-8.77 (m 1H), 8.00 (s, 1H), 7.90 (s, 1H), 5.48 (s, 2H), 4.42-4.38 (m, 2H), 3.85 (s, 1H), 3.16 (s, 2H), 2.19-2.17 (m, 1H), 2.08-1.40 (m, 18H)
Chiral purity 97.81%
The following compounds were prepared similarly
(cis or trans) 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 106)
Yield: 2%
m/z: M+1 397.13
(trans or cis) 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 107)
Yield: 2%
m/z: M+1 397.13
The following compounds can be prepared similarly
7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 123), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 124), 7-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 125), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-ethyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 126), N-ethyl-7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 127), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 149), 3-{1-Ethyl-4-[(3-hydroxycyclobutyl)amino]-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 152), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 153), 3-[1-Ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 154), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 155), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 156), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 163), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 164), 7-[1-Ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 170), 7-[4-(Cyclohexylamino)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 177), N-ethyl-7-[1-ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 202), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-methyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 271), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-ethyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 272), N-cyclopropyl-7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 273), 7-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 274), 7-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-cyclopropyl-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 275), N-cyclopropyl-7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-ene-2-carboxamide (Compound No. 276), 3-{4-[(1,1-Dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-N-ethyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 281), N-cyclopropyl-3-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 282), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-cyclopropyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 283), N-cyclopropyl-3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 284), N-ethyl-3-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 285), 3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-ethyl-1-oxa-2-azaspiro[4.5]dec-2-ene-8-carboxamide (Compound No. 286).
Example 46
Preparation of 5-(8-azido-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine
3-[4-(Cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-yl 4-methylbenzenesulfonate (0.00090 mole) (example 39) is taken in dimethylformamide. Sodium azide (0.0027 mole) is added. The reaction mixture is stirred at 60-70° C. overnight. It is cooled and water is added and extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography.
Example 47
Preparation of 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-1-oxa-2-azaspiro[4.5]dec-2-en-8-amine (Compound No. 338)
Lithium aluminium hydride (0.0018 mole) is taken in tetrahydrofuran. 5-(8-Azido-1-oxa-2-azaspiro[4.5]dec-2-en-3-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (0.00047 mole) (example 46) is added. The reaction mixture is stirred at room temperature overnight. It is quenched with aqueous sodium sulphate solution followed by ethyl acetate. The filtration is done through celite pad and extraction is done with ethyl acetate. The organic layer is washed with brine, dried and concentrated under reduced pressure to give crude compound, which is purified by column chromatography.
The following compounds can be prepared similarly
5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 128), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 129), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-1-ethyl-3-methyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 171), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-cyclohexyl-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 178), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 190), 5-(2-Amino-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl)-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 191), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-cyclohexyl-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 309), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-1-ethyl-N-(tetrahydro-2H-pyran-4-yl)-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 310), 5-[2-(Aminomethyl)-5-oxa-6-azaspiro[3.4]oct-6-en-7-yl]-N-(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-4-amine (Compound No. 311).
Example 48
Preparation of 3-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-N-methyl-1-oxa-2-azaspiro[4.5]dec-2-en-8-amine (Compound No. 142)
The title compound is prepared by following the procedure of example 24.
Example 49
Preparation of N-{7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}acetamide (Compound No. 130)
The title compound is prepared by following the procedure of example 23.
The following compounds can be prepared similarly
N-{7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}acetamide (Compound No. 131), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)acetamide (Compound No. 192), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)acetamide (Compound No. 193), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)propanamide (Compound No. 194), N-(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-3-methyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)propanamide (Compound No. 195), N-{7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 203), N-{7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 204), N-{7-[1-ethyl-3-methyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}propanamide (Compound No. 205), N-[(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methyl]acetamide (Compound No. 312), N-[(7-{4-[(1,1-dioxidotetrahydro-2H-thiopyran-4-yl)amino]-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl}-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl)methyl]propanamide (Compound No. 313), N-({7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)propanamide (Compound No. 314), N-({7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)propanamide (Compound No. 315), N-({7-[4-(cyclohexylamino)-1-ethyl-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)acetamide (Compound No. 316), N-({7-[1-ethyl-4-(tetrahydro-2H-pyran-4-ylamino)-1H-pyrazolo[3,4-b]pyridin-5-yl]-5-oxa-6-azaspiro[3.4]oct-6-en-2-yl}methyl)acetamide (Compound No. 317).
Example 50
Efficacy of Compounds
(a)(i) PDE4B Enzyme Assay
The efficacy of compounds as PDE4 inhibitors was determined by an enzyme assay using cell lysate of HEK293 cells transfected with PDE4B2 plasmids as PDE4B source. The enzyme reaction was carried out in the presence of cAMP (1 μM) at 30° C. in the presence or absence of test compound for 45-60 min. An aliquot of this reaction mixture was taken further for the ELISA assay and the protocol of the kit followed to determine level of cAMP in the sample. The concentration of the cAMP in the sample directly correlated with the degree of PDE4 enzyme inhibition. Results were expressed as percent control and the IC 50 values of test compounds were reported. IC 50 values of test compounds were found to be in the range of 3 nM to 10 μM concentration.
(a)(ii) PDE7 Enzyme Assay
The efficacy of compounds as PDE7 inhibitors was determined by an enzyme assay using recombinant human PDE7A enzyme ( J. Med . Chem. (2000) 43, 683-689). The enzyme reaction was carried out in the presence of cAMP (1 μM) at 37° C. in the presence or absence of test compound for 60 min. An aliquot of this reaction mixture was taken further for the ELISA assay and the protocol of the kit was followed to determine level of cAMP in the sample. The concentration of the cAMP in the sample directly correlated with the degree of PDE7 enzyme inhibition. Results were expressed as percent control and the IC 50 values of test compounds, calculated using Graph pad prism, were found to be in the range of 3 NM to 10 μM concentration.
(b) Cell based Assay for TNF-α Release
Method of Isolation of Human Peripheral Blood Mononuclear Cells (PBMNC's)
Human whole blood was collected in vacutainer tubes containing heparin or EDTA as an anti coagulant. The blood was diluted (1:1) in sterile phosphate buffered saline and 10 ml was carefully layered over 5 ml Ficoll Hypaque gradient (density 1.077 g/ml) in a 15 ml conical centrifuge tube. The sample was centrifuged at 3000 rpm for 25 minutes in a swing-out rotor at room temperature. After centrifugation, interface of cells were collected, diluted at least 1:5 with PBS (phosphate buffered saline) and washed three times by centrifugation at 2500 rpm for 10 minutes at room temperature. The cells were resuspended in serum free RPMI 1640 medium at a concentration of 2 million cells/ml.
LPS (Lipopolysaccharide) Stimulation of Human PBMNC's
PBMN cells (0.1 ml; 2 million/ml) were co-incubated with 20 μl of compound (final DMSO concentration of 0.2%) for 10 min in a flat bottom 96 well microtiter plate. Compounds were dissolved in DMSO initially and diluted in medium for a final concentration of 0.2% DMSO. LPS (1 μg/ml, final concentration) was then added at a volume of 10 μl per well. After 30 min, 20 μl of fetal calf serum (final concentration of 10%) was added to each well. Cultures were incubated overnight at 37° C. in an atmosphere of 5% CO 2 and 95% air. Supernatant were then removed and tested by ELISA for TNF-α release using a commercial kit (e.g. BD Biosciences). For whole blood, the plasma samples were diluted 1:20 for ELISA. The level of TNF-α in treated wells was compared with the vehicle (0.2% DMSO in RPMI medium) treated controls and inhibitory potency of compound was expressed as IC 50 values calculated by using Graph pad prism. IC 50 values of test compounds were found to be in the range of 5 nM to 2.5 μM concentration.
Percent inhibition = 100 - Percent TNF - α in drug treated Percent TNF - α in vehicle treated × 100
(c) In-Vitro Assay to Evaluate Efficacy of Compounds in Combination with p38 MAP Kinase Inhibitors
Perform the assay as described in (b) above, with individual compounds and their combinations tested at sub-optimal doses.
(d) In-Vitro Assay to Evaluate Efficacy of Compounds in Combination with β2-Agonists
Measurement of Intracellular cAMP Elevation in U937 Cells
Grow U937 cells (human promonocytic cell line) in endotoxin-free RPMI 1640+HEPES medium containing 10% (v/v) heat-inactivated foetal bovine serum and 1% (v/v) of an antibiotic solution (5000 IU/ml penicillin, 5000 μg/ml streptomycin). Resuspend cells (0.25×10 6 /200 μA) in Krebs' buffer solution and incubate at 37° C. for 15 min in the presence of test compounds or vehicle (0.2% DMSO in RPMI medium). Initiate generation of cAMP by adding 50 μl of 10 μM prostaglandin (PGE2). Stop the reaction after 15 min, by adding 1 N HCl (50 μA) and place on ice for 30 min. Centrifuge the sample (450 g, 3 min), and measure levels of cAMP in the supernatant using cAMP enzyme-linked immunosorbent assay kit (Assay Designs). Calculate percent inhibition by the following formula and calculate IC 50 value using Graph pad prism.
Percent
inhibition
=
100
-
Percent
conversion
in
drug
treated
Percent
conversion
in
vehicle
treated
×
100
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The present invention relates to phosphodiesterase (PDE) type 4, phosphodiesterase (PDE) type 7 and dual PDE type 4/PDE type 7 inhibitors. Compounds disclosed herein having the structure of Formula 1: can be useful in the treatment, prevention, inhibition or suppression of CNS diseases, for example, multiple sclerosis; various pathological conditions such as diseases affecting the immune system, including AIDS, rejection of transplant, auto-immune disorders such as T-cell related diseases, for example, rheumatoid arthritis; inflammatory diseases such as respiratory inflammation diseases including chronic obstructive pulmonary disease (COPD), asthma, bronchitis, allergic rhinitis, adult respiratory distress syndrome (ARDS) and other inflammatory diseases including but not limited to psoriasis, shock, atopic dermatitis, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis; gastrointestinal inflammation diseases such as Crohn's disease, colitis, pancreatitis as well as different types of cancers including leukaemia; especially in humans. Processes for the preparation of disclosed compounds, pharmaceutical compositions containing the disclosed compounds and their use as PDE type 4, PDE type 7 and dual PDE type 4/PDE type 7 inhibitors are provided.
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BACKGROUND ART
[0001] The invention relates to a method of and apparatus for processing a binary, ternary or higher order compound to improve stoichiometry. The invention further relates to fabricating a device, and to such devices.
[0002] Physical vapour transport (PVT) is a crystal growth technique used for preparing CdTe. It has been recognised that PVT of CdTe requires a highly stoichiometric starting compound, since the transport rate of the vapour species falls off rapidly as the composition of the starting compound deviates from perfect stoichiometry (see reference [1] & reference [6]). If the starting compound has perfect stoichiometry, i.e. equal amounts of the species Cd and Te, then congruent sublimation of the vapour takes place. However, as the stoichiometry deviates to either excess Cd or excess Te, the transport rates fall by orders of magnitude. If the deviation is too large, growth is completely inhibited.
[0003] The use of highly stoichiometric starting material is beneficial not only for PVT growth of CdTe but also for other materials and growth techniques, such as Bridgman, high-pressure Bridgman and Markov.
[0004] Su et al (see reference [2]) heat treat a CdTe starting compound to remove excess Te and improve the CdTe stoichiometry. Samples were heat treated, i.e. annealed, for 24 or 48 hours at 870° C. To examine the effect of the heat treatment, the CdTe stoichiometry was measured before and after heat treatment using an optical absorption technique. The optical absorption technique is described in Carles et al [3] and Mullins et al [4] where the technique is used during vapour growth. The optical absorption is used to measure the partial pressure of Te 2 vapour, P(Te 2 ), while the sample is maintained at an elevated temperature of 870° C. The corresponding partial pressure of Cd, P(Cd), is calculated from the stoichiometric invariant, i.e. the equation
P ( Cd ) P ( Te 2 ) 1/2 =K ( T )
[0005] where K(T) is the equilibrium constant which depends only on temperature T. (The Cd pressure was too low to measure accurately the Cd absorption peak in the Te-rich samples used). The partial pressure ratio P(Cd)/P(Te 2 ) is a measurement of the stoichiometry of the CdTe. If the CdTe has perfect stoichiometry, then material loss is solely by congruent sublimation which implies loss of equal amounts of Cd and Te thereby giving P(Cd)/P(Te 2 )=2. Other Cd and Te vapour species are only present in small amounts at 870° C. and are ignored.
[0006] The optical absorption measurements showed that the as-synthesised material was in all cases Te-rich. P(Cd)/P(Te 2 ) varied between 0.007 (highly Te rich) to 1.92 (only very slightly Te rich). After heat treatment, measured P(Cd)/P(Te 2 ) varied between 1.84 and 3.4. In particular, the heat treatment was successful in removing the large quantities of excess Te from the highly Te-rich samples, providing material that generally has moderate excess amounts of Cd.
[0007] Heat treatment is thus shown generally to improve stoichiometry of the Te-rich as-synthesised material, although precise control of the stoichiometry is not possible. An unwanted consequence of the heat treatment is material loss of the CdTe compound. The 24 or 48 hour anneal was performed under vacuum and the material loss stated to be ‘reasonable’. But, during the pre-anneal and post-anneal optical absorption measurements, which are performed under non-vacuum conditions, the required heating to 870° C. is reported to result in loss of about 10% of the CdTe in only 8 minutes. It is not possible to measure the stoichiometry during the vacuum anneal because the vapour pressures are too low.
[0008] Further heat treatment methods for CdTe are discussed by Giebel et al [8] and by Mochizuki [9].
SUMMARY OF THE INVENTION
[0009] According to a first aspect of the invention there is provided a method of heat treatment of a charge of compound material comprising a plurality of n atomic species to remove an excess of at least one of the atomic species. The method comprises: (a) heating the charge to a temperature above a melting temperature of at least one of the atomic species and below the melting temperature of the compound; (b) monitoring a gas pressure associated with one of the atomic species during the heating; and (c) controlling the heating in response to the monitored gas pressure.
[0010] By monitoring the stoichiometry of a compound during heat treatment, it becomes possible to stop the heat treatment in a controlled fashion. More specifically, there is a direct relation between current gas pressure in the annealing chamber and the current stoichiometry. Heat treatment can thus be stopped once a target stoichiometry is reached, as defined by a corresponding target gas pressure. The target value may correspond to a stoichiometric balance between the atomic species in the charge of material, or a limited excess of one species within the solubility limit for the compound concerned. The target value may be defined in terms of a gas pressure of only one gas species, or in terms of multiple gas species. The gas pressure of two or more of the atomic species may be monitored during the heating.
[0011] Preferably, the charge is at least partially enclosed to inhibit loss of the compound material and to elevate the gas pressure for the monitoring. The pressure may also be elevated by applying an inert gas to the charge, this also serving to inhibit loss of the compound material.
[0012] In an embodiment of the invention, the gas pressure is monitored by an optical absorption method the carrying out of which is facilitated by elevated pressure of the monitored gas species.
[0013] According to a second aspect of the invention there is provided a method of growing a crystalline compound, comprising: annealing a charge of material comprising a plurality of n atomic species according to the heat treatment method of the first aspect; placing the annealed charge into a growth chamber; and growing a crystalline compound incorporating material from the annealed charge.
[0014] According to a third aspect of the invention there is provided a method of fabricating a device, comprising: growing a crystalline compound according to the second aspect; and fabricating a device from the crystalline compound.
[0015] According to a fourth aspect of the invention there is provided a device fabricated according to the third aspect of the invention.
[0016] According to a fifth aspect of the invention there is provided a heat treatment chamber comprising: a treatment region containing a charge of compound material comprising a plurality of n atomic species, each atomic species being associated with at least one gas species; and a gas permeable barrier at least partially enclosing the treatment region, the barrier being sufficiently permeable to passage of the gas species from the charge, but sufficiently resistive to elevate the gas vapour pressure of at least one of the gas species in the treatment region.
[0017] The heat treatment chamber may be provided in combination with a measurement chamber arranged in gaseous communication with the heat treatment chamber.
[0018] According to a sixth aspect of the invention there is provided a heat treatment apparatus comprising: a heat treatment chamber having a treatment region in which a charge of compound material comprising a plurality of n atomic species can be placed for heat treatment, each atomic species being associated with at least one gas species, the treatment region being at least partially enclosed by a gas permeable barrier for elevating the gas vapour pressure of at least one of the gas species in the treatment region; a measurement device for measuring gas vapour pressure of at least one of the gas species in the treatment region; a furnace for heating the heat treatment chamber; and a control device operable to control the furnace responsive to a vapour pressure signal of at least one of the gas species from the measurement device.
[0019] The measurement device may include a measurement chamber in gaseous communication with the treatment region of the heat treatment chamber.
[0020] The furnace preferably has first and second zones maintainable at different temperatures. In operation, the measurement chamber is arranged in the first zone and the heat treatment chamber is arranged in the second zone.
[0021] The measurement chamber may include an optical access so that the measurement device can measure gas pressure by optical absorption in the measurement chamber.
[0022] The control device is preferably operable to maintain the heat treatment chamber at an elevated temperature until a target value of the gas pressure is measured by the measurement device. The target value is defined by a vapour pressure of at least one of the gas species. The target value may also be defined by a ratio of vapour pressures of two of the gas species.
[0023] In an embodiment of the invention, the pressure of both Cd and Te 2 vapours emitted from a CdTe charge were monitored during heat treatment to provide a real time monitoring of the effective stoichiometry of the charge. In this way, the heat treatment can be stopped at a point at which a desired target stoichiometry is reached. The target stoichiometry may be perfect stoichiometry, i.e. equal amounts of Cd and Te in the CdTe compound, or may be a desired excess of one or other of Cd or Te.
[0024] Under the conditions of the heat treatment used in the embodiment, tellurium vapour is known to consist of more than 95% diatomic molecules. Other tellurium gas species could therefore be ignored.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] For a better understanding of the invention and to show how the same may be carried into effect reference is now made by way of example to the accompanying drawings in which:
[0026] [0026]FIG. 1 shows a heat treatment chamber arranged in a two-zone furnace;
[0027] [0027]FIG. 2 shows a temperature profile across the two-zone furnace of FIG. 1;
[0028] [0028]FIG. 3 shows a system incorporating the heat treatment chamber and two-zone furnace of FIG. 1;
[0029] [0029]FIG. 4 shows measured partial pressure of Te 2 during heat treatment;
[0030] [0030]FIG. 5 shows a quartz ampoule and pulling rod for growing a crystal using material processed in the system of FIG. 3;
[0031] [0031]FIG. 6 shows the temperature profile lengthwise along a PVT growth oven; and
[0032] [0032]FIG. 7 shows an alternative heat treatment chamber arranged in a two-zone furnace.
DETAILED DESCRIPTION
[0033] A controlled heat treatment method and apparatus for producing material of any desired stoichiometry is now described.
[0034] [0034]FIG. 1 shows a heat treatment chamber 30 arranged in a two-zone furnace 7 .
[0035] The two-zone furnace 7 is generally tubular in cross-section and approximately 50 cm long. The furnace 7 has heating coils 7 ′. The heating coils 7 ′ may be resistive or inductive. The heating coils 7 ′ are subdivided into two individually controllable groups arranged lengthwise along the furnace 7 to define two heating zones, designated Zone A and Zone B. In these zones, the temperature may be individually set using temperature controllers (not shown).
[0036] The heat treatment chamber 30 has a body 1 which is generally tubular in cross-section and made of quartz. At one end of the chamber body 1 , a capillary tube 2 leads to an optical measurement cell 3 . The capillary tube 2 is a simple small diameter tube. The optical measurement cell 3 is provided with access windows 25 facing each other to allow passage of a light beam through the cell 3 . At the other end of the chamber body 1 there is provided a pair of valves. One valve 10 leads to a vacuum pump (not shown) for evacuating the chamber 30 . The pump and other vacuum components preferably do not use oil in order to reduce contamination. The pump may be a turbomolecular pump. Another valve 8 is used to introduce inert gas into the chamber 30 from a remote inert gas supply (not shown). The interior of the chamber body 1 is divided into two by a cylindrical plug 4 made of quartz. Quartz wool, which acts as wadding 6 , is placed behind the plug 4 . To the left of the plug 4 , as viewed in FIG. 1, there is shown a charge 5 of material for heat treatment.
[0037] The dimensions of the parts were as follows. The chamber body 1 comprises a 25 cm long tube of 3 cm diameter. The plug 4 is 3 cm long. The cell 3 comprises a tube of 5 cm in length and 1 cm in diameter. The inner diameter of body 1 is less than 2 mm greater than the outer diameter of the plug 4 . Typically the spacing between the outer surface of the plug 4 and inner surface of the body 1 may be 0.5 to 1 mm.
[0038] To load material for heat treatment, the charge 5 is placed into the chamber body 1 towards the end adjacent the capillary tube 2 . The plug 4 is then inserted to the position shown in FIG. 1. Next, the wadding 6 is placed behind the plug 4 . Placing the wadding 6 behind the plug 4 has the effect of decreasing the effective gap between plug 4 and chamber body 1 . Good reproducibility was achieved with a thickness of 5 cm or more for the quartz wool wadding. Without the quartz wool wadding, the barrier provided by the plug would only have around a 0.5 mm dimension which is larger than the mean free path of the Cd atoms and Te 2 molecules at the working pressures. A significant pressure enhancement effect would then not occur. More generally, the barrier for inducing effusive flux, however fabricated, will need to have a characteristic dimension approximately equal to or less than the mean free paths of the relevant gas species under anneal conditions.
[0039] The heat treatment chamber 30 loaded with the charge 5 is then placed in the furnace 7 ready for heat treatment. During heat treatment, atomic or molecular vapours (e.g. Cd and Te 2 vapours for CdTe charge) pass to the optical measurement cell 3 through the capillary tube 2 . The placement of the heat treatment chamber 30 is such that the charge 5 lies in Zone B and the measurement cell 3 lies in Zone A, as illustrated. This allows the optical measurement cell 3 to be maintained at a temperature a few degrees higher than the charge 5 in the chamber body 1 (e.g. ΔT=5° C.) to avoid deposition of material on the windows 25 .
[0040] [0040]FIG. 2 shows schematically the temperature profile across Zone A and Zone B during heat treatment (T v. x). As can be seen, Zone B is controlled so that a substantially flat temperature profile is maintained across the charge 5 , with Zone A being controlled to provide an elevated temperature in the measurement cell 3 .
[0041] Because the temperature difference between cell 3 and body 1 is only small, the partial pressure in the optical measurement cell 3 is substantially the same as in the region surrounding the charge 5 . Optical absorption measurements made by a light beam traversing the cell 3 through its windows 25 can thus provide sufficiently accurate partial pressure readings of one or more vapour species emitted from the charge.
[0042] [0042]FIG. 3 shows the heat treatment chamber 30 and furnace 7 already described with reference to FIG. 1 within an overall system including further components associated with the optical absorption measurement, temperature sensing and control.
[0043] A temperature sensor in the form of a thermocouple 24 is placed in the furnace 7 adjacent to the CdTe polycrystals 5 in the heat treatment chamber 30 .
[0044] The general arrangement used for the optical absorption measurements is now described. A light source is arranged to direct a light beam through the optical measurement cell. The light beam enters and exits the cell through the cell windows. The light source is selected so that it produces light at a wavelength where the vapour species of interest has some absorption, preferably strong absorption. If two or more co-existing vapour species are to be measured, the respective wavelengths are preferably chosen so that absorption of each wavelength is predominantly caused by only one of the co-existing vapour species. A part of the light beam is split off before entering the cell, to provide a reference beam to compare with the other part of the beam which traverses the cell, referred to as the measurement beam in the following. The degree of absorption of the measurement beam in the cell is measured by comparing the respective intensities of the reference and measurement beams with a suitable photodetector or photodetectors, such as photomultiplier tubes, semiconductor diodes, charged-coupled display devices, etc.
[0045] Referring to FIG. 3, there is shown a measurement set-up suitable for measuring absorption of two vapour species, more specifically Cd and Te 2 . A laser 11 is arranged to direct a laser beam directly through the cell 3 , in and out of respective ones of the windows 25 . For measuring absorption of Cd and Te 2 a commercially available helium-cadmium (He—Cd) laser is used. A He—Cd laser has lasing wavelengths at 325 nm and 442 nm. The 325 nm laser line is strongly absorbed by Cd vapour, and the 442 nm laser line is strongly absorbed by Te 2 vapour. The use of a laser source makes the optical system easy to align, even if quite a long furnace is used. However, in general, a non-laser light source may be used, for example a discharge lamp.
[0046] The specific optical arrangement for routing the beams is now described. However, any number of optical arrangements could be envisaged. The laser 11 is optically, coupled to a beam-splitter 21 arranged to divide an incoming beam into two beams. The transmitted part forms the measurement beam that passes through the cell 3 and the reflected part forms the reference beam. The reference beam is directed to a mirror 21 ′ which deflects it to a further beam splitter 23 . The part of the reference beam transmitted by the beam splitter 23 passes through a 325 nm band-pass filter 18 to a photodetector 15 responsive to that wavelength. The part of the reference beam reflected by the beam splitter 23 passes through a 442 nm band-pass filter 19 , via a mirror 23 ′, to a photodetector 13 responsive to that wavelength. Going back to the measurement beam, after traversing the cell 3 , it is received by a beam splitter 22 . A transmitted part of the measurement beam then passes through a 325 run band-pass filter 17 to a photodetector 14 responsive to that wavelength. The part of the reference beam reflected by the beam splitter 22 passes through a 442 nm band-pass filter 16 , via a mirror 22 ′, to a photodetector 12 responsive to that wavelength. For detecting 442 nm light, the detectors 12 and 13 may be silicon photodiodes made by Hamamatsu (Japan) model S1227-1010BR. For detecting 325 nm light, the detectors 14 and 15 may be silicon photodiodes made by Hamamatsu (Japan) model S1227-1010BQ. It will also be appreciated that the band-pass filters 16 - 19 may be replaced with other filters, e.g. cut-off filters.
[0047] The use of filters 16 - 19 , and also beam splitters and mirrors 22 , 22 ′, 23 , 23 ′ is specific to applications which use a single light beam containing multiple wavelengths. If separate source beams are used for each wavelength, or if only one vapour species is to be measured, these components could be omitted.
[0048] The system is controlled by a control device in the form of a personal computer 20 . The personal computer 20 is connected to receive input signals from the photodetectors 12 - 15 . More specifically, the personal computer 20 has a data acquisition board (not shown) with inputs connected by signal lines to outputs of each of the four photodetectors 12 - 15 . The data acquisition board is operable to deliver data readings of the light signal intensity periodically, with a sampling frequency of 10 Hz. The partial pressures are calculated by the personal computer 20 in real time from the light intensity signals from the photodetectors. The vapour pressures inside the cell 3 can thus be determined every 0.1 sec. In addition, the personal computer 20 is connected to the thermocouple 24 so that the temperature of the charge 5 can also be monitored by the personal computer 20 .
[0049] To improve signal-to-noise ratio, standard lock-in detection techniques may be used, for example with an optical chopper being placed in the laser beam path.
[0050] The origin of the relationships used to calculate the partial pressures of the vapour species from the optical absorption measurements is now described with reference to the example of Cd and Te 2 . The same methodology can be applied equally well to other vapour species.
[0051] The system is calibrated by monitoring, as a function of temperature, the absorption of the 325 nm laser line by Cd vapour in a chamber containing only cadmium vapour. The same procedure is repeated for tellurium by monitoring the absorption of the 442 nm line by Te 2 vapour in chambers containing only tellurium vapour. This calibration serves to determine the relation between the optical absorption and the pressure for each vapour species of interest. Moreover, the calibration can take into account any optical absorption of one vapour species at a wavelength where the predominant absorption is from another vapour species. Specifically, the calibration for CdTe takes into account the fact that there is some absorption by Te 2 vapour at 325 nm, the wavelength designated for monitoring absorption of Cd vapour.
[0052] As described in reference [3], optical absorption is related to vapour pressure by the functional relationships:
log P Cd =−5300 /T+ 5.106 (1)
log P Te2 =−5960.2 /T+ 4.7192 (2)
[0053] where P is pressure in atmospheres (atm) and T is temperature in degrees Kelvin (K). The optical density D for a given vapour species is generally given by the expression:
D =log I 0 /I =log V 0 /V (3)
[0054] where I 0 , V o and I, V are the optical intensity and the voltage measured by the photodetectors corresponding respectively to the reference beam and the measurement beam.
[0055] The optical densities D=D Cd and D=D Te2 were measured as a function of temperature to determine the following specific forms of equation (3):
log D Cd (atm)=−5849.5 /T ( K )+5.101 at a wavelength of 325 nm (4)
log D Te2 (atm)=−5769.2 /T ( K )+6.5819 at a wavelength of 442 nm (5)
[0056] Relations (1), (2), (4) and (5) can be combined to relate optical density to partial pressure. Namely, the following relationships connect the partial pressure P Cd to the optical density D Cd and the partial pressure P Te2 to the optical density D Te2 :
log P Cd =0.9061 log D Cd +0.4842 (6)
log P Te2 =1.0331 log D Te2 −2.0806 (7)
[0057] The small absorption of Te 2 at 325 nm was also measured and taken into account. The absorption of Cd vapour at a 442 nm was negligible and not taken into account.
[0058] The heat treatment method and apparatus is now described with reference to a specific example of heat treatment of CdTe powder.
[0059] The quartz elements 1, 4 and 6 are etched, rinsed with water and ethanol, and dried in a clean oven. For degassing, elements 1 and 4 are then: (i) heated at 800° C. in oxygen, in order to remove organic contaminants; and (ii) heated at 1000° C. for at least 8 hours under vacuum in the configuration of FIG. 1. A vacuum better than 1×10 −3 Pa (1×10 −5 mbar) is recommended. The quartz wool for the wadding 6 is separately treated according to the same two degassing steps.
[0060] The charge 5 is polycrystalline CdTe prepared according to the method and apparatus described in reference [7]. The polycrystalline CdTe is ground into a powder with grains of diameter less than 0.5 mm. The charge 5 is loaded into the chamber body 5 . The plug 4 and wadding 6 are then inserted as described further above. In the experiments carried out, between 60-150 grammes of this material were introduced into the chamber body 1 . However, any suitable amount could be considered.
[0061] The valve 10 is opened, and a turbomolecular pump of the vacuum system evacuates the chamber body 1 and the optical measurement cell 3 for at least 24 hours. This allows removal of most of the oxygen to prevent oxidation of the charge 5 during the high temperature treatment that is to follow.
[0062] Then, the temperature is raised to 300° C. for 3-4 hours in order to degas the system.
[0063] Then, 0.5×10 5 Pa (0.5 atm) of Ar plus 3% H 2 are introduced and the system is maintained at 300° C. for 3 hours. Since H 2 is strongly reactive it should serve to purge the system, eliminating impurities.
[0064] After cooling to room temperature, the purging procedure is carried out three times. Each time six-nine purity ( 6 N) argon is introduced through valve 8 and the system is then evacuated through valve 10 .
[0065] Then, 15,000 Pa (150 mbar) of argon (Ar) gas is introduced by valve 8 . Alternatively, argon gas can be replaced with a mixture of Ar and H 2 in order to prevent any oxidation of the charge. The inert gas reduces the mean free path of the vapour molecules of Cd and Te 2 , thus having the important effect of limiting the effusion of these species out of the zone of the chamber body 1 where the polycrystals are stored. This is important for facilitating the optical absorption measurements, which are easier to make accurately at higher pressures. In fact, varying the inert gas pressure can be used to control the rate of effusion. Increasing the inert gas pressure, slows the transport of the excess components through the plug 4 and wadding 6 .
[0066] Typically, the heat treatment comprises a first heating phase, of about 2 hours, to reach an annealing temperature of 900° C. This temperature is intermediate between the melting point of the compound CdTe (about 1092° C.) on the one hand and the melting points of the elemental species Te (450° C.) and Cd (320° C.) on the other hand. The annealing temperature is preferably well above the respective melting points of the elemental constituents of the binary compound to increase the vapour pressures and the evaporation rates of any excess elemental components. An anneal temperature equal to at least the midway temperature between the melting point of the highest melting point elemental component of the compound and the melting point of the highest melting point is preferred. The midway temperature for CdTe would be 771° C., i.e. 450+(1092−450)/2.
[0067] While the charge 5 placed in Zone B is held at a temperature of about 900° C., the cell 3 in Zone A is held around 5° C. higher in temperature. At 900° C. any excess Cd or Te components of the CdTe exit in a liquid phase (see FIG. 2).
[0068] The liquid parts of the excess Cd or Te correspond to very high equilibrium vapour pressures, therefore Cd and Te evaporate very fast and create high vapour pressure inside the region of the chamber body 1 where the CdTe charge 5 is placed.
[0069] Te 2 vapour in equilibrium with stoichiometric CdTe at 900° C. has a pressure of about 500 Pa (5 mbar). Te 2 vapour in equilibrium with liquid Te at the same temperature reach vapour pressure of the order of atmospheres. Cd vapour in equilibrium with stoichiometric CdTe at 900° C. has a pressure of about 1000 Pa (10 mbar). Cd vapour in equilibrium with liquid Cd at the same temperature reach vapour pressure of the order of atmospheres. Consequently, if the charge is Te or Cd deviated, the sublimation of CdTe is inhibited. Moreover, the quantity of excess Cd that gives rise (following the approximate relation PV=nRT) to this equilibrium pressure depends upon the mass-to-volume ratio in the region of the chamber body 1 where the charge 5 is located. This means that, by increasing the mass-to-volume ratio, a smaller percentage deviation in Cd (or Te) gives rise to the equilibrium pressure of Cd (or Te) from CdTe. Since the sublimation of CdTe is inhibited, the effusive flux is dominated by the excess components.
[0070] Because of the difference of partial pressures existing on either side of the plug 4 , i.e. between the region to the left of the plug 4 occupied by the charge 5 (higher partial pressures) and the region to the right of the plug 4 and wadding 6 (lower pressure), the excesses of Cd and/or Te spread as Cd and Te 2 vapours through to the right region of the chamber body 1 through the annular channel formed between the close-fitting inner surface of chamber body 1 and the outer surface of the plug 4 , and through the wadding 6 .
[0071] The inner and outer walls of the chamber body 1 , plug 4 and wadding 6 thus act collectively as a barrier or effusive hole that limits the velocity of migration of the vapours away from the charge 5 . This has the important effect of raising the pressure in the vicinity of the heated charge to inhibit excessive sublimation of the charge while excess components are being evaporated. Excess components are thus evaporated in a relatively high pressure atmosphere. The high pressure not only inhibits material loss through sublimation, but also facilitates the optical absorption measurements which become easier to make, and to make accurately, at higher pressures.
[0072] While the charge 5 is being heated at around 900° C., the vapour pressures of Cd and Te 2 are monitored. At this temperature, the liquid part of the excess component (Cd or Te) corresponds to a very high equilibrium vapour pressure. The excess components will therefore evaporate very fast and produce a high vapour pressure inside the chamber body 1 . This high vapour pressure inhibits the CdTe sublimation, as previously mentioned.
[0073] The personal computer 20 evaluates from equations (4) and (5) the optical density D Cd for Cd vapour and the optical density D Te2 for Te 2 vapour on the basis of the photodetector readings. The temperature of the charge is monitored by the signal from the thermocouple 24 . The optical density D Te2 is corrected in order to take in account the absorption of the light at 325 nm. Using the calculated values of the optical densities, D Cd and D Te , the computer 20 then determines the pressures P Cd and P Te2 ) by using the expressions (6) and (7). The Cd and Te 2 pressures were evaluated every 0.1 sec during the heat treatment.
[0074] [0074]FIG. 4 shows the temporal evolution, t, of Te 2 vapour pressure, P, during the annealing at 900° C., as determined in real time during the anneal by the computer 20 . As can be seen, initially the Te 2 vapour pressure is relatively high at approximately 0.014×10 5 Pa (0.014 atm). This high pressure exists for somewhat more than two hours without significant change. This is indicative of a charge having considerable excess Te, indeed so much that it is outside the solubility region of Te in CdTe and has precipitated out to form Te droplets. During this period, the pressure is dominated by evaporation of precipitated Te.
[0075] After the high pressure plateau, a fast decrease of the Te 2 vapour pressure is observed. The Te 2 vapour pressure falls from 0.015×10 5 Pa (0.014 atm) to about 0.009×10 5 Pa (0.009 atm) in about 50 minutes. The fast decrease is considered to be a transition as the precipitated Te is exhausted.
[0076] There then follows a gradual decrease in the Te 2 pressure over 17 or more hours from 0.009×10 5 Pa (0.009 atm) towards 0.006×10 5 Pa (0.006 atm) which is approximately 600 Pa (6 mbar). The significance of this pressure is that it corresponds to the vapour pressure of pure stoichiometric vapour (P Cd =2 P Te2 ). The gradual pressure decrease is considered to result from a gradual refining of the stoichiometry of the charge material within the region of solubility of Te in CdTe.
[0077] The heat treatment is stopped at around 20 hours when the stoichiometric pressure of 500 Pa (5 mbar) is attained. This is ideal if the heat-treated charge is to be used as source material for growth of crystalline CdTe by physical vapour transport (PVT).
[0078] If the heat treatment were continued after reaching the pressure of stoichiometric vapour (500 Pa, i.e. 5 mbar, in the case of Te 2 vapour from CdTe), no further refinement would occur, only wasteful loss of material as in the prior art, where it is not possible to make any in situ measurement of the vapour pressure during heat treatment.
[0079] The in situ monitoring of vapour pressure during the anneal also provides the possibility of stopping the heat treatment at any target vapour pressure above the stoichiometric pressure. In general, it is expected that the vapour pressure of a relevant gas species associated with many other compounds will show the same basic functional form as illustrated in FIG. 4. Namely, after a compound has become free of precipitates, there will be a gradual pressure reduction from an elevated pressure to a stoichiometric pressure. The in situ measured pressure can thus be presumed to correlate directly with the stoichiometry of the charge during this heat-treatment period. Consequently, with the method and apparatus described herein it is possible to stop the heat treatment to produce a compound of a desired level of deviation from perfect stoichiometry. In other words, it becomes possible to stop the process of heat treatment at a target vapour pressure to provide material having a reproducible stoichiometric composition.
[0080] Perfect stoichiometry is often, but not always, what is desired. For example, there are some applications for which non-stoichiometric CdTe is required and the present apparatus and method can provide such material. As described in reference [5] the conductivity of CdTe is correlated to its stoichiometry. The present method and apparatus will thus allow CdTe of a desired conductivity type or value range to be provided
[0081] The heat treatment method and apparatus thus allows an exact determination of the time at which the heat treatment is best stopped. This can be effected simply by switching-off the heating coils and waiting the cooling of the charge, or by removal of the heat treatment chamber from the furnace.
[0082] It has been observed that much of the Cd and Te 2 lost from the charge during the heat treatment, will have condensed in the wadding 6 . Consequently, in order to reduce contamination of the heat-treated CdTe, the chamber body 1 can be severed in the region of the plug 4 to separate off the wadding 6 prior to removal of the heat-treated charge 5 .
[0083] To assess the success of the above-described heat treatment in achieving near-perfect stoichiometry CdTe, mass transport experiments were carried out. It is known from reference [1] that mass transport of CdTe in a given thermal gradient is a function of the stoichiometry deviation. The heat-treated CdTe was placed into a closed quartz ampoule. Mass transport experiments were then carried out in a configuration similar to the one described in reference [1]. Mass transport never failed to take place for any of the tested samples. According to reference [1] (see page 556 thereof), mass transport will only occur if the CdTe source material is deviated by less than 0.04 mole % in Te or less than 0.01 mole % in Cd. It can therefore be inferred that the heat-treated CdTe obtained from the above-described method and apparatus was in all cases highly stoichiometric.
[0084] The heat-treated CdTe was then used as source material for growing crystalline CdTe by PVT, as now described with reference to FIG. 5 and FIG. 6.
[0085] [0085]FIG. 5 shows an amount of heat-treated CdTe material 43 after its introduction in the base of a quartz ampoule 41 . The ampoule 41 was connected to a vacuum system and sealed under a vacuum of less than 10 −3 Pa (10 −5 mbar). The ampoule 41 was then introduced into a vertical furnace for PVT growth connected to a pulling rod 42 .
[0086] [0086]FIG. 6 shows the thermal profile lengthwise along the PVT growth furnace (L v. T), with the ampoule 41 schematically shown in the plot at its initial position. The ampoule 41 was then moved slowly upwards in the furnace by the pulling rod 42 so that it experiences a rise and fall in temperature defined by the temperature profile along the furnace. At the end of the growth process, the furnace was slowly cooled.
[0087] Examination showed that the PVT-grown CdTe had large single grains, indicating qualitatively that the growth was high quality. Resistivity measurements were then carried out to provide a quantitative measure of the material quality.
[0088] In all, five PVT growths of CdTe were performed, providing the following resistivity data:
Sample Resistivity (Ohm.cm) 1 5 × 10 8 2 4 × 10 9 3 2.5 × 10 8 4 1.5 × 10 8 5 2 × 10 8
[0089] As can be seen from the table, all samples have high resistivity values, indicating low defect concentrations and overall good quality.
[0090] Moreover, in order to provide an evaluation of the stoichiometry of the treated material, the equilibrium pressure of Cd and Te 2 vapours were measured at 870° C. before and after heat treatment.
[0091] A first sample was of commercially available CdTe acquired from ESPI, US. Before heat treatment, the sample had a measured Te 2 pressure of 4000 Pa (40 mbar). After heat treatment, the measured Te 2 pressure was 450 Pa (4.5 mbar).
[0092] A second sample was CdTe synthesised by the present inventors. Before heat treatment, the sample had a measured Te 2 pressure of 1400 Pa (14 mbar). After heat treatment, the measured Te 2 pressure was 450 Pa (4.5 mbar).
[0093] The Te 2 equilibrium pressure for both samples after heat treatment is thus close to that expected for perfect stoichiometry (see reference [10], in particular equation 8 at page 196).
[0094] [0094]FIG. 7 shows an alternative heat treatment chamber 30 arranged in a two-zone furnace 7 with inductive or resistive heating coils 7 ′. Many of the design details will be understood from the above description of the heat treatment chamber of FIG. 1, so the following description is relatively brief. The alternative design has a quartz inner sleeve 9 for containing a charge 5 . The inner sleeve 9 is closed at one end save for the opening of a capillary tube 2 leading to an optical measurement cell 3 with optical access windows 25 . The inner sleeve 9 is open at its other end for receiving a plug 4 in close fit. Quartz wadding 6 is packed behind the plug 4 and tube 9 within a quartz outer sleeve 1 . The outer sleeve 1 extends in one direction beyond the closed end of the inner sleeve 9 and forms a vacuum-tight seal around the capillary tube 2 . The outer sleeve 1 extends in the other direction to a vacuum flange 26 . The vacuum flange 26 abuts a further extension sleeve 27 which has first and second valves 8 and 10 therein, respectively for admission of inert gas and for pumping with a vacuum pump. In use, after conclusion of heat treatment, the extension sleeve 27 can be removed by releasing the vacuum flange 26 . The wadding 6 , contaminated with depositions of evaporated excess components, can then be extracted. A separate sawing action is thus avoided, allowing parts of the heat treatment chamber to be reused. The inner sleeve 9 with heat-treated charge 5 can then be extracted. To do this, the capillary tube 2 has to be cut. Alternatively, the outer sleeve 1 can be cut along the dashed line of FIG. 3.
[0095] Although described above with specific reference to CdTe, the controlled heat treatment method and apparatus could be used for treating a wide variety of compound materials, such as IV-IV, III-V or II-VI compounds. Examples of IV-IV compounds are SiGe and SiC. Examples of III-V compounds are GaAs, InP, GaInAs and GaInAsP. Examples of some other II-VI binary compounds are ZnTe, CdSe, CdS, ZnSe, ZnS, and associated ternary or quaternary compounds. In each case a convenient temperature for the heat treatment should be readily ascertainable.
[0096] Generally, for binary compounds, the partial pressure of only one elemental vapour species needs to be measured, since the other can then be inferred. For ternary compounds, the partial pressures of at least two elemental vapour species will need to be made. For quaternary, compounds the partial pressures of at least three elemental vapour species will need to be measured.
REFERENCES
[0097] 1. Yellin & Szapiro: Journal of Crystal Growth, vol. 69, pages 555-560 (1984)
[0098] 2. Su et al: Journal of Crystal Growth, vol. 183, pages 519-524 (1998)
[0099] 3. Carles et al: Journal of Crystal Growth, vol. 174, pages 740-745 (1997)
[0100] 4. Mullins et al: Journal of Crystal Growth, vol. 208, pages 211-218 (2000)
[0101] 5. Berdling: Applied Physics Letters, vol. 74, pages 552-554 (1999)
[0102] 6. Laasch et al: Journal of Crystal Growth, vol. 174, pages 696-707 (1997)
[0103] 7. EP 98124186.2.
[0104] 8. Giebel et al: Journal of Crystal Growth, vol. 86, pages 386-390 (1988)
[0105] 9. Mochizuki: Journal of Crystal Growth, vol. 73, pages 510-514 (1985)
[0106] 10. De Largy et al: Journal of Crystal Growth, vol. 61, pages 194-198 (1983)
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A heat treatment chamber ( 30 ) is provided comprising a treatment region containing a charge ( 5 ) of compound material comprising a plurality of n atomic species, each atomic species being associated with at least one gas species. The chamber ( 30 ) is placed in a furnace ( 7 ). The chamber has a gas permeable barrier, constituted by a plug ( 4 ) and wadding ( 6 ), which partially encloses the treatment region. The barrier serves as an effusive hole to inhibit, but not prevent, gas vapour release, thereby to elevate the gas vapour pressure in the treatment region. Application of inert gas through a valve ( 8 ) is also used to increase background pressure in the treatment region during heat treatment. The elevated gas pressures present in the treatment region during treatment are measurable in an absorption cell ( 3 ) adjacent to the treatment region. It is thus possible to monitor the gas pressures during heat treatment and thereby stop the heat treatment once a desired charge stoichiometry is achieved. This improves over prior art heat treatment which is carried out in vacuum and thus precludes optical absorption measurement of the gas pressures during heat treatment.
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BACKGROUND OF THE INVENTION
The invention relates to a mash copper (or mash tun) having a body of circular cross-section and a tun bottom inclined to the centre and constructed as a heating surface.
Mash coppers having a circular cross-section and a conical or uniformly arched heating bottom are known. In such mash coppers the mixing of the mash and the heat transfer are not optimal. The mash is moved with a pushing motion in the copper, the mash particles preferably moving in horizontal planes. To obtain, in spite of this, a sufficient mixing and an improved heat transfer flow breakers must generally be installed and in addition a relatively high speed of rotation of the agitator must be used. However, high peripheral speeds of the stirrer or agitator have technological disadvantages because there is a danger of damage to the glume particles both at the sharp-edged parts of the agitator and of the flow breakers.
Furthermore, mash coppers having a rectangular cross-section also are known. In such mash coppers, although a more pronounced upward movement of the mash particles and thus an improved mixing is obtained, in the vicinity of the (usually rounded) corners of the vessel a pulsating stirring action results and thus an irregular heat transfer. Also disadvantageous is the large peripheral speed of the agitators required in mash coppers with rectangular cross-section and the relatively high energy consumption.
SUMMARY OF THE INVENTION
The invention has for its objective avoidance of the defects of the known constructions by providing a mash copper which is distinguished by an excellent energy-saving mixing of the tun content wherein a uniform migration of the mash particles from the bottom to the top take place, an approximately uniform contact of all mash particles with the heating surface exists, and in addition a particularly careful treatment of the mash is ensured.
This objective is achieved according to the invention by a construction in which the bottom of a mash copper of circular cross-section comprises the following parts:
(a) two planar bottom portions which are disposed in mirror-image manner with respect to a first vertical centre plane of the copper and include an angle between about 140° and 156°,
(b) two gusset portions which are disposed in mirror-image manner with respect to a second vertical centre plane of the copper offset by about 90° with respect to the first and taper from the periphery to the centre of the copper bottom and the roof-like inclined surfaces of which enclose with each other an angle between about 90° and 130° and the ridge-like edge of which forms with the horizontal an angle between about 3° and 5°.
DESCRIPTION OF THE DRAWINGS
The foregoing and other details of the invention will become apparent from the following description of a presently preferred embodiment illustrated in the accompanying drawings, wherein:
FIG. 1 is a vertical sectional view through a mash copper taken along the vertical plane B of FIG. 2, the agitator being omitted;
FIG. 2 is a horizontal cross-sectional view along the line II--II of FIG. 1;
FIG. 3 is a partial vertical section through a gusset portion on the copper bottom corresponding to the section III--III in FIG. 2;
FIG. 4 is a vertical sectional view in the vertical centre plane A of FIG. 5, including an agitator for illustrating the flow conditions in the copper; and
FIG. 5 is a horizontal sectional view along the line V--V of FIG. 4, and illustrating the flow conditions in the copper.
DETAILED DESCRIPTION
The construction of the tun bottom itself will first be explained with particular reference to FIGS. 1-3.
The mash tun or copper has a body 1 which, as is apparent from FIG. 2, is of circular cross-section. The bottom 2 is constructed as a heating surface and is inclined to the centre. The bottom 2 is secured, preferably welded, within the cylindrical wall 3 of the copper 1.
The tun bottom 2 itself comprises a plurality of portions, i.e., two planar portions 4, 5 and two gusset portions 6, 7 tapering from the periphery to the centre of the bottom 2. The two planar bottom portions 4, 5, which constitute the clearly greater part of the area of the bottom 2, are disposed in mirror-image manner with respect to a first vertical centre plane A of the copper 1, enclosing an angle α between 140° and 156°, and preferably about 150°. The two gusset portions 6, 7, which represent only a relatively small part of the bottom area (cf. especially FIG. 2), have a roof-like cross-section (cf. gusset portion 6 in FIG. 1), the roof-like inclined surfaces 6a, 6b and 7a, 7b of each gusset portion 6, 7 enclosing an angle B between 90° and 130°, and preferably about 110°. The tapering gusset portions 6, 7 have ridge-like (upper) edges 6c, 7c forming, as shown in FIG. 3, an angle γ between 3° and 5° to a horizontal plane H. The two gusset portions 6, 7 are disposed in mirror-image manner with respect to a second vertical centre plane B of the copper 1, the second vertical centre plane being offset by 90° with respect to the first vertical centre plane A.
Since the tun bottom 2 is intended as a heating surface for the mash copper 1, heating means are necessary and may be provided in the usual manner on the lower side of the tun bottom in the form of heating channels, heating conduits, etc. In the disclosed tun bottom construction, however, it is preferred to provide heating channels 8 at the lower sides of the two planar bottom portions 4, 5 only; thus, no heating of the bottom takes place beneath the gusset portions 6, 7. The heating channels 8 are, as is apparent in particular from FIG. 2, substantially rectilinear and extend substantially parallel to each other and parallel to the first vertical centre plane A (and thus also parallel to the ridge-like edges 6c, 7c of the gusset portions 6, 7, which also lie in the plane A). The heating channels 8 may be constructed in any suitable form, for example as welded-on tubes, half-tubes or, as is illustrated in FIG. 1, by welded-on angle pieces. The heating of the tun bottom 2 is thus indirect, for example with the aid of steam or a suitable heating liquid (e.g., high-pressure hot water). The construction and arrangement of the heating channels 8 outlined above are particularly simple compared to known tun bottom constructions in which double jackets or spirally welded heating tubes or channels are provided for the heating elements.
As is illustrated in FIGS. 4 and 5 the mash copper 1 includes an agitator blade 9 which is disposed in the centre of the tun bottom 2 and can be rotatably driven about a vertical axis 10, in this case in the direction of the arrow 11. In the embodiment of FIG. 4 the agitator means is driven from below by a drive motor 12 and suitable couplings. The mash copper 1 may otherwise be constructed in the usual manner and depending on the type of construction, have a cover 13 which is flat or conical, as shown in FIGS. 1 and 4. The copper can be supported on low extension 3a (FIG. 1) of the cylindrical casing 3 or on separate supports 14 (FIG. 4).
The mode of operation of the mash copper is illustrated in FIGS. 4 and 5 by corresponding arrows. During the operation the agitator blade 9 is set in rotation in the direction of the arrow 11, the blade 9 being driven at a peripheral speed between 2.0 to 2.8 m/s, and preferably at a peripheral speed of about 2.5 m/s. The mash heated indirectly by the heating channels 8 via the bottom 2 is set in motion in the direction of the arrows illustrated in FIGS. 4 and 5, and forms a relatively flat depression 15 shown in dash lines, in the central region of the mash surface 16. This depression, which is relatively small compared with known constructions, prevents oxygen from being dispersed into the mash and is advantageous as regards the quality of the final product.
The construction and arrangement of the gusset portions 6, 7 of the tun bottom 2 also have a particularly favourable effect. In spite of the relatively small peripheral speed of the agitator 9 compared with known constructions these gusset portions 6, 7 contribute to an extremely good mixing of the mash moving as indicated by the arrows in FIGS. 4 and 5; the gusset portions 6, 7 act simultaneously as so-called flow or wave breakers in the mash moved by the agitator blade 9, reliably preventing a purely circular motion of the entire mash filling, i.e., a rotating mash filling. In addition, the relatively low peripheral speed of the agitator 9 and the shape of the gusset portions 6, 7 reliably prevent any glume particles in the mash from being damaged.
The disclosed embodiment is representative of a presently preferred form of the invention, but is intended to be illustrative rather than definitive thereof. The invention is defined in the claims.
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A mash tun or copper having a body of circular cross-section and a heated bottom which is inclined to the center and having two planar bottom portions and two roof-like gusset portions. Such a mash copper is distinguished by an excellent energy-saving mixing of the tun content.
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BACKGROUND OF THE INVENTION
The present invention relates to a data transmission system for transmitting data over telephone lines or similar analog lines and, more particularly, to a jitter cancelling apparatus for carrier phase control associated with a receiver of such a data transmission system.
In a data transmission system, signals usually undergo various kinds of deterioration as typified by amplitude distortions, delay distortions, carrier frequency offsets and carrier phase jitters while being transmitted over lines. Among them, amplitude distortions and delay distortions are almost time-invariant or, if time-variant, the variation is slow enough to allow such distortions to be compensated for by so-called automatic equalizers. Carrier phase jitters, on the other hand, result in time-variant distortions and this kind of distortion has hitherto been absorbed by a phase locked loop (PLL).
The PLL scheme, however, cannot sufficiently suppress phase jitters (especially, high-frequency jitters) unless the frequency band of the PLL is broadened to the order of 200 hertz to 300 hertz. Such a broad loop band would deteriorate the noise characteristic of the PLL and thereby lower the resistivity to noise of the entire data transmission system.
Another implementation for the suppression of phase jitters heretofore proposed is a jitter canceller system as disclosed in U.S. Pat. No. 4,639,939. The jitter canceller system uses a predictive filter, which is tuned to phase jitters, so as to cancel phase jitters being superimposed on a carrier wave. This type of system can be implemented with a narrow-band PLL which is adapted to recover a carrier wave, thereby eliminating the deterioration of the resistivity to noise. However, a problem with the jitter canceller system is that the predictive filter has to be scaled up in inverse proportion to the lower limit of phase jitter frequency which is to be suppressed. Should the system be designed to cope with even the jitter whose frequency is as low as 20 hertz or so, the hardware scale would become excessively large and therefore impractical.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus capable of cancelling phase jitters over a wide frequency range while reducing the hardware scale of the apparatus.
A jitter cancelling apparatus of the present invention has a phase locked loop for suppressing phase jitters whose frequency is lower than 50 hertz, a jitter canceller for suppressing phase jitters the frequency of which is higher than 50 hertz, and a control circuit for controlling the PLL and jitter canceller. The control circuit has a jitter frequency measuring circuit and, when the measured jitter frequency is lower than 50 herts, renders the jitter canceller inoperative. When the measured jitter frequency is higher than 50 hertz, the control circuit sets up a PLL frequency band of 1 hertz so as to allow the jitters to be mainly cancelled by the jitter canceller.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken with the accompanying drawings in which:
FIG. 1 is a block diagram showing an embodiment of the present invention; and
FIG. 2 to 4 is a block diagrams showing the phase detector in detail.
FIG. 3 is a block diagram showing the loop filter in detail.
FIG. 4 is a block diagram showing the zero-cross counter in detail.
In the drawings, thick lines represent complex signals and thin lines, real signals or control signals.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, a jitter cancelling apparatus embodying the present invention is shown in a schematic block diagram. As shown, the apparatus has an input terminal 116 to which a complex baseband signal is applied, and a first phase rotator 101 which rotates the baseband signal by a first phase to produce a first phase-rotated signal. A second phase rotator 102 rotates the first phase-rotated signal by a second phase to output a second phase-rotated signal. A discriminator 103 discriminates the second phase-rotated signal to produce a discriminated signal. A phase detector 104 detects the phase of the first phase-rotated signal on the basis of the output of the discriminator 103, i.e., the discriminated received signal and the first phase-rotated signal which is fed thereto from the phase rotator 101. The first phase-rotated signal outputted by the phase detector 104 is multiplied by a constant K 1 or K 2 (K 1 >K 2 ) using a multiplier 105, and the resulting signal is smoothed by a loop filter 106. The smoothed output of the loop filter 106 is integrated by an integrator 107. In response to the integrated phase, a trigonometric function generator 108 (simply labeled as "e j θ 1") generates a first phase θ 1 . This first phase is applied to the phase rotator 101, as stated earlier, so that the received signal is rotated on the basis of the first phase. The elements 101 and 103 to 108 stated above form a common PLL in combination. The constants K 1 and K 2 are selected one at a time by a selector 114 and used to set up a loop gain of such a PLL. In the illustrative embodiment, the loop gains K 1 and K 2 are selected to provide a loop frequency band of about 50 hertz and a loop frequency band of about 1 hertz, respectively.
The detected phase from the phase detector 104 is also routed to a predictive filter 109 via a switch 115. In response, the predictive filter 109 predicts a phase jitter. A trigonometric function generator 110 (simply labeled as "e j θ 2") generates a second phase θ 2 in response to the predicted phase jitter and delivers it to the phase rotator 102. The phase rotator 102, therefore, rotates the first phase-rotated signal as previously stated, in response to the second phase. A phase detector 111 detects the phase of the second phase-rotated signal on the basis of the second phase-rotated signal and the discriminated signal, the detected phase being fed to the predictive filter 109 in the form of a control signal for coefficient adjustment. The coefficient adjustment of the prediction filter 109 per se is shown and described in the previously mentioned U.S. Pat. No. 4,639,939 in detail, and redundant description will be omitted for simplicity.
In the illustrative embodiment, the predictive filter 109 has a number of taps N which is selected such that the minimum prediction frequency is about 50 hertz.
A zero-cross counter 112 counts the number of times that the phase signal from the phase detector 104 crosses the zero level within a predetermined period of time. Hence, the output of the zero-cross counter 112 is proportional to the frequency of the detected phase signal, i.e., the frequency of a phase jitter. A comparator 113 determines whether the output of the zero-cross counter 112 is greater or smaller than a threshold value TH which is representative of the frequency of 50 hertz.
When the frequency of a phase jitter is higher than 50 hertz as determined by the comparator 113, the selector 114 selects K 2 as a loop coefficient and, at the same time, closes the switch 115. In this condition, a loop frequency band of about 1 hertz is set up and the predictive filter 109 is activated, whereby the phase jitter is mainly suppressed by the phase rotator 102. Conversely, when the frequency of a phase jitter is lower than 50 hertz, the selector 114 selects K 1 as a loop coefficient and opens the switch 115. Then, a loop band of about 50 hertz is set up and the predictive filter 109 is deactivated, so that the phase jitter is suppressed by the phase rotator 101.
Referring to FIG. 2, a specific construction of the phase detector 104 or 111 is shown. As shown, the phase detector 104 (111) has a terminal 201 for receiving the first (second) phase-rotated signal from the phase rotator 101 (102), a terminal 202 for receiving the discriminated signal from the discriminator 103, a complex conjugate unit 203 for producing a complex conjugate signal of the discriminated received signal, a multiplier 204 for producing a product of the first phase-rotated signal and the complex conjugate signal and an imaginary part selector 205 for separating an imaginary part of the product.
Assuming that a signal appearing on the terminal 201 is
x=γe.sup.jθ Eq. (1)
and that a signal appearing on the terminal 202 is
x=γe.sup.jθ Eq. (2)
then the complex conjugate unit 203 modifies the Eq. (2) as
x*=γe.sup.-jθ Eq. (3)
After the multiplier 204 has multiplied the signals represented by the Eqs. (1) and (3), the imaginary part selector 205 separates only an imaginary part y of the product. The imaginary part y is expressed as: ##EQU1## assuming that C=γγand θ-θ<<1.
FIG. 3 indicates a specific construction of the loop filter 106. In the figure, the loop filter 106 is implemented as an ordinary full integration type loop filter and has coefficient units 301 and 302, an integrator 304, and an adder 303. The transfer function of the loop filter 106 is expressed as ##EQU2##
FIG. 4 is a schematic block diagram showing a specific construction of the zero-cross counter 112. In the figure, the zero-cross counter 112 observes the signs of successive sampled values so as to count the transitions of sign. Specifically, the zero-cross counter 112 is made up of a sign bit detector 401 for detecting the sign of a signal, a flip-flop 402 to be set and reset on the basis of the detected sign, and a counter 403 for counting outputs of the flip-flop 402.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof.
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A jitter cancelling apparatus cancels both low and high frequency jitter in a carrier signal. The jitter cancelling apparatus has both a phase-locked-loop for cancelling lower frequency jitter and a predictive jitter canceller for cancelling higher frequency jitter. The jitter cancelling apparatus also has a control circuit which contains a jitter frequency measuring circuit for measuring jitter frequency. The control circuit determines whether the jitter cancelling circuit or the phase locked-loop is effectively operative according to whether the jitter frequency is above or below a predetermined value.
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FIELD OF THE INVENTION
This invention is a surgical device. In particular, it is a guide catheter assembly. The guide catheter assembly is used to cooperate with a micro-catheter in accessing a tissue target within the body, typically a target which is accessible through the vascular system. Central to the invention is the use of a braided metallic reinforcing member, situated within the catheter body in such a way to create a catheter section having an exceptionally thin wall, controlled stiffness, and high resistance to kinking. The catheter has a terminal segment which is not supported by a braid and the polymer making up that terminal segment is of equal hardness to or is harder than the polymer of the segment located just proximally. The braid may have a single pitch or may vary in pitch along the axis of the catheter or catheter section. The braided reinforcing member typically is embedded in a flexible outer tubing member. An inner tubing member is lubricious. The terminal segment may also have a smaller diameter than does its more proximal regions.
BACKGROUND OF THE INVENTION
Catheters are increasingly used to access remote regions of the human body and, in doing so, delivering diagnostic or therapeutic agents to those sites. In particular, catheters which use the circulatory system as the pathway to these treatment sites are especially practical. Catheters are also used to access other regions of the body, e.g., genito-urinary regions, for a variety of therapeutic and diagnostic reasons. One such treatment of circulatory system diseases is via angioplasty (PCA). Such a procedure uses catheters having balloons on their distal tips. It is similarly common that those catheters are used to deliver a radio-opaque agent to the site in question prior to the PCA procedure to view the problem prior to treatment.
Often the target which one desires to access by catheter is within a soft tissue such as the liver or the brain. These are difficult sites to reach. The catheter must be introduced through a large artery such as those found in the groin or in the neck and then be passed through ever-narrower regions of the arterial system until the catheter reaches the selected site. Often such pathways will wind back upon themselves in a multi-looped path. These catheters are difficult to design and to utilize in that they must be fairly stiff at their proximal end so to allow the pushing and manipulation of the catheter as it progresses through the body, and yet must be sufficiently flexible at the distal end to allow passage of the catheter tip through the loops and increasingly smaller blood vessels mentioned above and yet at the same time not cause significant trauma to the blood vessel or to the surrounding tissue. Further details on the problems and an early, but yet effective, way of designing a catheter for such a traversal may be found in U.S. Pat. No. 4,739,768, to Engelson. These catheters are designed to be used with a guidewire. A guidewire is simply a wire, typically of very sophisticated design, which is the "scout" for the catheter. The catheter fits over and slides along the guidewire as it passes through the vasculature. Said another way, the guidewire is used to select the proper path through the vasculature with the urging of the attending physician and the catheter slides along behind once the proper path is established.
There are other ways of causing a catheter to proceed through the human vasculature to a selected site, but a guidewire-aided catheter is considered to be both quite quick and somewhat more accurate than the other procedures. One such alternative procedure is the use of a flow-directed catheter. These devices often have a small balloon situated on the distal end of the catheter which may be alternately deflated and inflated as the need to select a route for the catheter is encountered. Flow-directed catheters are rarely used as guide catheters.
This inventive catheter is used to direct a smaller catheter from a body entry site to a site intermediate to the treatment site. The use of this catheter extends the site at which smaller catheter first enters the bloodstream.
This invention is an adaptable one and may be used in a variety of catheter formats. The invention utilizes the concept of combining one or more polymeric tubes with a metallic braid comprising wires or ribbons of a stainless steel or super-elastic alloy. The construction technique has the benefit of producing catheter sections having small overall diameters but with exceptional strength, resistance to kinking, and recovery from kinking (even in vivo) should such kinking occur.
The use of braids in a catheter body is not a novel concept. Typical background patents are discussed below. However, none of these documents have used our concept to produce a catheter which has the physical capabilities of the catheter of this invention.
Multi-Wrap Catheters
There are a number of catheters discussed in the literature which utilize catheter bodies having multiply-wrapped reinforcing material. These catheters include structures having braided bands or ones in which the spirally wound material is simply wound in one direction and the following layer or layers are wound in the other.
Crippendorf, U.S. Pat. No. 2,437,542, describes a "catheter-type instrument" which is typically used as a ureteral or urethral catheter. The physical design is said to be one having a distal section of greater flexibility and a proximal section of lesser flexibility. The device is made of intertwined threads of silk, cotton, or some synthetic fiber. It is made by impregnating a fabric-based tube with a stiffening medium which renders the tube stiff yet flexible. The thus-plasticized tubing is then dipped in some other medium to allow the formation of a flexible varnish-like layer. This latter material may be a tung oil base or a phenolic resin and a suitable plasticizer.
Similarly, U.S. Pat. No. 3,416,531, to Edwards, shows a catheter having braiding-edge walls. The device further has additional layers of other polymers such as TEFLON and the like. The strands found in the braiding in the walls appear to be threads having circular cross-sections. The device is shown to be fairly stiff in that it is designed so that it may be bent using a fairly large handle at its proximal end.
U.S. Pat. No. 3,924,632, to Cook, shows a catheter body utilizing fiberglass bands wrapped spirally for the length of the catheter. As is shown in FIG. 2 and the explanation of the Figure at column 3, lines 12 and following, the catheter uses fiberglass bands which are braided, that is to say, bands which are spiraled in one direction cross over and under bands which are spiraled in the opposite direction. Additionally, it should be observed that FIG. 3 depicts a catheter shaft having both an inner lining or core 30 and an outer tube 35.
U.S. Pat. No. 4,425,919, to Alston, Jr. et al., shows a multilayered catheter assembly using multi-stranded flat wire braid. The braid 14 in FIG. 3 further covers an interior tubing or substrate 12.
U.S. Pat. No. 4,484,586 shows a method for the production of a hollow, conductive medical tubing. The conductive wires are placed in the walls of hollow tubing specifically for implantation in the human body, particularly for pacemaker leads. The tubing is preferably made of an annealed copper wire which has been coated with a body-compatible polymer such as a polyurethane or a silicone. After coating, the copper wire is wound into a tube. The wound substrate is then coated with still another polymer to produce a tubing having spiral conducting wires in its wall.
A document showing the use of a helically wound ribbon of flexible material in a catheter is U.S. Pat. No. 4,516,972, to Samson. This device is a guiding catheter and it may be produced from one or more wound ribbons. The preferred ribbon is a polyaramid material known as Kevlar 49. Again, this device is a device which must be fairly stiff. It is a device which is designed to take a "set" and remain in a particular configuration as another catheter is passed through it. It must be soft enough so as not to cause substantial trauma, but it is certainly not for use with a guidewire.
U.S. Pat. No. 4,806,182, to Rydell et al, shows a device using a stainless steel braid imbedded in its wall and having an inner layer of a polyfluorocarbon. The process also described therein is a way to laminate the polyfluorocarbon to a polyurethane inner layer so as to prevent delamination.
U.S. Pat. No. 4,832,681, to Lenck, shows a method and apparatus useful for artificial fertilization. The device itself is a long portion of tubing which, depending upon its specific materials of construction, may be made somewhat stiffer by the addition of a spiral reinforcement comprising stainless steel wire.
U.S. Pat. No. 4,981,478, to Evard et al., discloses a multi-sectioned or composite vascular catheter. The interior section of the catheter appears to have three sections making up the shaft. The most interior (and distal) section, 47, appears to be a pair of coils 13 and 24 having a polymeric tubing member 21 placed within it. The next, more proximal, section is 41, and FIG. 4 shows it to be "wrapped or braided" about the next inner layer discussed just above. The drawing does not show it to be braided but, instead, a series of spirally wrapped individual strands. Finally, the outermost tubular section of this catheter core is another fiber layer 49, of similar construction to the middle section 26 discussed just above.
Another catheter showing the use of braided wire is shown in U.S. Pat. No. 5,037,404, to Gold et al. Mention is made in Gold et al of the concept of varying the pitch angle between wound strands so to result in a device having differing flexibilities at differing portions of the device. The differing flexibilities are caused by the difference in pitch angle. No mention is made of the particular uses to which the Gold et al. device may be placed.
U.S. Pat. No. 5,057,092, to Webster, Jr., shows a catheter device used to monitor cardiovascular electrical activity or to electrically stimulate the heart. The catheter uses braided helical members having a high modulus of elasticity, e.g., stainless steel. The braid is a fairly complicated, multi-component pattern shown very well in FIG. 2.
U.S. Pat. No. 5,176,660 shows the production of catheters having reinforcing strands in their sheath wall. The metallic strands are wound throughout the tubular sheath in a helical crossing pattern so to produce a substantially stronger sheath. The reinforcing filaments are used to increase the longitudinal stiffness of the catheter for good "pushability". The device appears to be quite strong and is wound at a tension of about 250,000 lb./in. 2 or more. The flat strands themselves are said to have a width of between 0.006 and 0.020 inches and a thickness of 0.0015 and 0.004 inches.
Another variation which utilizes a catheter wall having helically placed liquid crystal fibrils is found in U.S. Pat. No. 5,248,305, to Zdrahala. The catheter body is extruded through an annular die, having relatively rotating inner and outer mandrel dies. In this way, the tube containing the liquid crystal polymer plastic-containing material exhibits a bit of circumferential orientation due to the rotating die parts. At column 2, line 40 and following, the patent suggests that the rotation rate of the inner and outer walls of the die may be varied as the tube is extruded, with the result that various sections of the extruded tube exhibit differing stiffnesses.
U.S. Pat. No. 5,217,482 shows a balloon catheter having a stainless steel hypotube catheter shaft and a distal balloon. Certain sections of the device shown in the patent use a spiral ribbon of stainless steel secured to the outer sleeve by a suitable adhesive to act as a transition section from a section of very high stiffness to a section of comparatively low stiffness.
Japanese Kokai 05-220,225, owned by the Terumo Corporation, describes a catheter in which the torsional rigidity of the main body is varied by incorporating onto an inner tubular section 33, a wire layer which is tightly knitted at the proximal section of the catheter and more loosely knitted at a midsection.
Single-Layer Reinforced Catheters
There are a variety of catheters which, unlike the devices discussed above, utilize but a single layer of reinforcing material.
For instance, U.S. Pat. No. 243,396 to Pfarre, patented in June of 1881, shows the use of a surgical tube having a wire helix situated within the tube wall. The wire helix is said to be vulcanized into the cover of the device.
U.S. Pat. No. 2,211,975, to Hendrickson, shows a similar device also comprising a stainless steel wire 15 embedded in the inner wall of a rubber catheter.
U.S. Pat. No. 3,757,768, to de Toledo, shows a "unitary, combined spring guide-catheter that includes an inner wall portion formed as a continuous helical spring with the helices in contact with each other and an outer wall portion formed from an inert plastic material enclosing the spring in such a manner as to become firmly bonded to the spring while having its outer surface smooth". There is no suggestion to separate the windings of the coil in any fashion.
U.S. Pat. No. 4,430,083 describes a catheter used for percutaneous administration of a thrombolytic agent directly to a clot in a coronary artery. The device itself is an elongated, flexible tube supported by helically wound wire having a specific cross-sectional shape. The wire is wound into a series of tight, contiguous coils to allow heat shrinking of tubing onto the outside of the wire of the shape of the outer surface of the wire as wound into the helix provides the heat-shrunk tubing with footing for a tight fit.
U.S. Pat. No. 4,567,024, to Coneys, shows a catheter which employs a set of helical strips within the wall of the catheter. However, the helical strips are of a radio-opaque material, e.g., fluorinated ethylene-propylene. It is not clear that the blended radio-opaque material necessarily provides any physical benefit other than the ability to allow the catheter shaft to be seen when viewed with a fluoroscope.
U.S. Pat. No. 4,737,153, to Shimamura et al., describes a device which is characterized as a "reinforced therapeutic tube" and which uses a spiral reinforcing material embedded within the wall of the device.
U.S. Pat. No. 5,069,674, to Fearnot et al. (and its parent, U.S. Pat. No. 4,985,022), shows a small diameter epidural catheter having a distal tip made up of a stainless steel wire which is helically wound and placed within a tubular sheath or tube.
Similarly, U.S. Pat. No. 5,178,158, to de Toledo, shows what is characterized as a "convertible wire for use as a guidewire or catheter". The patent describes a structure which comprises an interior wire or spring section shown, in the drawings, to be of generally rectangular cross-section. Outer layers of the device include a polyamide sheath placed adjacent to the helical coil at the proximal end of the catheter (see column 4, lines 64 and following). The device also comprises an outer sheath 40 of Teflon that extends from the proximal end 12 to the distal end 14 of the device. The overlying sheath 40 may extend or overhang at the proximal or the distal end of the catheter. The distal tip portion 13 is said to be "flexible, soft, and floppy". The PCT Published Application corresponding to this patent is WO 92/07507.
U.S. Pat. No. 5,184,627 shows a guidewire suitable for infusion of medicaments to various sites along the guidewire. The guidewire is made up of a helically wound coil having a polyamide sheath enclosing its proximal portion and a Teflon sheath tightly covering the entire wire coil. The coil is closed at its distal end.
U.S. Pat. No. 5,313,967, to Lieber et al., shows a medical device, a portion of which is a helical coil which apparently may include an outer plastic sheath in some variations. Apparently, a secondary helix of a somewhat similar design (in that it is formed by rotating a flat wire or the like along its longitudinal axis to form a screw-like configuration) is included within the helical coil to provide axial pushability and torque transmission.
U.S. Pat. No. 5,405,338, to Kranys, describes a helically wound catheter incorporating a shaft component having a helically wound coil with a skin or webbing supported by the coil. The skin or webbing is said to contribute "negligibly to the resistance of the catheter to axially directed compressive forces . . . " The catheter may include an inner, taut skin component.
The PCT application, WO 93/15785, to Sutton et al., describes kink-resistant tubing made up of a thin layer of an encapsulating material and a reinforcing coil. As is shown in the drawings, the supporting material is embedded within the wall of the tubing in each instance.
The PCT application bearing the number WO 93/05842, to Shin et al., shows a ribbon-wrapped catheter. The device is shown as a section of a dilatation catheter. The inner section 34 is a helically wound coil and is preferably a flat wire. See, page 6, lines 25 and following. The coil is then wrapped with a heat-shrunk jacket 34 formed of low-density polyethylene. A lubricious material such as a silicone coating may then be placed on the inner surface of the spring coil to "enhance handling of the guidewire". It is also said, on page 6 of the document, that the "entire spring coil, before it is wound or jacketed, may be coated with other materials such as Teflon to enhance lubricity or provide other advantages. In some embodiments, the spring coil has been plated with gold."
Endoscope Structures
Various endoscopic structures, used primarily in sizes which are larger than endovascular catheters utilize structures including stiffener materials.
U.S. Pat. No. 4,676,229, to Krasnicki et al., describes an endoscopic structure 30 having an ultra-thin walled tubular substrate 31 formed of a lubricious material such as TEFLON. The structure contains a filament supported substrate. The filament is coated with and embedded into a filler material, typically an elastomeric material. A highly lubricious outer coating 35, all as shown in FIG. 2, forms the outer layer of the device. FIG. 3 in Krasnicki et al., describes another variation of the endoscopic device in which a different selection of polymer tubing is utilized but the placement of the filamentary support remains varied in an intermediate material of an elastomer. In some variations of the device, the filament is strongly bonded to the inner tubular substrate using an adhesive 37 "such as an epoxy cement having sufficient bond strength to hold the filament to the substrate as it is deformed into a tight radius." See, column 3, lines 50 and following.
U.S. Pat. No. 4,899,787, to Ouchi et al. (and its foreign relative, German Offenlegungshrifft DE-3242449) describes a flexible tube for use in an endoscope having a flexible, basic tubular core structure made up of three parts. The three parts are an outer meshwork tube, an intermediate thermoplastic resin tube bonded to the outer meshwork tube, and an inner ribbon made of a stainless steel or the like which is adherent to the two polymeric and meshwork tubes such that the resin tube maintains an adherent compressive pressure in the finished flexible tube. The patent also suggests the production of an endoscope tube having "flexibility which varies in step-wise manner from one end of the tube to the other . . . [and is produced] by integrally bonding two or more thermoplastic resin tube sections formed of respective resin materials having different hardnesses to the outer surface of the tubular core structure . . . ". See, column 2, lines 48 and following.
U.S. Pat. No. 5,180,376 describes an introducer sheath utilizing a thin, flat wire metal coil surrounded only on its exterior surface with a plastic tube of coating. The flat wire coil is placed there to lower the "resistance of the sheath to buckling while minimizing the wall thickness of the sheath." A variation using two counter-wound metal ribbons is also described.
European Patent Application 0,098,100 describes a flexible tube for an endoscope which uses a helically wound metallic strip having a braided covering contiguous to the outer surface of the coil and having still further out a polymeric coating 9. Interior to the coil is a pair of slender flexible sheaths which are secured to a "front-end piece 10" by soldering.
Japanese Kokai 2-283,346, describes a flexible endoscope tube. The tubular outer shell is made up of two layers of a high molecular weight laminated material. The tube also has an inner layer of an elastic material and interior to it all is a metallic ribbon providing stiffening.
Japanese Kokai 03-023830, also shows the skin for flexible tube used in an endoscope which is made up of a braid 3 prepared by knitting a fine wire of a metal with a flexible portion 2 which is prepared by spirally winding an elastic belt sheet-like material and a skin 4 with which the whole outer surface of the device is covered. The document appears to emphasize the use of a particular polyester elastomer.
Japanese Kokai 5-56,910, appears to show a multi-layered endoscope tube made up of layers of the spiral wound metallic ribbon covered by a polymeric sheath.
French Patent Document 2,613,231, describes a medical probe used with an endoscope or for some other device used to stimulate the heart. The device appears to be a helix having a spacing between 0 and 0.25mm (See page 4, line 20) preferably rectangular in cross section (See Page 4, Line 1) and of a multiphase alloy such as M35N, SYNTACOBEN, or ELGELOY (See Page 4).
German Offenlegungshrifft DE-3642107 describes an endoscope tube, formed of a spiral tube, a braid formed of fibers interwoven into a net (which braid is fitted on the outer peripheral surface of the spiral tube), and a sheath covering the outer peripheral surface of the braid.
None of the noted devices have the structure required by the claims recited herein.
Other Anti-kinking Configurations
U.S. Pat. No. 5,222,949, to Kaldany, describes a tube in which a number of circumferential bands are placed at regular intervals along a catheter shaft. The bands may be integrated into the wall of the catheter. A variety of methods for producing the bands in the tubular wall are discussed. These methods include periodically irradiating the wall to produce bands of a higher integral of cross-linking.
European Patent Application No. 0,421,650-A1 describes a method for producing a catheter from a roll of polymer film while incorporating other materials such as tinfoil elements or the like.
None of the documents cited above provides a structure required by the disclosure and claims recited below.
SUMMARY OF THE INVENTION
This invention includes a catheter section made up of an inner liner and an outer covering and having a braid located in that outer covering. The inner liner may be of a polymeric lubricious composition.
The braid, in its most basic form, comprises a number of small wires or ribbons wound and treated in such a way that the resulting braid is dimensionally stable and the braided ribbons do not twist. The more basic forms of braids used in this invention include those which are made up of an even number of equally sized members. Half of the members are woven in a clockwise direction (as viewed along the axis of the braid) and the remaining half are woven in a counterclockwise direction. The various members may, of course, be of differing size but the sum of the members used in a particular direction should equal those wound in the other direction. Any imbalance will typically cause a helical curl in the resulting catheter. The alloys of choice are stainless steel although super-elastic alloys are also suitable. Nitinol is one such alloy. It is an alloy of nickel and titanium which is blended and heat treated in a specific way to produce an alloy having exceptional resistance to plastic deformation upon physical strain. Especially preferred liners comprise polytetrafluoroethylene (TFE) polymer. Hydrophilic coatings both on the interior and exterior are additionally contemplated.
This inventive catheter may include catheter sections with braids having more than one pitch or diameter or braid density in a section. The stiffness of the catheter section may be varied continuously by continuously varying the pitch or in a stepwise fashion by stepwise varying the pitch. The pitch may be varied during production of the braid or by changing the diameter of the braid after production. The braid may be partially constructed of polymeric fibers or carbon fibers either replacing a portion of the metallic ribbons or polymeric materials or placed in conjunction with a ribbon in the braid. Other metals, e.g., noble metals such as members of the platinum group or gold, may be used in the braid itself in much the same way to impart radio-opacity to the braid. To tailor the stiffness of the braid, the braid may first be wound and portions of the ribbon then removed. Also, the braid may be discontinuous.
The catheter has a terminal section which is solely polymeric and is of a polymer which is either harder than or is equal in hardness to the polymer in the next more proximal section. The outer covering is preferably a thermoplastic elastomer enclosing a braid. An inner liner of a lubricious material is also desirable. The terminal section may have a diameter less than that of the more proximal sections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in side view, a typical catheter made using the concepts of this invention.
FIGS. 2A and 2B show, in magnification, partial, side view, cross-sections of the catheter sections made using this invention.
FIG. 3 shows, in magnification, partial, end view, cross-section of a catheter section made using this invention.
FIG. 4 shows, in magnification, a partial, side view, cross-section of a terminal section made using this invention.
FIGS. 5 and 6 show in magnified cross-section, various distal end sections of catheters.
FIG. 7 shows, in magnification, a partial, side view, cross-section of a terminal section having a blood-control tip.
FIG. 8 shows in magnified cross-section, a tapered distal end section of a catheter made according to this invention.
DESCRIPTION OF THE INVENTION
This catheter is a guide catheter. The catheter of this invention is used to guide other smaller catheters typically from an entry point in the human body to some intermediate point between that entry point and the site to be treated or studied. Guide catheters are typically, therefore, larger in outside and inside diameter than is the perfusion or balloon catheter which passes through it. It is often somewhat stiffer in overall flexibility so to pass through blood vessels having little curvature without significant assistance. Since the guide catheter is used as an adjunct to a separate smaller catheter, it is desirable that the guide catheter be able to go as far as is possible into the vasculature so to minimize the distance that the smaller catheter must then traverse. However, because guide catheters are sometimes used to pass between an entry site such as the femoral artery in the groin, through the trunk of the body, through the aortic arch, and into one of the various arteries stemming upward from the aortic arch, the tip of many guiding catheters is given a sharp or modest bend to allow it to pass into the ostium of those arteries without much assistance. Consequently, the stiffness needed to select the arterial ostium is contra to the goal of passing ever more distal into the vasculature. Inherent stiffness reduces the ability of the catheter both to follow a guidewire, when such is used, and secondly to pass into complicated and bending vasculature. We have found that by providing a short distal tip having a polymer which is the same hardness as or preferably is slightly harder, i.e., higher Shore number, than is the polymer in the next more proximal section, that the resulting tip provides significantly higher ease of penetrating into the vasculature and enhances its ability to follow and track a guidewire once into a vascular region where such a guidewire is desirable.
FIG. 1 shows a highly desirable variation (100) of the inventive catheter. In particular, the catheter includes at least three, and preferably four or more, sections which are supported by a metallic braid and a terminal portion which is not so supported. The polymer in the terminal portion (102) has the same or, preferably, higher Durometer value than the polymer in the outer layer of the next more proximal section adjacent it. For purposes of discussing this invention, the following conventions are used in describing the various sections: the most distal portion adjacent the terminal portion (102) is known as the distal segment (104). The next more proximal segment is known as the primary mid-section (106). The next more proximal section is known as the secondary mid-section (108). The most proximal and stiffest section is known simply as the proximal section (110). A through lumen extends from one end of the catheter to the other. A coupler of some type (112) is secured to the proximal end. The coupler (112) may be a manifold or "Y" type coupler. A sidearm of such coupler allows introduction of fluids such as radio-opacifiers into the lumen even as the inner catheter is passing through the guide catheter lumen. Obviously, some type of a seal may be included in the coupler to prevent leakage of bodily fluids from the proximal end of the catheter during use. Such seals, however, are not shown for the purpose of maintaining simplicity of the description of the invention. Radio-opaque bands may be independently placed within the catheter to show placement of various portions of the catheter. More desirable is the use of pacifiers which are added to the polymers. Suitable pacifiers include barium sulfate, bismuth trioxide, bismuth carbonate, powdered tungsten, powdered tantalum, or the like so that the location of various portions of the catheter may be visualized using a fluoroscope. It is desirable to vary the loading of dopant or radio-opacifier so that the various portions can be discriminated. The various portions or segments of the catheter which are proximal of terminal portion (102) are each made in a similar way although out of different materials.
FIGS. 2A and 2B show the two preferred ways of producing sections of the inventive catheter. Specifically, FIG. 2A shows an outer covering member (202) in which a wire based braid (204) is embedded. Interior to the section (200) is a lubricious inner layer (206). A number of these sections (200) are desirably assembled as shown in FIG. 2A and butted together as shown in FIG. 1 or may be formed so that the inner lubricious layer (206) and/or the wire braid (204) is continuous across two or more of the catheter sections (104, 106, 108, and 110 in FIG. 1).
FIG. 2B shows a variation of the inventive catheter section (210) in which the wire braid (204) is instead a ribbon braid (208). Again, lubricious inner liner (206) is seen therein. The ribbon braid (208) is embedded in the outer layer (202).
FIG. 3 shows a cross-sectional view of the variation (200) shown in FIG. 2A. Outer covering (202) is shown with the embedded wire braid (204) and the inner lubricious layer (206). FIG. 3 simply shows that the wire braid (204) is outside the outer diameter of the inner lubricious layer (206). Wire braid (204) (and its analog ribbon braid (208)) need not be completely covered on each of their respective surfaces by the material making up the outer surface (202), but it is desirable to let it do so.
The metallic braids (204, 208) are preferably made up of a number of metallic ribbons or wires, a majority of which comprise stainless steels (e.g., SS303, SS308, SS310, SS311, etc.).
Other highly desirable materials for those wires or ribbons are members of a class of alloys known as super-elastic alloys. Preferred super-elastic alloys include the class of titanium/nickel materials known generically as nitinol; alloys which were discovered by the U.S. Naval Ordnance Laboratory. These materials are discussed at length in U.S. Pat. No. 3,174,851 to Buehler et al., U.S. Pat. No. 3,351,463 to Rozner et al. and U.S. Pat. No. 3,753,700 to Harrison et al. Commercial alloys containing some amount, commonly up to about 5%, of one or more other members of the iron group, e.g., Fe, Cr, Co, etc., are considered to be encompassed within the class of super-elastic Ni/Ti alloys suitable for this service. When using a braid containing some amount of a super-elastic alloy, an additional step may be desirable to preserve the shape of the stiffening braid. For instance, with a Cr-containing Ni/Ti superelastic alloy which has been rolled into a 1×4 mil ribbon and formed into a 16-member braid, some heat treatment is desirable. The braid may be placed onto a, e.g., metallic mandrel, of an appropriate size and then heated to a temperature of 600° to 750° F. for a few minutes, to set the appropriate shape. After the heat treatment the braid (204, 208) retains its shape and the alloy retains its super-elastic properties.
Metallic ribbons that are suitable for use in the braid (208) of this invention desirably are between 0.25 mil and 3.5 mil in thickness and 2.5 mil and 12.0 mil in width. The term "ribbon" is meant to include elongated cross-sections such as a rectangle, oval, or semi-oval. When used as ribbons, these cross-sections should have an aspect ratio of thickness-width of at least 0.5.
It is within the scope of this invention that the ribbons or wires making up the braid (204, 208) also contain a minor amount of other materials. Fibrous materials, both synthetic and natural, may also be used. In certain applications, particularly smaller diameter catheter sections, more malleable metals and alloys, e.g., bold, platinum, palladium, rhodium, etc., may be used. A platinum alloy with a few percent of tungsten is sometimes preferred partially because of its radiopacity.
Suitable nonmetallic ribbons or wires include materials such as those made of polyaramides (Kevlar), polyethylene terephthalate (Dacron), or carbon fibers. The braids used in this invention may be made using commercial tubular braiders. The term "braid" is meant to include tubular constructions in which the ribbons making up the construction are woven in an in-and-out fashion as they cross, so as to form a tubular member defining a single lumen. The braid members may be woven in such a fashion that 2-4 braid members are woven together in a single weaving path. Typically, this is not the case. It is much more likely that a single-strand weaving path, as is shown in FIGS. 2A and 2B is used.
The braids shown in FIGS. 2A and 2B have a nominal pitch angle of 45° Clearly the invention is not so limited. Other braid angles from 20° to 60° are also suitable. One important variation of this invention is the ability to vary the pitch angle of the braid either as the braid is woven or at the time the braid is included in catheter section or sections. The braid need not be continuous throughout the length of the catheter. In this way, the braid itself may be used to vary the flexibility of various sections of the catheter.
Referring again to FIGS. 2A and 2B, the materials of construction are as follows. Outer tube covering (202) desirably comprises a thermoplastic elastomer such as PEBAX or a polyurethane such as Pellethane (Dow Chemicals) and Carbothane (Thermedics). These materials are desirable because they are easily placed onto to the outside of the braiding by the laminating techniques described below. Nevertheless it may be desirable when producing a catheter such as that shown in FIG. 1A having sections of multiple flexibility to use materials having different moduli of flexibility and hardness (e.g., durometer values) such as discussed below. For instance, in the four flexibility section variation of a catheter assembly (100) shown in FIG. 1, the outer coverings for each of the sections may be a polymer of another family, e.g., polyolefins such as polyethylene (LLDPE and LDPE), polypropylene, with and without alloying of materials such as polyvinyl acetate or ethylvinyl acetate; polyesters such as various of the Nylons, polyethyleneterephthalate (PET); polyvinylchloride; polysulphones, including polyethersulphones, polyphenylsulphones; various ketone-based resins such as polyaryletheretherketone (PEEK) and variations of such as PEKK, PEKEKK; polyetheramides such as the polyether block amide sold as PEBAX by Atochem, and the like. These are suitable because they may be placed around the outer surface of the braid (204 in FIG. 2A and 208 in FIG. 2B). Stiffer materials might be placed in the region proximal on catheter assembly (100) shown in FIG. 1. More flexible materials might be placed on the exterior of section (106 and 108 in FIG. 1) and the most flexible on distal section (104) of FIG. 1. By varying the composition of the materials in this way, a catheter having fairly consistent outside diameter can be produced and yet have the desired flexibility. The most preferred polymeric material used in the outer surface assembly (202) are thermoplastic elastomers such as PEBAX.
Again, central to this invention is the use of a material in the terminal section (102 in FIG. 1) having a hardness greater than that of the material in the next more proximal section (104).
The inner liner (206) in the variations found in FIGS. 2A and 2B is preferably a lubricious material such as polytetrafluorethylene or other appropriate fluorocarbon polymers, other lubricious polymers such as polyarylenes, and the like. Further, inner liner (206) may be a laminate of polyfluorocarbon on the interior and a polyurethane adjacent to the braid.
The polyetheramide and TFE combination is highly desirable, in that the outer surface of the TFE tubing employed may be chemically etched using solutions such as mixtures of metallic sodium and ammonia so that the TFE tubing will form a strong mechanical bond with adjacent polymers. When using the methodology described below, the preferred polyetheramide is melted into place using a temporary shrink wrap tubing as a forming member. The polymer flows through the interstices of the braid and bonds either to the etched polyfluorocarbon surface or to the polymer found on the other surface of the braid.
As noted above, each of the polymeric materials used in this inventive catheter may be filled with a radio-opaque filler material such as barium sulfate, bismuth trioxide, bismuth carbonate, powdered tungsten, powdered tantalum, or the like so that it will show up in some contrast to the materials which neighbor it. It is almost always desirable to be able to see, at least in a slight fashion, the outline of the catheter being introduced into the various regions of the body. It is to be appreciated that most of the tubing utilized in the devices of this invention is of such small size that fluoroscopy is otherwise unable to provide a good outline of those devices. Furthermore, it may be desirable in certain circumstances to differentiate between the various sections of the catheter by including differing amounts, loading, or types of radio-opaque fillers to different sections of the catheter.
Highly preferred for use of the inventive catheter as shown in FIG. 1 as a guiding catheter for introduction of a micro-catheter such as is shown in U.S. Pat. No. 4,739,768, to Engelson, or in U.S. patent application Ser. No. 08/641,259, to Samson et al, is the following:
______________________________________Section length (cm) preferred materials Shore Hardness______________________________________102 0.2-0.6 PEBAX 33D-37D104 5-9 PEBAX 30D-35D106 3-7 PEBAX 48D-55D108 1-9 PEBAX 60D-68D110 50-70 NYLON11/ 72D-85D NYLON______________________________________ 12
Each of these preferred materials is desirably infused with 25-55% barium sulfate radio-opacifier. The preferred material for inner layer (206) is a thin-walled (e.g., 0.001-0.0015") PTFE tubing of which the outer surface has been etched to provide a suitable bond with the outer layer (202). Typical outer diameters of the catheter are in the range of 0.065-0.100"; typical inner diameters are in the range of 0.048-0.082". The braid material is preferably 304SS wire with a diameter of 0.001 to 0.0015".
As noted above, the various sections of the catheter shown in FIG. 1 (104, 106, 108, and 110) are desirably made of the materials shown in either FIG. 2A or 2B and simply butt-welded together using heat. It is also desirable that the various outer coverings (202) for each of the sections be applied separately to a single interval braid (204 or 208) and inner liner (206).
FIG. 4 shows a highly desirable termination section (220). In this variation, the termination segment (222) overlaps the next more proximal portion (224) in a half-lap arrangement. The lubricious inner liner (206) terminates interior to the half-lap joint. A small chamfer (226) may be placed at the distal extremity so to allow a better passage of the device through blood vessels. Obviously chamfer (226) may be in other suitable shapes. The terminal portion (222) may be heat welded onto the remainder of the catheter assembly.
FIGS. 5 and 6 show desired shapes for the terminal regions of the inventive catheter. For instance, in FIG. 5 is shown a catheter which has been molded so that it has a radiused 45° turn near to its distal end. Similarly, FIG. 6 shows a pair of radiused turns to produce a catheter having a specific end configuration. It is within the scope of this invention that any variation of distal tip be accommodated to this structure. Because of the slightly harder terminal tip, the more proximal portions are used to progress the catheter further into the vasculature. Consequently, these tips are of more use in this inventive catheter than are others known in the art.
FIG. 7 shows a further variation of the invention in which the catheter device shown in any of the preceding Figures is covered with an outer tubing (250) which "necks down" distally of the terminal section (222) and fits tightly about micro-catheter (252). The outer covering (250) may be made of, e.g., a shrink-wrap material such as irradiated and oriented polyethylene, which has been shrunk onto the shaft of the catheter assembly. The variation shown in FIG. 7 has one or more slits (254) which operate as "one-way" valves against the micro-catheter (252) outer surface. This valving region prevents the body fluids from flowing into the catheter yet allows fluids such as radio-opaque materials to flow outwardly. The outer covering (250) may extend proximally up the catheter as long as is convenient.
FIG. 8 shows still another variation (260) of the inventive guide catheter assembly. In this variation (260), the micro-catheter (252) is shown extending from the distal end of the guide catheter (260). The terminal section (262) in this variation is quite extensive. The polymer making up the terminal section (262) is preferably the same hardness as is the next more proximal section (264). As may be seen in the drawing, the terminal section (262) has a narrow diameter section (264) and a tapered section (268). The inner lumen of narrow diameter section (266) fits closely about the outer diameter of microcatheter (252), e.g., with a clearance of 0.002" or so. Radio-opaque materials may be ejected through the end of the catheter assembly in the annular space outside the micro-catheter (252). In this way, radio-opaque fluids may also be ejected through the hole to improve visibility of the vessel. As was the case with the variations above, the braid reinforced sections are only to be found proximal of the terminal section, e.g., beginning in the section (264).
Although this invention has been described with reference to preferred embodiments and examples, those having ordinary skill in this art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention as found in the claims which follow.
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This is a guide catheter assembly. The guide catheter assembly is used to cooperate with a micro-catheter in accessing a tissue target within the body, typically a target which is accessible through the vascular system. Central to the invention is the use of a braided metallic reinforcing member, situated within the catheter body in such a way to create a catheter section having an exceptionally thin wall, controlled stiffness, and high resistance to kinking. The catheter has a terminal segment which is not supported by a braid and the polymer making up that terminal segment is either the same hardness as is the polymer making up the outer covering of next more adjacent section or, preferably, the polymer is harder than is the polymer making up the segment located just proximally of that terminal segment. The braid may have a single pitch or may vary in pitch along the axis of the catheter or catheter section. The braided reinforcing member typically is embedded in a flexible outer tubing member. An inner tubing member is lubricious.
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BACKGROUND OF THE INVENTION
This invention stems from two developments in the field of data processing. On the one hand, there is a rise in the number and variety of subscription data base and computing services. Access to these subscription services is usually made via asynchronous communication over telephone lines using ASCII defined characters. Such communications require the user to have a terminal (such as a teletypewriter) and a modem (modulator-demodulator) to enable transmission and reception of ASCII characters on the telephone line. Most so-called "dumb" terminals (that is, terminals without any local data processing capacity) employ line lengths of at least 64 characters and most often use 80 character lines. For this reason, most current subscription services have their transmission formatted for line lengths of 64 characters or more.
The second development is the increase in the use of small computers, such as the Texas Instruments 99/4 Home Computer, for personal and small business use. These new computer users could often make advantageous use of the subscription data base and computing services to enable access to data necessary for their programs or to augment the limited processing capacity of their computers.
Direct communication between subscription data base and computing services and the small computer users is made difficult because these systems are not compatible. Many small computers use CRT displays in which the data is formatted in lines of 40 characters or less. These small computers are often not programmed to advantageously perform the two way asynchronous communications necessary to use the subscription services. The amount of data displayable on the CRT displays is severly limited in comparison with the print out capacity of the typical terminal. Thus the small computer should store received characters for later reading in many applications. Because the memory capacity of these small computers is often limited, maximum use of the available memory is required.
SUMMARY OF THE INVENTION
It is an object of the present invention to enable asynchronous communications between a remote system and a small computer.
In the preferred embodiment of the present invention, the above object and further objects are obtained by providing a plug-in read only memory module with appropriate data stored therein for attachment to and employment with a suitable small computer.
In the preferred embodiment of the present invention, the plug-in read only memory module includes an auto-incrementing address feature to enable more rapid data read out.
In the preferred embodiment of the present invention, the terminal emulator enables division of the memory of the small computer into a temporary data input buffer into which received data is stored on an interrupt basis, a display memory for storing data corresponding to characters displayed by a video display system and a received line memory. The terminal emulator provides memory control which reads data out of the temporary data input buffer for storage in the display memory and in the received line memory according to predetermined sequences. The memory control preferably also enables transfer of a subset of the data stored in the received line memory into the display memory, the subset being operator controlled. This feature enables review of data sent from the remote system even after disconnection of the communications link between the remote system and the small computer.
In the preferred embodiment of the present invention, the terminal emulator enables recognition of control characters received from the remote system when these characters are read out of the temporary input buffer. The terminal emulator then provides the format in the display memory indicated by the control character and provides the required data format and control character storage in the received line memory to duplicate the received data format by reading out the received line memory.
In the preferred embodiment of the present invention, the terminal emulator enters data into the display memory in two mode. In one mode, an intelligent wrap function is employed which prevents the break up of a word which extends beyond a display line by moving the entire word to the next display line. In the other mode, no intelligent wrap is used.
In the preferred embodiment of the present invention, the terminal emulator enables detection of a depressed key of a keyboard. Upon detection of such a depressed key the terminal emulator determines the meaning ascribed to the depressed key. If the depressed key corresponds to a transmittable character, the terminal emulator enables transmission of a signal to the remote system indicating the transmittable character.
It is another object of the present invention to provide a data transfer control between data received by the remote system, data stored in the small computer and local peripheral device such as a mass memory storage system or a printer.
In the preferred embodiment of the present invention, the terminal emulator enables operator selectable data transfer formatting for at least a disk unit, a magnetic tape unit and a printer. The terminal emulator generates the proper signals for transmission of data stored in the received line memory to the operator selected device. The terminal emulator formats the data sent to the printer in an intelligent wrap manner taking into account the number of columns in the print lines to prevent breakup of a word at the end of a print line. This intelligent wrap is achieved by looking forward in the received line memory at a memory location corresponding to the end of a print line prior to sending data to the printer. If a line would otherwise have ended in the middle of a word, the terminal emulator reformats the data to place that entire word at the beginning of the following lines. The terminal emulator also provides any necessary translation of data received from a local peripheral into the form stored in the received line memory.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure and operation of the terminal emulator of the present invention will become clear from the foregoing detailed description taken in conjunction with the drawings, in which:
FIGS. 1a and 1b illustrate a typical small computer system including a ROM library module which may embody the present invention;
FIG. 2 is a block diagram of the video display processor of the small computer system illustrated in FIG. 1;
FIG. 3 is a block diagram of a typical ROM library module;
FIG. 4 is a flow chart illustrating the logical operation of the ROM library module illustrated in FIG. 3;
FIG. 5 is a block diagram of a typical asynchronous digital communications system in which the terminal emulator of the present invention may be employed;
FIG. 6 is a flow chart illustrating the logical operation of the interrupt receiving program of one embodiment of the terminal emulator;
FIG. 7 is a flow chart illustrating the logical operation of the primary program of one embodiment of the terminal emulator;
FIGS. 8a to 8c are illustration of the data format of data stored in the circular interrupt buffer, the display memory and the received line memory;
FIG. 9 is a flow chart illustrating the logical operation of the character storage subroutine of one embodiment of the terminal emulator; and
FIGS. 10a and 10b are flow charts illustrating the logical operation of the local peripheral input and output programs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1a illustrates the physical structure of the preferred embodiment of the terminal emulator of the present invention. Digital computing system 10 includes computer mainframe 11 and plug-in ROM library module 54. ROM library module 54 plugs into computer mainframe 11 in the manner illustrated in the dashed lines.
Shown in FIG. 1b is a digital computing system 10 incorporating the preferred embodiment of the present invention. In general, the digital computing system 10 is comprised of a central processing unit (CPU) 12, a memory subsystem 14, an input/output (I/O) subsystem 16, and a video display subsystem 18. The CPU 12, which may be a monolithic microprocessor such as the Texas Instruments 9985, operates in a conventional manner under the control of digital control programs stored in the memory subsystem 14, usually in response to processing requests initiated via the input/output subsystem 16. In the input/output subsystem 16, an I/O control unit 20, which may be a monolithic integrated circuit such as the Texas Instruments 9901, operates in a conventional manner to interface a CPU communication bus 22 to an I/O bus 24 connected to one or more I/O units 26. By way of example, the I/O units 26 may be such conventional devices as the following: input devices, including a keyboard 28, a plurality of handheld units 30, and various types of remote sensors 32; output devices, such as a speech synthesizer unit 34 and a hard copy printer 36, and bidirectional input and output devices such as a magnetic disk unit 38, a magnetic tape unit 40, and a communication modem 42.
In the memory subsystem 14, it is frequently desirable to combine a quantity of read only memory (ROM) with a quantity of read/write, random access memory (RAM). In such a configuration, support programs, such as a suitable operating system and a desired assembler or compiler, are stored in the ROM, while user programs and volatile data are stored in the RAM. In this form, the relatively static programs and data are maintained in the relatively less expensive ROM, so that only the relatively transient program and data need be stored in the generally more expensive RAM.
In the preferred form shown in FIG. 1b, the memory subsystem 14 is also configured to take advantage of the low cost of relatively slow ROM and of dynamic RAM, without substantially degrading the performance of the CPU 12. More particularly, in the ROM portion of memory subsystem 14, a relatively limited amount of fast ROM 44, preferably of the N channel MOS type, such as the Texas Instruments 4732, is directly connected to the CPU 12 via a CPU memory bus 46, while a larger amount of relatively slow ROM 48, preferably of the P channel MOS type, such as the Texas Instruments 0430, is connected to the CPU 12 via a bus buffer 50, such as the Texas Instruments 74LS245, interposed between the CPU memory bus 46 and an auxiliary bus 52. By providing each device comprising the slow ROM with an internal auto-incrementing address counter, the CPU overhead associated with sequentially accessing the slow ROM 48 is greatly reduced. If, in addition, each of the devices comprising the slow ROM 48 is assigned a unique ROM address page number, as in the 0430, an additional plurality of such devices may be incorporated to form a ROM library module 54 for connection to the auxiliary bus 52 via a suitable plug-in type port.
In the RAM portion of the memory subsystem 14, a block of dynamic RAM 56, preferably of the N Channel MOS type such as the Texas Instruments 4027, is connected via RAM bus 58 to the CPU memory bus 46 via a video display processor (VDP) 60. More particularly, the VDP 60 is constructed to provide in addition to other functions to be described below, an auto-incrementing address counter capability, similar to that incorporated in the devices comprising the slow ROM 48. In addition, the VDP 60 provides for the periodic refreshing of the contents of the various devices comprising the RAM 56. Thus, the CPU 12 is relieved of the burden of supplying addresses for each of a series of sequential accesses to the RAM 56, and of the considerable overhead normally associated with the periodic refreshing of dynamic random access memory.
In the video display subsystem 18, the VDP 60 may be activated by the CPU 12 via the CPU memory bus 46 to generate all video, control and synchronization signals necessary for the display on a raster-scanned television unit of a set of display data previously generated by the CPU 12 and stored in the RAM 56. The resultant composite video signal is provided via a signal path 62 for application either to a dedicated monitor unit or to a conventional RF modulator 64 before application to a conventional television receiver. In the preferred form, a sound generator 66, such as the Texas Instruments 9919, is connected to the CPU 12 via the auxiliary bus 52 and provides a CPU-controlled audio signal which may be applied to an auxiliary speaker 68 via a signal path 70 or to the RF modulator 64 via a signal path 72 for mixing with the composite video signal provided by the VDP 60.
The facilitate system initialization and synchronization, it is preferred that the VDP 60 respond to a manual reset or an external synchronization signal on a signal path 74, by placing the various control portions thereof in a known state. Similarly, it is considered desirable that the VDP 60 be capable of receiving an externally produced, composite video signal via a signal path 76, and mixing the external video signal with the internally-generated composite video signal for output via the signal path 62. For example, it may be desirable in some circumstances to combine the composite video signal generated by the VDP 60 with a composite video signal produced via an auxiliary television camera or derived from a broadcast television signal. In such a configuration, the VDP may be conveniently synchronized with the external video source by extracting in a conventional manner appropriate synchronizing portions of the external video signal on the signal path 76 for application to the VDP 60 via the signal path 74. As will be readily apparent to those skilled in the art, the external video input and synchronization capability of the VDP also facilitates the chaining of two or more VDP 60 devices, to greatly enhance the data display and animation capabilities of the digital computing system 10.
GENERAL DESCRIPTION OF THE VIDEO DISPLAY PROCESSOR
Shown in FIG. 2 is a block diagram of the circuit comprising the video display processor 60 shown in FIG. 1. In general, the VDP 60 is constructed to operate in both a RAM controller mode and in a video controller mode, with substantial simultaneity occurring between these modes. In addition, much of the circuitry for accomplishing the RAM controller functions may be conveniently employed, together with additional circuitry, for accomplishing the video controller functions. In this manner, substantial savings in time and circuitry are realized.
In general, a CPU interface 78 responds to access requests from the CPU 12 via the CPU memory bus 46. When a CPU access request is initially received, the CPU interface 78 transfers the selected RAM address to a register control 80 via a register bus 82 for storage in a particular one of a set of control registers 84. In the case of a write request, the CPU interface 78 then latches the write data from the CPU memory, bus 46 into a CPU data register 86 via a VDP address and data bus 88, and initiates a CPU write access request for service by a RAM control 90. In response to the write request, the RAM control 90 will retrieve the RAM address from the control registers 84 via the register control 80, and pass the RAM address to the RAM 56 via the RAM bus 58. Thereafter, the RAM control 90 will transfer the write data from the CPU data register 86 to the RAM 56 via the RAM bus 58. In the case of a read request, the CPU interface 78 will simply initiate a CPU read access request for service by the RAM control 90. As in the case of a write request, the RAM control 90 then transfers the RAM address from the control registers 84 to the RAM 56. Thereafter, the RAM control 90 cooperates with the RAM 56 to latch the read data provided by the RAM 56 via the RAM bus 58 into the CPU data register 86. When the CPU 12 calls for the data, the CPU interface 78 transfers the read data provided by the CPU data register 86 on the VDP address and data bus 88 to the CPU 12 via the CPU memory bus 46.
As soon as a write request has been serviced, the RAM control 90 will automatically increment the RAM address contained in the control registers 84, so that a subsequent CPU write access request can be made into the next sequential address location in the RAM 56 merely by transferring the write data from the CPU 12 into the CPU data register 86 via the CPU interface 78. Similarly, the RAM control 90 will automatically increment the RAM address contained in the control registers 84 after a read request has been serviced, so that a subsequent CPU read access request can be made from the next sequential address location in the RAM 56 as soon as the CPU interface 78 has completed the transfer of the preceeding read data to the CPU 12. Thus, the CPU 12 spends a minimum amount of time waiting for a data transfer after an access request is issued.
When a VDP register access is received, the CPU interface 78 transfers the address of the particular one of the set of control registers 84 to the register control 80 via the register bus 82. In the case of a register write request, the CPU interface 78 transfers the write data from the CPU memory bus 46 to the register bus 82, for subsequent latching into the selected control register 84 via the register control 80. In the case of a register read request, the register control 80 connects the selected control register 84 to the register bus 62, with the CPU interface 78 subsequently connecting the register bus 82 to the CPU memory bus 46.
When the VDP 60 is operating in the RAM controller mode only, the RAM control 90 operates in a conventional manner to periodically access each of the refresh segments in the RAM 56. Thus, RAM contents are protected in the event that the CPU 12 fails to exercise each of the refresh segments through normal RAM accesses.
In the video controller mode, the VDP 60 generates a composite video signal in accordance with a set of control parameters established in the control registers 84, using a set of display data arrays stored in the RAM 56. In general, the composite video signal, when displayed on a suitable video display unit, produces a video display image comprised of M columns of N rows of individual, discrete video display elements or pixels. For convenience of information display, however, the (M×N) pixels may be considered as being logically associated into smaller contiguous groups or blocks which may be configured or defined to form discernible characters of "patterns", as in conventional character generations. In addition, however, the preferred form of the VDP 60 accommodates a plurality of mobile blocks or "sprites" which may be freely moved relative to the fixed display image by defining or selecting a particular column U and row V at which the upper left corner of the sprite is to be displayed. Thus, the VDP 60 generates the composite video signal in synchronization with the instantaneous column X and row Y position of the raster scan so as to display either the fixed patterns or the mobile sprites, as appropriate.
In the preferred form, the VDP 60 operates in a text mode. In the text mode, the VDP 60 generates a 40 column, 24 row image of patterns (6×8 pixels) selected from a pattern generator table (256 pattern definition blocks) according to a pattern name table (960 pattern names). The VDP 60 provides a selection of 16 distinct colors, including white, gray, black and a special transparent state to be described in greater detail below.
During system initialization and as required thereafter, the VDP 60, operating in the memory controller mode, cooperates with the CPU 12 to establish in the RAM 50 the appropriate display data arrays. To enable the VDP 60 to operate in the text mode, the CPU 12 should store in the RAM 56 the pattern table relied upon by the VDP 60. In particular, the pattern generator table comprises a plurality of consecutive pattern definition blocks, each consisting of 8, 6-bit bytes, which define the bit patterns for each individual pattern, as in conventional character generators. In contrast, the pattern name table consists of a row-by-column ordered array of pattern names which map the pattern definition blocks into each of the 40 columns of 24 rows of patterns comprising a full screen video pattern image. In addition, a pattern color table establishes a pair of video color codes associated with each of 32 contiguous sets of 8 pattern definition blocks of the pattern generator table, with each of the video color codes corresponding to a particular one of the sixteen available colors. Thus, the pattern name table, the pattern generator table, and the pattern color table represent an ordered array whereby the individual bits comprising a pattern definition block map the video color codes assigned via the pattern color table into each of the M columns of N rows of pixels comprising a full screen video pattern image.
In general, a sequence control 92 operates in a conventional manner to maintain a cyclic column count X and a cyclic row count Y indicative of the time sequential position of the raster scan of the video display unit. As will be clear to those skilled in the art, only a portion of the total raster scan period is devoted to actively displaying patterns on the video display unit, since a portion of each row of horizontal scan is devoted to horizontal retrace, while a number of complete row and horizontal scans are required to perform vertical retrace and related synchronization. However, at least during the active display period, the sequence control 92 makes the column count X and the row count Y available via the VDP address and data bus 88. The sequence control 92 also provides a color reference signal having a frequency related to the NTSC 3.57 MHz carrier, via a signal path 94, and a set of sync signals of substantially conventional form via a sync bus 96. In response to the reset/external sync signal on the signal path 74, the sequence control 92 clears the column and row counts, and generally synchronizes the color reference signal and the sync signals with the external source. In the preferred form, the sequence control 92 is comprised of a clock circuit of conventional form, and a pair of control programmable logic arrays (PLA's) for providing various control signals via a control bus 98 depending on the current column and row counts.
An overlay control 100, responsive to the column and row counts, periodically requests the RAM control 90 to retrieve selected portions of the pattern table from the RAM 56. As the display data is provided by the RAM 56 via the RAM bus 58, the overlay control 100 receives the pattern data, and provides a pattern signal via a pattern bus 102, comprising the bit in the pattern generator table which maps the pixel in the column X of the row Y of the video pattern image when 1≦X≦M and 1≦Y≦N. In addition, the overlay control 100 receives the video color codes assigned to each pattern during the display thereof. In other words, the overlay control 100 processes the pattern data arrays so as to provide the proper bit patterns for each of the selected patterns during the entire period that the display is active.
Each pattern signal, and the associated video color code, are applied to a priority selector 104 via the pattern bus 102. In response to receiving only the pattern signal, the priority selector 104 will select a respective one of the video color codes associated with the pattern signal, depending upon the current digital value thereof. If no pattern signal is being received, the priority selector 104 will generally select a default video color code provided by one of the control registers 84 via a default color bus 106. In each case, the video color code corresponding to the current selected pattern signal is provided via a color bus 108 as a video control signal.
A color phase generator 110, which forms a portion of a composite video generator 112, receives the color reference signal provided by the sequence control 92 via signal path 94, and generates the six NTSC color phase signals, each phase shifted by a predetermined amount relative to the color reference signal. In a color decoder 114, the video color codes, comprising the video control signal provided by priority selector 104 via the color bus 108, are decoded, and applied to a video mixer 116, together with the color phase signals provided by the color phase generator 110. In the video mixer 116, each of the video color codes decoded via the color decoder 114 selectively couples a complimentary pair of the color phase signals to a gating network to generate the information portion of a composite video signal for output via the signal path 62. In addition, the video mixer 116 receives the sync signals provided by the sequence control 92 via the sync bus 96, and generates the standard horizontal, vertical and color burst portions of the composite video signal in response thereto. In the preferred form, the video mixer 116 may be placed in an external video mode wherein an external video signal received via the signal path 76 is selectively merged with the internally-generated composite video signal for output via the signal path 62.
DESCRIPTION OF THE ROM LIBRARY MODULE
Shown in FIG. 3 is a block diagram illustrating the operation of each discrete device comprising the slow ROM 48 (FIG. 1), generally in accordance with the logic diagram shown in FIG. 4. In general, the ROM 48 is responsive to ROM access requests provided by the CPU 12 via the memory bus 46, and coupled to the auxiliary bus 52 via the bus buffer 50. In particular, the CPU 12 may write a new address into an address counter 476 in the ROM 48, read the address currently in the address counter 476, or read the data contained in a ROM array 478 at the address contained in the address counter 476. In the preferred form, the ROM array 478 contains 6144 8-bit bytes of processing information, each of which is sequentially or randomly addressable via the lower 13 bits of a 16 bit address. The upper 3 bits of the 16 bit address comprise a page designation which specifies a desired one of eight individual devices comprising the ROM 48, in the manner set forth below.
In response to receiving a write (decision block 480) address (decision block 482) ROM access request from the CPU 12 generally via the auxiliary bus 52, a sequence control 484 prepares to receive the first 8 of the 16 bits comprising the new address by shifting the address bits contained in the lower 8 bit positions of the address counter 476 into the upper 8 bit positions thereof (processing block 486). When the first 8 address bits of the new address become available on the auxiliary bus 52, the sequence control 484 enables an input buffer 488 and loads the first 8 address bits into the lower 8 bit positions of the address counter 476 via an input bus 490 (processing block 492). To "remember" that the first 8 bits of the new address have already been loaded, the sequence control 484 toggles an internal flag (processing block 494). If, as a result, the flag is in the set state (decision block 496), the sequence control 484 will generate a ready signal (processing block 498) for application to the CPU 12 via the auxiliary bus 52, indicating that the ROM 48 is ready to receive the second 8 bits of the address.
Upon receiving a second write (decision block 480) address (decision block 482) ROM access request, the sequence control 484 will shift the first 8 bits of the new address from the lower 8 bit positions of the address counter 476 into the upper 8 bit positions thereof (processing block 486). When the second 8 bits of the new address are provided by the CPU 12 via the auxiliary bus 52, the sequence control 484 will enable the input buffer 488 and load the second 8 bits of the new address into the lower 8 bit positions in the address counter 476 via the input bus 490 (processing block 492). If, after the flag has been toggled a second time (processing block 494), the flag is in the reset state (decision block 496), the sequence control 484 will perform an auto-incrementing procedure 500.
In the auto-incrementing procedure 500, the sequence control 484 will load the address currently contained in the address counter 476 into an address latch 502 (processing block 504). The sequence control 484 will then increment the address contained in the address counter 476 (processing block 506). Using the address contained in the address latch 502, the sequence control 484 then transfers the processing information contained in the ROM array 478 at the particular address location into a data latch 508 (processing block 510). Upon completion of the auto-incrementing procedure 500, the sequence control 484 will make sure that the flag is reset (processing block 512) and then generate the ready signal (processing block 498) to indicate to the CPU 12 that the ROM 48 is ready to receive the next ROM access request from the CPU 12.
If the subsequent ROM access request is a read (decision block 480) data (decision block 514) command, the sequence control 484 will transfer the processing information stored in the data latch 508 into an output latch 516 (processing block 518). If the page designation portion of the address contained in the address counter 476 corresponds to the unique page number assigned to the particular device at the time of manufacturing (decision block 520), a page select 522 will enable an output buffer 524 via a signal path 526 (processing block 528), to couple the processing information provided by the output latch 516 via an output bus 530 to the auxiliary bus 52. Thereafter, or if the page number does not correspond (decision block 520), the sequence control 484 will perform the auto-incrementing procedure 500, described above, make sure that the flag is reset (processing block 512), and generate the ready signal (processing block 498) to indicate that the requested data is available on the auxiliary bus 52.
In response to receiving a read (decision block 480) address (decision block 514) ROM access request, the sequence control 484 will transfer the 8 address bits contained in the upper 8 bit positions of the address counter 476 to the output latch 516 (processing block 532). The sequence control 484 will then enable the output buffer 524 (processing block 534) to couple the upper address byte provided by the output latch 516 via the output bus 530 to the auxiliary bus 52. The sequence control 484 then shifts the 8 address bits contained in the lower 8 bit positions of the address counter 476 into the upper 8 bit positions thereof (processing block 536). Thereafter, the sequence control 484 will make sure that the flag is reset (processing block 512), and will generate the ready signal (processing block 498) to indicate to the CPU 12 that the upper byte of the address is available on the auxiliary bus 52.
Upon receiving a subsequent read (decision block 480) address (decision block 514) command, the sequence control 484 will transfer the lower byte of the address, now in the upper 8 bit positions of the address counter 476, to the output latch 516 (processing block 532), and enable the output buffer 524 (processing block 534) to couple the lower address byte to the auxiliary bus 52. As before, the sequence control 484 will then shift the 8 bits contained in the lower bit positions of the address counter 476 into the upper 8 bits positions thereof (processing block 536), make sure that the flag is reset (processing block 512), and generate the ready signal (processing block 498) to indicate to the CPU 12 that the lower address byte is available on the auxiliary bus 52.
In response to receiving a write (decision block 480) date (decision block 482) ROM access request, the sequence control 484 will simply perform the auto-incrementing procedure 500, before resetting the flag (processing block 512) and generating the ready signal (processing block 498) to indicate completion of the command. Thus, the write data command is a convenient method for resetting the flag, while accomplishing an auto-incrementing operation.
In the preferred mode of operation, the CPU 12 initially issues a write data command, to reset the flag. The CPU 12 then provides a selected starting address via two consecutive write address commands. Thereafter, the ROM 48 will automatically provide the processing information contained at sequentially higher address locations in response to each subsequent read data command issued by the CPU 12. As part of the auto-incrementing procedure 500 performed in response to each read data command, the ROM 48 loads the data latch 508 with the next sequential byte so that it will be available for rapid transfer to the CPU 12. Thus, the CPU 12 spends a minimal amount of time waiting for the data after a read data command is issued.
DESCRIPTION OF THE COMMUNICATIONS SYSTEMS OPERATION
FIG. 5 illustrates the equipment required to use the preferred embodiment of the communication system of the present invention. A remote system 15, which may comprise a subscription data base system, or another digital computing system is connected via a signal path 17 to a modem 19. Modem 19 converts the signals from remote system 15 into signal types compatible with communications line 23. Communications line 23 is employed to connect the remote system 15 with the digital computing system 10. Modem 42 illustrated in FIG. 1b is composed of modem 41, which converts the signals on communications line 23 to the electrical signal type RS232, these signals being passed on signal path 43 to RS232 converter 45 and hence along I/O bus 24 to digital computing system 10. RS232 is an electrical standard for asynchronous digital communications. This set of electrical standards is widely used in commercially available modems which may be employed for modem 41 and thus RS232 converter 45 is employed to convert these standard signals to the signals required for I/O bus 24. In FIG. 5, digital computing system 10 is shown as comprised of computer main frame 11 and plug-in ROM module 54. It should be understood that communications line 23 may take the form of any convenient medium for two way communication and may include further pairs of modems for conversion of the signal type to a different signal type.
Plug-in ROM module 54 enables proper programming of digital computing system 10 for advantageous two way communication with the remote system 15. This communications process will be described in two parts, reception of communications from remote system 15 to digital computing system 10 and transmission of communications from digital computing system 10 to remote system 15. Although the reception of communications will be described first, it is understood that transmission and reception of communications between remote system 15 and digital computing system 10 can take place virtually simultaneously.
Initially, modem 41 and RS232 converter 45 are set for the communications characteristics required, such as baud rate, number of data bits, parity type, number of stop bits and duplex mode. Communications may begin once these data characteristics are set. In the preferred embodiment, once data characters are converted into the form readable on I/O bus 24 by RS232 converter 45, they are entered into a temporary buffer memory on an interrupt basis, that is, once a data character has been received and converted by RS232 converter 45, the programmed operation of CPU 12 is interrupted so that this data character may be stored in the temporary buffer memory. This process is illustrated in the flow chart of FIG. 6. If a character has been received (decision block 31), then the operation of CPU 12 is interrupted (processing block 33). Next, a write pointer is incremented (processing block 35) and the received character is stored in the temporary buffer memory (processing block 37) at the memory location indicated by the write pointer. Once the data character has been stored, the value of the write pointer indicates the position within the tempoary buffer memory at which the last received character has been stored. By entering received characters into the temporary buffer memory on an interrupt basis as described above, it is assured that digital computing system 10 is ready for receiving communications from remote system 15 at all times. This insures that no received data is lost because CPU 12 is busy performing other programmed tasks. The temporary buffer memory preferably takes the form of a circular interrupt buffer. This buffer is circularly addressed, that is, once the memory locations of the circular interrupt buffer are filled, the next received character is entered into the first memory location. As described in greater detail below, this circular interrupt buffer will be periodically checked to determine if any new characters have been written therein. The size of the circular interrupt buffer should be great enough to prevent loss of received characters by overflowing the capacity of the circular interrupt buffer while the CPU is performing other tasks between checking the buffer. In addition, the size of this circular interrupt buffer should be kept as small as possible so as to preserve random access memory locations for other uses. In the preferred embodiment, it has been found convenient to employ a circular interrupt buffer having 256 memory locations because a buffer of this size can be conveniently addressed by a single 8 bit byte. When incremented, this address byte provides an automatic carry over from decimal 255 to decimal 0, thereby automatically providing the required circular addressing.
The flow of operations within the main program for CPU 12 stored in plug-in ROM module 54 is illustrated in FIG. 7. The program begins with a test to determine whether a key from keyboard 28 noted in FIG. 1 has been pressed (decision block 51). If one of the keys of keyboard 28 has been pressed, the program determines whether it is a command key (decision block 53) or an arrow key (decision block 57). Upon the determination of the nature of the key pressed, either command subroutine 55 or scrolling subroutine 59 is executed. These subroutines will be described in further detail below. In the event that the key pressed is neither a command key nor an arrow key, the program tests to determine if the half duplex mode has been set (decision block 61). If so, the write pointer is incremented (processing block 63) and the character is stored in the circular interrupt buffer at the new location (processing block 65). This enables the user to view the entered character via the video display. The program then requires CPU 12 to transmit the appropriate character (processing block 67). In the event that a key has not been pressed, CPU 12 tests to determine whether a read pointer is equal to the write pointer (decision block 68). The read pointer is similar to the write pointer except that it indicates the last address read. If these pointers are equal, then no new characters have been stored in the circular interrupt buffer since the last character was read. In this case, the program returns to the beginning. If the read pointer does not equal the writer pointer, then CPU 12 increments the read pointer (decision block 69). Next, the character stored in the memory location within the circular interrupt buffer indicated by the read pointer is read out (processing block 71). This read out character will be stored in other memory locations in a manner which will be described in further detail below (also processing block 71). CPU 12 then retests the read and write pointers (decision block 68) and remains within this read out loop until the read and write pointers are equal, indicating that the last character written into the circular interrupt buffer has been read out. Thus, once it is determined that the last character written in the circular interrupt buffer has not been read out, CPU 12 reads out each of the characters written in the circular interrupt buffer since the last character read out before performing any other functions. This lock-up in the read out loop is provided because it is possible for the CPU 12 to remain within one of the subroutines 55 or 59 for a considerable period, during which period the circular interrupt buffer may be nearly filled with newly received characters. By remaining within the read out loop until each stored character has been read out, the possibility of losing data by exceeding the capacity of the circular interrupt buffer reduced.
The terminal emulator enables division of RAM 56 into at least three separately defined memory areas. FIG. 8 illustrates the memory format of three separate memory means. FIG. 8a illustrates the data format in the previously mentioned circular interrupt buffer. As described above, the circular interrupt buffer includes 256 memory locations 73. FIG. 8a also schematically illustrates the write pointer 75 and the read pointer 77 which each indicates one of the 256 memory locations 73. FIG. 8b illustrates the organization of the display memory. The display memory has 960 memory locations 79. These memory locations 79 are organized into 24 groups of 40 memory locations each. Therefore each memory location 70 corresponds to one of the display locations in the monitor or TV receiver display which has 24 lines of 40 characters each. Curser 81 is illustrated schematically as indicating a particular memory location 79. The function of this curser 81 will be described in greater detail below. FIG. 8c illustrates the memory format of the received line memory. As explained in greater detail below, the line length within the received line memory is controlled by the transmitted line length from remote system 15. FIG. 8c illustrates a line of N memory locations 83 followed by a line of M memory locations 83. Note each line begins with a leading length byte 85 and ends with a trailing length byte 87. Also note that FIG. 8c schematically illustrates oldest line start position 89 which indicates the beginning of the line of N memory locations. The meanings of these terms and their use within the terminal emulator will be described in greater detail below.
In general, the data read from the circular interrupt buffer will be stored in both the display memory and the received line memory. The display memory corresponds to the pattern name table mentioned above in the explanation of the operation of the video display processor because it stores data characters corresponding to characters in the video display. FIG. 9 illustrates logic operations involved in one embodiment of the character storage subroutine 71 illustrated in FIG. 7.
A data communications system such as illustrated in FIG. 5 will usually employ the ASCII character set. The ASCII character set is a widely used set of alphanumeric and control characters employed in digital communication systems. This character set includes displayable characters, i.e., those characters which may appear in a video display such as employed in the present system and control characters which alert the receiving system to perform special functions. After a received character is read out of the circular interrupt buffer (processing block 71 of FIG. 7) the system determines whether or not it is a control character (decision block 93). If this character is not a control character, that is, if it is a displayable character, then the digital bits representing this character are entered into respective memory locations in the display memory and the received line memory in the manner set forth below. If it is determined that this character is a control character, then this control character must be decoded in order for the terminal emulator to take the proper action (processing block 95). Preferably, the terminal emulator will recognize the following control characters: start of header; bell; backspace; line feed; carriage return, form feed; and escape. Preferably, the terminal emulator would store a cursor character displayable as a solid block in the memory location within the display memory where the next received character is to be entered. This will have the effect of placing this solid block curser in the usual display at the position where the next received character is to be written. Once such a received character is entered into the display memory, the curser will be moved to the next following memory location. Thus, the curser serves as a visual indication to the operator of the portion of the video display where the next received characters will be written. Upon decoding a received start of header control signal, the curser should be moved to the first column of the first line and thereafter newly received characters should be written starting from the first character position in the first line. The bell character is used to activate an audio alarm to alert the operator of the receiving system. In the present invention, it is most advantageous for sound generator 66 to produce a tone signal in response to recognition of a received bell character. This tone signal is then outputted either through speaker 68 or through the audio system of the TV through RF modulator 64. The backspace character is employed in order to erase a character already received. When a backspace character is received, the curser is moved into the position of the last received character and the position where the curser was is blank filled. In the received line memory, the position of the last received character is replaced by the trailing length byte and both the leading and trailing length bytes are decremented to reflect the new line length. The carriage return character is employed to determine the line in which newly received characters are entered into the display memory and to determine the line length of characters stored in the received line memory. The display memory moves the cursor to the beginning of the following line and enters any newly received characters into the first position in the next line. In addition, the received line memory terminates the preceding line and starts a new line with new leading and trailing length bytes. When a line feed is received in combination with a carriage return character, either before of after, it is ignored. In case a line feed character is received alone, the present line of the received line memory is ended at its current length and a new line is defined which is blank filled with the same number of characters as the number of characters in the previous line. In the display memory a similar process occurs in that the present display line is blank billed and a new line is begun having the same number of beginning blank characters as the corresponding line in the received line memory. If the number of these blank characters is greater than 40, then they cannot all be entered into the same display memory line. In such a case, a wrap around occurs with the blank characters entered into the memory locations in the display memory corresponding to the next display line. Any further received characters are then entered into the present line starting at the current position of the cursor, i.e., after having a predetermined number of blanks at the beginning of that received line. In the case in which a carriage return character is received alone, the present line of the display memory is blank filled and the cursor is moved to the first position of the next line. In the received line memory, the present line is terminated and the new line is started. In the case in which the remote system 15 transmits a series of carriage return signals, indicating a series of blank lines, the received line memory stores a series of blank lines each having a leading length byte indicating one character, a blank or space character, and a trailing length byte indicating one character. Reception of a form feed character indicates that a new display page should be started. The entire display memory is blank filled and the cursor is moved to the first display location of the first line. Thereafter, any new characters are entered beginning from this first position of the first line of the display. A received escape character alerts the terminal emulator that a special coded function is to be sent by remote system 15. The nature of the specially coded function and the particular meaning ascribed to it by the terminal emulator must be pre-arranged in advance between the digital computing system 10 and the remote system 15. The terminal emulator of the present invention preferably includes at least one set of escape codes which enables the remote system 15 to control the foreground color and the background color of the display produced by video display processor 60. This change of color is preferably accomplished in the following manner. Once an escape character is received, the terminal emulator decodes the next received character as indicating a special function according to a predetermined code. The terminal emulator decodes a particular received character as indicating the next following received characters will specify the new foreground color and background color. The foreground color corresponds to the video color code associated with the pattern signal applied to priority selector 104 via pattern bus 102. The background color corresponds to the default video color code applied to priority selector 104 via default color bus 106.
The ordinary order of entering characters into the display memory is to begin with the memory location corresponding to the display location in the upper left hand corner of the display. Next, the memory locations corresponding to the upper line are filled from left to right. The memory location corresponding to the first column of the second line immediately follows the memory location corresponding to the last column of the first line. Then the second line is filled from left to right in the same manner as the first line and then wrapped around to the beginning of the third line. Thus, each line of the display is written in the manner that the video display would ordinarily be read. Because the number of columns of the transmitted lines may not correspond exactly to the number of columns within each line selected for the video display, this invention preferably includes an intelligent wrap function. This intelligent wrap function would serve to prevent the breakup of individual words upon wrap around at the end of a display line. This intelligent wrap function would ordinarily operate in the following manner. Received characters would be entered into the display memory in the order in which they are received until the memory locations corresponding to an entire display line are entered. Thus the subroutine tests to determine if the end of a display line (or more particularly the memory location corresponding to the end of a display line) is reached (decision block 99). The next character, that is, the forty-first character from the beginning of the line in the preferred embodiment, would be tested to determine whether it is a space or (decision block 109) blank. If this character is a space or blank, the next character, i.e., the forty-second character from the beginning of the line, would be entered into the display memory location corresponding to the first column of the next line (processing block 111). Thereafter, the cursor would be updated (procession block 113) and the next line would be filled in the normal manner. If the forty-first character after the beginning of the line is not a space, then an ordinary wrap around to the memory location corresponding to the first column of the next line would break up a word. The system would then search backwards (processing block 115) from the thirty-ninth column of the present line to detect the blank or space character nearest to the end of the line. Then, all characters after that space to the end of the line would be transferred to the memory locations corresponding to the beginning of the following line (processing block 111). The memory locations corresponding to the end of the present line where these characters were previously stored would then be blank filled. Later received characters would then be entered into memory locations corresponding to the next following display positions in the next line after the characters moved from the end of the previous line. In certain unusual circumstances, there may be no blanks within the entire forty character line of the video display. In such a case, subroutine would branch from decision block 117 to processing block 119, thus the forty-first received character is entered into the memory location corresponding to the beginning of the following line and the following line is filled in the same manner as the preceding line. In such a case, it is not possible to prevent breakup of the long word.
The terminal emulator would also preferably operate in a mode in which this intelligent wrap function is not employed. In the case in which the intelligent wrap is not employed, the memory locations of the display memory would be filled for each of the first 39 characters of each line. Thereafter, the 40th character in each line would be replaced by the last received character until the remote system terminates the line via a carriage return or line feed character. Then the next received character would be entered into the memory location corresponding to the beginning of the next line. The replacement of the final character in the line with the next received character within that transmitted line serves to indicate to the operator that characters are being received and that the wrap function is off. Ordinarily, data would be entered into the display memory with the wrap off only in the case in which the received data includes column information and the alignment of those columns would be disturbed by the wrap function. In such a case, the scrolling function (described in further detail below) would enable the operator to view a page size window, having the dimensions of the video display, of the actually received data.
Besides the above described line-to-line overlap, the display memory also has a page-to-page overlap. If the remote system is transmitting a large amount of data, eventually the memory locations of the display memory will be completely filled and the video display will be completely filled with received characters. In the event that the received data exceeds the capacity of the display memory (decision block 101), the first two lines of the display memory are blank filled (processing block 105) and the received characters are then stored in the memory locations corresponding to the first line (processing block 107). This serves to erase the oldest displayed data when replaced by the newly received data. When each new line of new data is ended, the next following line of old data is erased and blank filled processing block 103). This serves to visually separate the old data below the blank line from the new data above the blank line.
The entry format into the received line memory differs from that into the display memory. Firstly, the received line memory has a large number of memory locations, larger than the number of memory locations in the display memory for entering characters received from remote system 15 as they are received. The received line memory has a variable line length, that is, the length of the character lines stored within the received line memory is controlled by the line length transmitted by remote system 15 rather than being controlled by the received line memory. These line lengths are determined by carriage return or line feed characters sent by remote system 15 in a manner which was described in greater detail above. Each stored line within the received line memory has length byte preceding the characters and a length byte after the characters. In the preferred embodiment, each line stored always has these two length bytes regardless of whether the remote system 15 has ended a transmitted line or not. When a new character is received, it is entered into the memory location following the memory location which stores the last received character (processing block 123). The trailing length byte is moved to the next following memory location after the received character and updated to reflect the new line length (processing block 129). Similarly, the preceding length byte is updated to reflect the new line length (also processing block 129). Characters are entered in this manner until remote system 15 transmits carriage return or line feed characters which terminate the line. The terminal emulator preferably also includes a feature which automatically terminates a line and begins a new line when the line length reaches 132 characters because the longest line length widely employed in digital communications is 132 characters.
When the received line memory is filled with characters received from remote system 15 (decision block 123), the received line memory undergoes a wrap around function similar to that of the display memory (processing block 127). To aid in memory control functions when such a memory wrap around occurs, the received line memory keeps an address pointer which identifies the location of the beginning of the oldest line stored. Assuming that remote system 15 transmits a greater number of characters than can be stored in the received line memory, newly received characters are stored in memory locations previously occupied by the oldest stored line. In such an event, the oldest line stored address pointer is changed to reflect the beginning of the next oldest stored line in order to prevent addressing of the newly stored data out of order or the addressing of any remaining portion of the oldest line stored when it is partially replaced by new characters (processing block 125). The system employs the leading and trailing length bytes in order to clearly identify the beginning and ending of each line. The provision of both leading and trailing length bytes simplifies the programming for working backward during scrolling. Memory wrap around in the received line memory (processing block 127) will occur less often than in the display memory because the received line memory has a greater number of memory locations than the display memory. In addition, use of variable length lines in the received line memory assures the best utilization of the available memory space.
The storage of the received characters in the received line memory enables the operator to view these received characters after reception has been completed. This later viewing of received data is accomplished using the scrolling function mentioned above. As mentioned above, the arrow keys on the keyboard provide the operator input for the scrolling function. The scrolling function differs somewhat when the wrap function is on from when the wrap function is off, therefore, the scrolling function will be described separately for each of these cases. When the wrap is on, the up and down arrows move the display lines up and down, respectively. When the displayed lines are moved up, the previously displayed top line is lost and a new line is entered into the vacated line at the bottom of the screen. Similarly, when the displayed lines are moved down, the bottom line is lost and a new data line is entered into the vacated top line. This wrap function moves the display line by line according to display lines with the intelligent wrap function on. That is, regardless of the fact that the received lines stored in the received line memory may be greater than the length of the lines displayed, the display changes according to displayed lines and not to the transmitted lines stored in the received line memory. The left and right arrows have no affect on the display when the wrap function is on, because all the data on the transmitted lines is formatted to fit within the display line. Pressing either the left or right arrow keys when the wrap function is on preferably causes the tone generator 66 to produce a beep tone to alert the operator that an illegal operation has been requested. When the wrap function is turned off, the arrow keys position the 24 line by 40 column display window at an operator controllable position within the lines as received. Thus, the up arrow enables display of those columns of the line following the last line previously displayed which are displayed in the lines appearing on the screen. Similarly, the down arrow enables display of that portion of the line above the first line on the display corresponding to the portions of the lines displayed. The right and left arrow keys enable the portion of the transmitted columns displayed to either be moved to the right or the left. Thus, the right arrow key causes the right column of each of the lines to be deleted and adds the column appearing before the first column previously displayed to the left hand column of the display. The left arrow key has a similar function in the opposite direction. As explained above, the display will be placed in a wrap off condition generally only for the case in which the remote system 15 has transmitted columnar data in which the column alignment would be lost using intelligent wrap or other similar situations. By employing the wrap off and the scrolling arrow keys in the manner set forth, the operator is able to view all of the data in its proper column alignment. In any case, if the operator selects a scrolling function which is invalid (that is, by pressing the down arrow when the first line received is already displayed or pressing the up arrow when the last line received in already displayed or a similar condition for the right and left arrows) then the terminal emulator preferably causes tone generator 66 to produce a beep tone to alert the operator that an invalid operation has been requested. This scrolling function, together with the storage of several pages of data within the received line memory permits advantageous reduction in the connect time between the remote system 15 and digital computing system 10. This reduction in the connection time is advantageous because many data base subscription services which would serve as remote system 15 charge on the basis of connect time.
The terminal emulator enables the operator to transmit from the digital computing system 10 to the remote system 15 via the keyboard 28. In accordance with the flow chart illustrated in FIG. 7, the keys pressed are transmitted to the remote system 15 one at a time. However, first the terminal emulator determines whether the key pressed is a command key (decision block 53). If this key pressed is a command key then the terminal emulator enters command subroutine 55. Pressing a command key alerts the digital computing system 10 that the operator wishes to command the system to perform a function rather than simply transmitting a digital character corresponding to a depressed key. The terminal emulator interprets the next depressed key as a command instruction. The computing system then takes the action indicated by the command instruction. This means may be employed to change other parameters such as determining whether an upper case or a lower case character is transmitted, or to enable the transmission of an ASCII control character in order to control the display mode of the remote system 15 determining whether the intelligent wrap function is on or off or transmission of a break signal to the remote system. This command sequence of a command key followed by a depressed key interpreted as a command instruction may also be used to select the local periphial device such as printer 36, disk unit 38 or magnetic tape unit 40 with which the terminal emulator will communicate. This communication with a local peripheral will be described in greater detail below. If the key pressed is not a command key, the main program then tests whether the key is an arrow key (decision block 57). If the key pressed is an arrow key, then the program enters the scrolling subroutine 59 which is described in further detail above. If the key pressed is neither a command key nor an arrow key, then it must be a transmittable ASCII character. In this case, the ASCII character is transmitted to the remote system (processing block 67).
As described above, the terminal emulator may operate in either a full duplex mode or a half duplex mode. It is well known that when operating digital asynchronous communications in a full duplex mode that the received system automatically echoes the transmitted character, that is, it sends the transmitted character back along the communications line to the original sending system. This two way transmission of the character serves an error detection function, because the original transmitting system receives confirmation that the transmitted character was correctly received. When the terminal emulator operates in the full duplex mode, the keys of keyboard 28 depressed are not entered into any memory of the digital computing system 10. Instead, the system awaits the return echoed character and then enters it into circular interrupt buffer in the manner of any other received character. This received character is stored and displayed in a manner like that fully described above. When the terminal emulator operates in a half duplex mode (decision block 61), ordinarily the remote system is then not expected to repeat the transmitted characters. In this case, the terminal emulator increments the write pointer (processing block 63) in a manner similar to the interrupt program during reception of transmitted characters and enters the transmitted character into the circular interrupt buffer (processing block 65). After having been entered into the circular interrupt buffer, these characters are displayed and stored in a like manner as received characters.
The terminal emulator also preferably includes programs for control of data transfer to and from local peripherals. Such programs should include program control for input and output to mass memory devices such as disk unit 38 and magnetic tape unit 40 as well as program control for output to a device such as printer 36. This program is illustrated in FIG. 10a. In order to enter data from a local peripheral, the terminal emulator must no longer be responsive to remote system 15 via communications line 23 but rather must be responsive only to signals appearing on I/O bus 24 (processing block 135). The program next requires the operator to specify the device so that this device may be properly addressed (processing block 137). The operator is required to enter the file name (processing block 141) if the specified device is disk unit 38 (decision block 139). One line of the data from the specified device is read (processing block 143) and then stored in the display memory (processing block 145) and the received line memory (processing block 147). This process is preferably accomplished by reading a line of the data provided by the specified device, storing this data in the circular interrupt buffer and incrementing the write pointer accordingly. Once this is done the data is entered into the display memory and the received line memory in the same manner as described above in relation to the reception of data from remote system. If the end of the specified file has been reached (decision block 149) then the program is exited (processing block 151). If the end of the file is not reached, the program checks to determine if the end of the received line memory has been reached (decision block 153). Preferably the end of the received line memory is signaled whenever the last stored input data character is less than 132 memory locations from the last available memory location. The figure 132 is used because it is the longest line length widely used in digital communications systems and because the data entry into the received line memory means automatically terminates a stored line and begins another line after 132 characters. When fewer than 132 memory locations remain it is not certain that an additional line can be entered without exceeding the memory capacity of the received line memory. If the end of the received line memory has not been reached, then the terminal emulator returns to read another line of data (processing block 143). If the end of the received line memory means has been reached, data input is stopped. The operator now has the option of scrolling through the data in the manner previously described. At this point, the operator has the option of exiting the program (processing block 157) or retrieving another display page of data (decision block 155). If a new data page is to be entered, this data is read from the mass memory device (processing block 159) and stored in the display memory and the received line memory (processing block 161). The data is entered into the display memory as described above. In the received line memory, the last number of whole lines of the first retrieved data is replaced by the newly retrieved data in a manner similar to the memory wrap around described above in relation to data received from remote system 15. Once this new page of data is stored, the operator may scroll the data and again has the option of exiting the program or retrieving another display page of data.
FIG. 10b illustrates the output program. In order to employ the output program a command sequence is entered via the keyboard by depressing the command key and then depressing the key which the terminal emulator recognizes as a command instruction to enter this program (processing block 163). The program then requires the operator to specify the peripheral device (processing block 165). If data is to be outputted to a local peripheral, the program checks to determine if the peripheral specified is a printer (decision block 167). If the selected device is a printer then an intelligent wrap is performed (processing block 167) on the data stored in the received line memory before transmission to the printer. The intelligent wrap is similar to the intelligent wrap employed for the display line memory, except for some minor changes. Because the line length already stored in the received line memory to known, the relation of the received line length to the line length of the printer line can be calculated before sending data to the printer. This is in contrast to the display memory intelligent wrap which was based on characters as they are received from remote system 15. After this intelligent wrap the lines are sent to the printer for printing (processing block 171). If the peripheral device is not a printer, then the lines are formatted for the device selected (processing block 173). Some devices such as disk unit 38, accept variable length lines in much the same manner as the received line memory and generate their own overhead such as line length characters. For these devices the lines are transmitted just as received, that is, omitting the leading and trailing length bytes but including a carriage return character at the end of each line. Other devices, such as a cassette tape recorder employed as magnetic tape unit 40, require the sending system to properly block the lines to correspond to a fixed format. Cassette tape recorders used as mass memory devices commonly require 64 character lines. Because the data sent must include length characters and may include lines of up to 132 characters, each received line is entered into three consecutive 64 character blocks with the unused remainder of these 192 character blocks blank filled. After the lines in the received line memory corresponding to one display page are sent, the operator has the option (decision block 175) of outputting another page in the same manner as before or the program may be exited (processing block 177).
Use of the terminal emulator for control of communications with remote system 15 and with local peripheral devices enables advantageous use of available memory and minimization of expense. If a small amount of data is to be received from remote system, it may be quickly stored in the received line memory thereby minimizing connect time to remote system 15 and reviewed at leisure employing the scrolling function. If a greater amount of data is to be received from remote system 15, this data may be entered into the received line memory up to its capacity and then stored in a local mass memory storage device such as a disk unit or a magnetic tape unit repeatedly until the required data is stored in the local mass memory storage device. This data stored in the local peripheral may be recalled and used without addressing the remote system 15 again. Lastly, data in the received line memory, from either a local mass memory storage device or from remote system 15, can be outputted to a local printer in an intelligent wrap made which prevents splitting of a word despite any differences in received line length and the print line length.
Although the present invention has been described in relation to a specific preferred embodiment, it will be clearly understood by those skilled in the art that other optional features may be included within the terminal emulator or substituted for features described without departing from the scope of the invention.
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A communications control system for enabling a small computer system, such as a personal computer, to emulate a terminal and thus to communicate with a remote system. Incoming data from the remote system is entered into a circular buffer on an interrupt basis. The communications control system alternately scans the circular buffer for newly entered data and the keyboard for operator generated messages. Any control characters are decoded and appropriate actions taken. Received alphanumeric characters are stored in a display memory for video display and in a system RAM for later retrieval and study. The display memory is optionally loaded in an intelligent wrap mode in which words are not broken on wrap around or a non-wrap mode which preserves the columns of the data as originally received. Scrolling controls enable the operator to enter a desired portion of the data stored in the system RAM into the display memory for viewing in either wrap-on or wrap-off modes. This invention also provides control of data transfer to and from the received line memory and local peripherals. In the preferred embodiment, the system is embodied by a plug in ROM module used with a compatible personal computer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 61/121,546 filed Dec. 11, 2008, entitled “Combined Web and Local Computing Environment”, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Historically, personal computing was carried out using applications installed on an operating system installed locally on a physical computer. An example of one such application is Microsoft Office applications which may be installed on the Microsoft Windows operating system all from Microsoft Inc. of Redmond, Wash. These may run on a personal computer (PC). These may be called local applications and a local operating system respectively as they are physically installed on the PC.
[0003] Recently an alternative has emerged where a user's files and applications may be hosted on servers in a data center and accessed across the Internet using a web browser. This arrangement may be called a web operating system, web desktop or a virtual hosted operating system as further defined in pending patent application PCT/IL2008/000318 entitled “VIRTUAL HOSTED OPERATING SYSTEM” published as WO2008/111049, the entire contents of which is incorporated herein by reference, and these terms are used interchangeably herein. In this context the term operating system does not include physical device drives but does typically include a hosted file system, desktop or other graphical user interface and other elements required to provide the user with a personal computing environment. An advantage is that the user's data is stored in a professional data center and may be accessed from any computer with a web browser, rather than being accessed from just one computer.
[0004] Additionally a virtual hosted operating system may be integrated with hosted applications such as the Google Docs word processor from Google Inc. of Mountainview, Calif. or the Zoho word processor from AdventNet, Inc. of Pleasanton, Calif., which themselves are hosted and accessed using a web browser. In this way the user may view their hosted files and edit them all within a web page in the web browser. The actual computer code for the application may run on the server or may be embedded in the downloaded web page to run in the browser on the PC or some combination of both as is known to those skilled in the art.
[0005] A problem emerges in that the applications currently available on the Web may be more limited or slower than applications available locally. For example, at the present time many users prefer to use Microsoft Office applications locally in preference to Web-based hosted applications such as Google Docs, since the Web-based hosted application may have fewer features or be less familiar.
[0006] However the security model of the web browser will typically prevent most types of communication between software running within a Web page—such as a Web Operating System—and local applications such as Microsoft Office, thus limiting the ability of the user to edit a common document in both local applications and hosted applications.
SUMMARY OF THE INVENTION
[0007] It is an aim of the present invention to overcome at least some of the disadvantages of the prior art. In certain embodiments, the limitation preventing most types of communication between software running within the Web page and the local applications is overcome, and thus a hosted computing environment is allowed to interact seamlessly with local applications providing the user with a seamless way to interact with files hosted on the server via the browser, edit the files with local applications and save the edited files back to the server.
[0008] According to certain embodiments a user may use a web browser to see a web page in which they can see data files, such as documents or spreadsheets, which are stored remotely. The same web page might also contain a desktop and other aspects of a full user computing environment. Typically, it will be an interactive page including Javascript, Flash or another programming language to create a rich graphical user interface.
[0009] The user may indicate their desire to edit one of those files using a local application, such as Microsoft Word, which is installed on the same computer where the Web Browser is running The indication will be given by a user interface gesture within the web page. The local application is launched and the file selected by the user is preferably automatically opened by communicating with the server where that file is stored. The user is then able to edit their file using the local application and save the edited file on the remote server.
[0010] The above principle may be applied to several interactions between a Web Operating System and local applications, for example:
Editing file types such as documents, spreadsheets, presentations, images, video, sound, or databases which are hosted, using local applications; Conversely, allowing files stored on the local computer to be listed, viewed and edited in the Web Page; and Retrieving information from the local system such as, without limitation, a user's location (if the computer has a Global Positioning System), orientation (if the computer has an accelerometer), or battery level.
[0014] Additional features and advantages of the invention will become apparent from the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings in which like numerals designate corresponding elements or sections throughout.
[0016] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
[0017] FIG. 1 illustrates a high level block diagram of an exemplary embodiment of an arrangement comprising at least one data center and at least one personal computer;
[0018] FIGS. 2A-2C illustrate a plurality of screen shots of an embodiment of a user interface for launching a local editor program to edit a hosted file;
[0019] FIG. 3 illustrates a high level flow chart of a method for launching a local editor program to edit a hosted file.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The overall design of the system may be understood with reference to FIG. 1 , which illustrates a high level block diagram of an exemplary embodiment comprising: a data center or series of data centers 100 and a personal computer 110 interconnected via a network 118 , such as the Internet. Data center 100 comprises a server or series of servers 101 each hosting at least one user data file 102 and a web operating system (OS) code 103 for embodying a virtual hosted operating system. Personal computer 110 comprises a local operating system (OS) 111 (such as Microsoft Windows, Mac OS or Linux) on which are installed one or more local applications(apps) 115 (such as Microsoft Word, OpenOffice, Adobe Photoshop), a locally stored user data file or files 116 , and a web browser 112 (such as Internet Explorer which is included in Microsoft Windows or FireFox from the Mozilla foundation). Web browser 112 is operative to display a Web page 113 which includes within it part of web OS code 103 which has been transmitted from data server 101 . Browser 112 preferably includes a plug-in 114 (such as the Java Runtime Environment from Sun Micrososystems Inc.). Instructions from operation of personal computer 110 are stored on a computer readable medium 117 . Personal computer 110 further comprises a processor operative to load and run instructions stored on computer readable medium 117 .
[0021] FIGS. 2A-2C illustrate a plurality of screen shots of an embodiment of a user interface. In FIG. 2A screen shot 200 displays web page 113 being displayed in web browser 112 of FIG. 1 ; a selected graphical representation 201 of a hosted user data file 102 of FIG. 1 ; and a graphical user interface 202 .
[0022] A typical use case and its embodiment may be understood by reference to the flow chart in FIG. 3 , combined with the user interface examples in FIG. 2A and the high level block diagram of FIG. 1 .
[0023] In the following example the user is using local operating system 111 , described without limitation in reference to Microsoft Windows.
[0024] In stage 301 the user opens a web browser, such as web browser 112 , illustrated without limitation as Mozilla Firefox.
[0025] In stage 302 the user types in to the web browser of stage 301 a URL, such as http://G.ho.st, causing the browser to load a web page, such as web page 113 , including web OS code 103 from data server 101 , which is rendered as web page 113 . The user logs in to the web page and sees their desktop or some other representation of their hosted data, optionally together with settings, hosted apps, and other aspects of a personal computing environment.
[0026] In stage 303 the user selects graphical representation 201 of FIG. 2A within the web page of a hosted file 102 and indicates the desire to perform an action. Indication of desire to perform an action is optionally done by right-clicking graphical representation 201 with a mouse, thereby obtaining a context menu, such as graphical user interface 202 , including an action such as “edit in local application” as illustrated in screenshot 200 . The user then selects the desired action to be performed, in the present example, in which the local application is word, “edit locally in Word”. Preferably the user is also offered an alternative action of editing the file within the web page using a web word processor.
[0027] The embodiment of the above steps requires only common programming techniques well known to those versed in the art and further described in the pending patent application referenced above. In an exemplary embodiment, computer readable instructions implementing the above steps are stored in web OS code 103 and computer readable medium 117 , respectively.
[0028] In stage 304 , in the event that the user has selected to edit in local application, a portion of the computer readable instructions inside web page 113 communicates the user's request to plug-in 114 . In a preferred embodiment plug-in 114 is included in browser 112 , however this is not meant to be limiting in any way and an alternative plug-in 114 can be provided. In one preferred embodiment the plug-in is the Java Runtime Environment from Sun Microsystems. This plug-in has the advantage that it works with all popular browsers and is already installed in many browsers since it serves a large number of purposes. Alternative embodiments include using signed Javascript, using the Google Gears plug-in, or writing a plug-in “native” to the browser.
[0029] In the preferred embodiment wherein plug-in 114 is the Java Runtime Environment from Sun Microsystems, web page 113 will embed a signed Java applet, e.g. using the HTML <applet> tag and preferably including the MAYSCRIPT attribute in that tag. Alternatively the applet can be dynamically added to the web page responsively to the user making a request in stage 303 , which requires the applet.
[0030] The following is an example of a Javascript function which can be used in all popular browsers to dynamically add a virtually invisible Java applet to a web page responsive to the need to execute stage 304 :
[0000]
function createAppletForLaunchingLocalApps ( ) {var
myApplet = document.createElement(“APPLET”);
myApplet.id = “ghostClientApplet”;
myApplet.archive = “../src/ghostClientApplet.jar”;
myApplet.code=
“ghost.clientApplet.ghostClientApplet.class”;
myApplet.width = “1”; // Some browsers can use 0 some
cannot
myApplet.height = “1”;
myApplet.MAYSCRIPT = “”;
var pageBody = document.getElementsByTagName(“body”)[0];
pageBody.appendChild(myApplet);
};
[0031] Preferably, at the time of initialization of the signed applet the user will automatically be asked to approve giving privileges to the signed applet with a user interface, as illustrated in screenshot 210 of FIG. 2B .
[0032] Once the applet is initialized the web page calls methods in the applet, for example to ask the applet to launch Microsoft Word and edit hosted file 102 , which by way of example may be accessible using the URL http://g.ho.st/webdav/sampleDoc.doc. Thus, in one non-limiting illustrative embodiment the method call might be:
doLaunch(‘WINWORD’, ‘http://g.ho.st/webdav/sampleDoc.doc’)
[0034] In stage 305 plug-in 114 passes a command to local operating system 111 to launch local application 115 and to pass information to local application 115 on how to access hosted file 102 .
[0035] The following is a typical embodiment of a method which will receive the name of a Windows application to launch and a parameter—typically identifying a file to edit—to pass to that application.
[0000]
public void doLaunch(final String app, final String url){
// Make sure full privileges of applet apply even when
called from Javascript:
AccessController.doPrivileged(new PrivilegedAction( ) {
public Object run( ) {
try {Runtime.getRuntime( ).exec(new String[ ] {“cmd.exe”,
“/c”, “start”, app, url});
}
catch (IOException ioe) {
ioe.printStackTrace( );
}
return null;
}
});
}
[0036] The above method has been described in an embodiment in which local operating system 111 is Microsoft Windows, however this is not meant to be limiting in any way and an appropriate method can be provided for other local operating systems, including, without limitation, Linux.
[0037] In one optional embodiment, upon initialization the applet communicates back to the web page that it is initialized. In such an embodiment the web page will wait for this before calling the doLaunch( ) method described above.
[0038] Optionally the applet will access the local file system to check if the requested application, in the present example Microsoft Word, is installed and will warn the user if it is not.
[0039] The execution of this computer implemented method will cause Windows to launch the desired local application 115 , in this example Microsoft Word, and will cause local application 115 to try to read hosted file 102 using the URL provided. In a preferred embodiment, the WEBDAV protocol is used to read and write remote files as this protocol is supported by Microsoft Office and other popular applications. In the current example Microsoft Word will issue an HTTP GET request to the URL provided and will read hosted file 102 . While reading the file, in one particular embodiment the user will see a window such as the one shown in screen shot 220 of FIG. 2C .
[0040] Thus in a preferred embodiment two types of communication are used—the command to launch a local app 115 is communicated to local operating system 111 via the Java applet Runtime.getRuntime( ).exec method while the content of hosted file 102 is retrieved by the desired local app 115 using WEBDAV HTTP directly from the server. Alternatively, the content of the file is passed via the browser and the Java applet.
[0041] In a preferred embodiment, stage 305 includes passing some security information to enable the desired local application 115 , such as Microsoft Word, to gain access to hosted file 102 . For example the URL passed may itself include a secret temporary password (known as a session id) obtained from server 101 and passed, for example, as follows:
[0000]
http://g.ho.st/webdav/sampleDoc.doc?secureSessionID=135791234
[0042] In stage 306 the user edits hosted file 102 by using the selected local application, such as local application 115 .
[0043] In stage 307 the user presses the Save button in local application 115 and local application 115 sends the updated file to server 101 , which will update hosted file 102 . Optionally, instead of a save button, a second user gesture is provided by the user associated with graphical representation of the file. The updated file is preferably sent using a WEBDAV HTTP PUT message to the same URL, such as
[0000]
PUT http://g.ho.st/webdav/sampleDoc.doc
?secureSessionID=135791234
[0044] This completes the two way communication between the virtual hosted operating system embodied by web OS code 103 and local OS 111 .
[0045] In optional stage 308 , web page 113 which embodies at least part of web OS code 103 , is automatically updated to show the changes to hosted file 102 . For example, the mouse over data on graphical representation 201 might be updated to show the new size and modified-date of updated hosted file 102 .
In summary, the prior art includes the following user experiences: A user views in the local OS an icon for a local file and gestures to launch a local editor which edits the file; and the user views in a web page of a web OS an icon representing a hosted file and gestures to launch another web page (or frame) with a hosted editor which edits the file within the browser.
[0049] Advantageously, according to certain of the present embodiments, a “familiar” workflow achieves a completely new effect which is a novel mixture of the two known workflows: A user views in the web page of a virtual hosted operating system, embodied by a web OS code, an icon representing a hosted file and gestures to launch a local application which edits the file within a local OS.
[0050] The above is one example of the two way communication between a virtual hosted operating system embodied by a web OS code and a local operating system which according to certain of the present embodiments is used to enable a user workflow spanning the virtual hosted operating system and the local operating system.
[0051] Advantageously, the above method may be further implemented to allow files stored on personal computer 110 to be listed, viewed and edited in a web page. In particular, web OS code 103 is programmed to call local file 116 from the hosted application by passing a call with the target address of local file 116 . Alternatively, other information may be retrieved by web OS code 103 from personal computer 110 , such as: location of the personal computer 110 , in the event that global positioning equipment is provisioned as part of personal computer 110 ; orientation of personal computer 110 , in the event that personal computer 110 is supplied with one or more accelerometers; or battery level of personal computer 110 , in the event the personal computer 110 is a portable battery operated device.
[0052] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
[0053] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein.
[0054] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the patent specification, including definitions, will prevail. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
[0055] The terms “include”, “comprise” and “have” and their conjugates as used herein mean “including but not necessarily limited to”.
[0056] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
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A system and method enabling two way communication between a virtual hosted operating system running in a web page and the local operating system and applications in order to allow a user to combine the advantages of both systems.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of PCT/DK98/00360 filed on Aug. 19, 1998 and claims priority under 35 U.S.C. 119 of Danish application PA 1997 00987 filed on Aug. 29, 1997, the contents of which are fully incorporated herein by reference.
TECHNICAL FIELD
This invention relates to novel mutant protease enzymes or enzyme variants useful in formulating detergent compositions and exhibiting improved wash performance in detergents; cleaning and detergent compositions containing said enzymes; mutated genes coding for the expression of said enzymes when inserted into a suitable host cell or organism; and such host cells transformed therewith and capable of expressing said enzyme variants.
BACKGROUND OF THE INVENTION
In the detergent industry enzymes have for more than 30 years been implemented in washing formulations. Enzymes used in such formulations comprise proteases, lipases, amylases, cellulases, as well as other enzymes, or mixtures thereof. Commercially most important enzymes are proteases.
An increasing number of commercially used proteases are protein engineered variants of naturally occurring wild type proteases, e.g. DURAZYM® (Novo Nordisk A/S), RELASE® (Novo Nordisk A/S), MAXAPEM® (Gist-Brocades N.V.), PURAFECT® (Genencor International, Inc.).
Further a number of protease variants are describe in the art, such as in EP 130756 (GENENTECH) (corresponding to U.S. Resissue Pat. No. 34,606 (GENENCOR)); EP 214435 (HENKEL); WO 87/04461 (AMGEN); WO 87/05050 (GENEX); EP 260105 (GENENCOR); Thomas, Russell, and Fersht (1985) Nature 318 375-376; Thomas, Russell, and Fersht (1987) J. Mol. Biol. 193 803-813; Russel and Fersht Nature 328 496-500 (1987); WO 88/08028 (Genex); WO 88/08033 (Amgen); WO 95/27049 (SOLVAY S.A.); WO 95/30011 (PROCTER & GAMBLE COMPANY); WO 95/30010 (PROCTER & GAMBLE COMPANY); WO 95/29979 (PROCTER & GAMBLE COMPANY); U.S. Pat. No. 5,543,302 (SOLVAY S.A.); EP 251 446 (GENENCOR); WO 89/06279 (NOVO NORDISK A/S); WO 91/00345 (NOVO NORDISK A/S); EP 525 610 A1 (SOLVAY); WO 94/02618 (GIST-BROCADES N.V.); and WO 96/34946 (NOVO NORDISK A/S).
However, even though a number of useful protease variants have been described, there is still a need for new improved protease variants for a number of industrial uses.
Therefore, an object of the present invention, is to provide improved protein engineered protease variants, especially for use in the detergent industry.
SUMMARY OF THE INVENTION
The present inventors have intensively studied numerous of the possible combinations of the T134 and Q137 residues of SAVINASE®, and identified a number of variants with increased improved wash performance.
For further details reference is made to working examples herein (vide infra).
Accordingly, the present invention relates in its first aspect to a subtilase protease variant having improved wash performance in detergents, comprising modification(s) in position(s) 134 and/or 137.
Preferably a subtilase variant according to the invention comprises modifications in position 137, and more preferred comprises modifications in both position 134 and 137.
In a second aspect the invention relates to a subtilase enzyme variant having improved wash performance in detergents, comprising at least one modification chosen from the group comprising:
134A+137L
134S+137L
134A+137E
137F
137L
134V+137T
134V+137L
134C+137S
134A+137C
137C
137D; or
a variant comprising one or more conservative modification(s) in any of the above mentioned variants (e.g. a conservative modification of a 134A(small a.a.)+137L variant include variants such as 134G(small a.a.)+137L, 134S(small a.a.)+137L, 134T(small a.a.)+137L, and 134M(small a.a.)+137L).
In a third aspect the invention relates to an isolated DNA sequence encoding a subtilase variant of the invention.
In a fourth aspect the invention relates to an expression vector comprising an isolated DNA sequence encoding a subtilase variant of the invention.
In a fifth aspect the invention relates to a microbial host cell transformed with an expression vector according to the fourth aspect.
In a further aspect the invention relates to the production of the subtilisin enzymes of the invention by inserting an expression vector according to the fourth aspect into a suitable microbial host, cultivating the host to express the desired subtilase enzyme, and recovering the enzyme product.
Even further the invention relates to a composition comprising a subtilase variant of the invention.
Finally the invention relates to the use of the mutant enzymes for a number of industrial relevant uses, in particular for use in cleaning compositions and cleaning compositions comprising the mutant enzymes, especially detergent compositions comprising the mutant subtilisin enzymes.
Definitions
Prior to discussing this invention in further detail, the following term will first be defined.
ABBREVIATIONS
Nomenclature of Amino Acids
A
=
Ala
=
Alanine
V
=
Val
=
Valine
L
=
Leu
=
Leucine
I
=
Ile
=
Isoleucine
P
=
Pro
=
Proline
F
=
Phe
=
Phenylalanine
W
=
Trp
=
Tryptophan
M
=
Met
=
Methionine
G
=
Gly
=
Glycine
S
=
Ser
=
Serine
T
=
Thr
=
Threonine
C
=
Cys
=
Cysteine
Y
=
Tyr
=
Tyrosine
N
=
Asn
=
Asparagine
Q
=
Gln
=
Glutamine
D
=
Asp
=
Aspartic Acid
E
=
Glu
=
Glutamic Acid
K
=
Lys
=
Lysine
R
=
Arg
=
Arginine
H
=
His
=
Histidine
X
=
Xaa
=
Any amino acid
Nomenclature of nucleic acids
A
=
Adenine
G
=
Guanine
C
=
Cytosine
T
=
Thymine (only in DNA)
U
=
Uracil (only in RNA)
Nomenclature of Variants
In describing the various enzyme variants produced or contemplated according to the invention, the following nomenclatures have been adapted for ease of reference:
Original amino acid(s) position(s) substituted amino acid(s)
According to this the substitution of Glutamic acid for glycine in position 195 is designated as:
Gly 195 Glu or G195E
a deletion of glycine in the same position is:
Gly 195* or G195*
and insertion of an additional amino acid residue such as lysine
Gly 195 GlyLys or G195GK
Where a deletion in comparison with the sequence used for the numbering is indicated, an insertion in such a position is indicated as:
*36 Asp or *36D
for insertion of an aspartic acid in position 36
Multiple mutations are separated by pluses, i.e.:
Arg 170 Tyr+Gly 195 Glu or R170Y+G195E
representing mutations in positions 170 and 195 substituting tyrosine and glutamic acid for arginine and glycine, respectively.
Proteases
Enzymes cleaving the amide linkages in protein substrates are classified as proteases, or (interchangeably) peptidases (see Walsh, 1979, Enzymatic Reaction Mechanisms. W. H. Freeman and Company, San Francisco, Chapter 3).
Numbering of Amino Acid Positions/residues
If no other mentioned the amino acid numbering used herein correspond to that of the subtilase BPN (BASBPN) sequence. For further description of the BPN sequence see Siezen et al., Protein Engng. 4 (1991) 719-737 and FIG. 1 .
Serine Proteases
A serine protease is an enzyme which catalyzes the hydrolysis of peptide bonds, and in which there is an essential serine residue at the active site (White, Handler and Smith, 1973 “ Principles of Biochemistry, ” Fifth Edition, McGraw-Hill Book Company, NY, pp. 271-272).
The bacterial serine proteases have molecular weights in the 20,000 to 45,000 Daltons range. They are inhibited by diisopropylfluorophosphate. They hydrolyze simple terminal esters and are similar in activity to eukaryotic chymotrypsin, also a serine protease. A more narrow term, alkaline protease, covering a sub-group, reflects the high pH optimum of some of the serine proteases, from pH 9.0 to 11.0 (for review, see Priest (1977) Bacteriological Rev. 41 711-753).
Subtilases
A sub-group of the serine proteases tentatively designated subtilases has been proposed by Siezen et al., Protein Engng. 4 (1991) 719-737. They are defined by homology analysis of more than 40 amino acid sequences of serine proteases previously referred to as subtilisin-like proteases. A subtilisin was previously defined as a serine protease produced by Gram-positive bacteria or fungi, and according to Siezen et al. now is a subgroup of the subtilases. A wide variety of subtilases have been identified, and the amino acid sequence of a number of subtilases have been determined. For a more detailed description of such subtilases and their amino acid sequences reference is made to Siezen et al. and FIG. 1 herein.
One subgroup of the subtilases, I-S1, comprises the “classical” subtilisins, such as subtilisin 168, subtilisin BPN′, subtilisin Carlsberg (ALCALASE®, NOVO NORDISK A/S), and subtilisin DY.
A further subgroup of the subtilases I-S2, is recognised by Siezen et al. (supra). Sub-group I-S2 proteases are described as highly alkaline subtilisins and comprise enzymes such as subtilisin PB92 (MAXACAL®, Gist-Brocades NV), subtilisin 309 (SAVINASE®, NOVO NORDISK A/S), subtilisin 147 (ESPERASE®, NOVO NORDISK A/S), and alkaline elastase YaB.
“SAVINASE®”
SAVINASE® is marketed by NOVO NORDISK A/S.
It is subtilisin 309 from B. Lentus and differs from BABP92 only in having N87S (see FIG. 1 herein).
Parent Subtilase
The term “parent subtilase” is a subtilase defined according to Siezen et al. (Protein Engineering 4:719-737 (1991)). For further details see description of “SUBTILASES” immediately above. A parent subtilase may also be a subtilase isolated from a natural source, wherein subsequent modification have been made while retaining the characteristic of a subtilase.
Alternatively the term “parent subtilase” may be termed “wild-type subtilase”.
Modification(s) of a Subtilase Variant
The term “modification(s)” used in connection with modification(s) of a subtilase variant as discussed herein is defined to include chemical modification as well as genetic manipulation. The modification(s) can be by substitution, deletion and/or insertions in or at the amino acid(s) of interest.
Subtilase Variant
In the context of this invention, the term subtilase variant or mutated subtilase means a subtilase that has been produced by an organism which is expressing a mutant gene derived from a parent microorganism which possessed an original or parent gene and which produced a corresponding parent enzyme, the parent gene having been mutated in order to produce the mutant gene from which said mutated subtilase protease is produced when expressed in a suitable host.
Homologous Subtilase Sequences
Specific amino acid residues of SAVINASE® subtilase are identified for modification herein to obtain a subtilase variant of the invention.
However, the invention is not limited to modifications of this particular subtilase, but extend to other parent (wild-type) subtilases, which have a homologous primary structure to that of SAVINASE®.
In order to identify other homologous subtilases, within the scope of this invention, an alignment of said subtilase(s) to a group of previously aligned subtilases is performed keeping the previous alignment constant. A comparison to 18 highly conserved residues in subtilases is performed. The 18 highly conserved residues are shown in table I (see Siezen et al. for further details relating to said conserved residues).
TABLE I
18 highly conserved residues in subtilases
Position:
Conserved residue
23
G
32
D
34
G
39
H
64
H
65
G
66
T
70
G
83
G
125
S
127
G
146
G
154
G
155
N
219
G
220
T
221
S
225
P
After aligning allowing for necessary insertions and deletions in order to maintain the alignment suitable homologous residues are identified. Said homologous residues can then be modified according to the invention.
Using the CLUSTALW (version 1.5, April 1995) computer alignment program (Thompson, J. D., Higgins, D. G. and Gibson, T. J. (1994) Nucleic Acids Research, 22:4673-4680.), with GAP open penalty of 10.0 and GAP extension penalty of 0.1, using the BLOSUM30 protein weight matrix, alignment of a given subtilase to a group of previously aligned subtilases is achieved using the Profile alignments option in the program. For a given subtilase to be within the scope of the invention, preferably 100% of the 18 highly conserved residues should be conserved. However, alignment of greater than or equal to 17 out of the 18 residues, or as little as 16 of said conserved residues is also adequate to identify homologous residues. Conservation of the, in subtilases, catalytic triad Asp32/His64/Ser221 should be maintained.
The previously defined alignment is shown FIG. 1, where the percent identity of the individual subtilases in this alignment to the 18 highly conserved residues are shown too.
Based on this description it is routine for a person skilled in the art to identify suitable homologous subtilases and corresponding homologous residues, which can be modified according to the invention. To illustrate this table II below shows a limited list a homologous subtilases and corresponding suitable residues to be modified according to the invention.
TABLE II
Homologous Subtilases and corresponding homologous residues,
suitable to be modified according to the invention
Pos\Enz.
BASBPN
BYSYAB
BLS309
BLS147
TVTHER
134 + 137
A134A +
T134A +
T134A +
T134A +
G134A +
A137L
Q137L
Q137L
L137L
Q137L
134 + 137
A134S +
T134S +
T134S +
T134S +
G134S +
A137L
Q137L
Q137L
L137L
Q137L
137
A137C
Q137C
Q137C
L137C
Q137C
It is obvious that a similar or larger table covering other homologous subtilases may easily be produced by a person skilled in the art.
Wash Performance
The ability of an enzyme to catalyze the degradation of various naturally occurring substrates present on the objects to be cleaned during e.g. wash is often referred to as its washing ability, washability, detergency, or wash performance. Throughout this application the term wash performance will be used to encompass this property.
Isolated DNA sequence
The term “isolated”, when applied to a DNA sequence molecule, denotes that the DNA sequence has been removed from its natural genetic milieu and is thus free of other extraneous or unwanted coding sequences, and is in a form suitable for use within genetically engineered protein production systems. Such isolated molecules are those that are separated from their natural environment and include cDNA and genomic clones. Isolated DNA molecules of the present invention are free of other genes with which they are ordinarily associated, but may include naturally occurring 5′ and 3′ untranslated regions such as promoters and terminators. The identification of associated regions will be evident to one of ordinary skill in the art (see for example, Dynan and Tijan, Nature 316:774-78, 1985). The term “an isolated DNA sequence” may alternatively be termed “a cloned DNA sequence”.
Isolated protein
When applied to a protein, the term “isolated” indicates that the protein is found in a condition other than its native environment. In a preferred form, the isolated protein is substantially free of other proteins, particularly other homologous proteins (i.e. “homologous impurities” (see below)). It is preferred to provide the protein in a highly purified form, i.e., greater than 40% pure, greater than 60% pure, greater than 80% pure, more preferably greater than 95% pure, and even more preferably greater than 99% pure, as determined by SDS-PAGE.
The term “isolated protein” may alternatively be termed “purified protein”.
Homologous Impurities
The term “homologous impurities” means any impurity (e.g. another polypeptide than the polypeptide of the invention) which originate from the homologous cell where the polypeptide of the invention is originally obtained from.
Obtained from
The term “obtained from” as used herein in connection with a specific microbial source, means that the polynucleotide and/or polypeptide produced by the specific source, or by a cell in which a gene from the source have been inserted.
Substrate
The term “Substrate” used in connection with a substrate for a protease is should be interpreted in its broadest form as comprising a compound containing at least one peptide bond susceptible to hydrolysis by a subtilisin protease.
Product
The term “product” used in connection with a product derived from a protease enzymatic reaction should in the context of this invention be interpreted to include the products of a hydrolysis reaction involving a subtilase protease. A product may be the substrate in a subsequent hydrolysis reaction.
BRIEF DESCRIPTION OF THE FIGURE BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows an alignment of a number of homologous subtilases (SEQ ID NOS:1-10), which are aligned to 18 highly conserved residues in subtilases. 18 highly conserved residues are highlighted in bold. All shown subtilases, except JP170, have 100% identity in said conserved residues. JP170 is having an “N” in stead of “G” in conserved residues G146.
DETAILED DESCRIPTION OF THE INVENTION
Subtilase Variants with Improved Wash Performance
The present inventors have identified the improved wash performance variants in BLS309 (SAVINASE®).
Accordingly, an embodiment of the invention relates to a subtilase enzyme variant, wherein the modification is chosen from the group comprising:
T134A+Q137L
T134S+Q137L
T134A+Q137E
Q137F
Q137L
T134V+Q137T
T134V+Q137L
T134C+Q137S
T134A+Q137C
Q137C
Q137D; or
a variant comprising one or more conservative modification(s) in any of the above mentioned variants (e.g. a conservative modification of a T134A(small a.a.)+Q137L variant include variants such as T134G(small a.a.)+Q137L, T134S(small a.a.)+Q137L, T134T(small a.a.)+Q137L, and T134M(small a.a.)+Q137L).
Numerous subtilase variants of the invention is tested herein and showing improved wash-performance in detergents (see working examples herein (vide infra)).
It is well known in the art that substitution of one amino acid to a similar conservative amino acid only give a minor change in the characteristic of the enzyme.
Table III below list groups of conservative amino acids.
TABLE III
Conservative amino acid substitutions
Basic:
arginine
lysine
histidine
Acidic:
glutamic acid
aspartic acid
Polar:
glutamine
asparagine
Hydrophobic:
leucine
isoleucine
valine
Aromatic:
phenylalanine
tryptophan
tyrosine
Small:
glycine
alanine
serine
threonine
methionine
Accordingly, subtilase variants such as 134A+137L, 134G+137L, 134S+137L, 134T+137L, and 134M+137L will have a similar wash-performance improvement. Further, subtilase variants such as T134A+Q137L, T134G+Q137L, T134S+Q137L, T134T+Q137L, and T134M+Q137L will have a similar wash-performance improvement too.
Based on the disclosed subtilase variants herein, it is routine work, for a person skilled in the art, to identify further suitable conservative substitutions in order to obtain a subtilase variant with improved wash-performance.
In embodiments of the invention, the subtilases of interest are those belonging to the subgroups I-S1 and I-S2.
Relating to subgroup I-S1 preferred parent subtilase is chosen from the group comprising ABSS168, BASBPN, BSSDY, and BLSCAR or functional variants thereof having retained the characteristic of sub-group I-S1.
Relating to subgroup I-S2 preferred parent subtilase is chosen from the group comprising BLS147, BLS309, BAPB92, TVTHER AND BYSYAB or functional variants thereof having retained the characteristic of sub-group I-S2.
The present invention also comprises any one or more modifications in the above mentioned positions in combination with any other modification to the amino acid sequence of the parent enzyme. Especially combinations with other modifications known in the art to provide improved properties to the enzyme are envisaged. The art describe a number of subtilase variants with different improved properties and a number of those are mentioned in the “Background of the invention” section herein (vide supra). Those references are disclosed here as references to identify a subtilase variant, which advantageously can be combined with a subtilase variant of the invention.
Such combinations comprise the positions: 222 (improve oxidation stability), 218 (improves thermal stability), substitutions in the Ca-binding sites stabilising the enzyme, e.g. position 76, and many other apparent from the prior art.
In further embodiments a subtilase variant of the invention may advantageously be combined with one or more modification(s) in any of the positions: 27, 36, 57, 76, 97, 101, 104, 120, 123, 167, 170, 206, 218, 222, 224, 235 and 274.
Specifically the following BLS309 and BAPB92 variants are considered appropriate for combination: K27R, *36D, S57P, N76D, G97N, S101G, V104A, V104N, V104Y, H120D, N123S, Y167A, Y167I, R170S, R170L, R170N, Q206E, N218S, M222S, M222A, T224S, K235L and T274A.
Furthermore variants comprising any of the variants V104N+S101G, K27R+V104Y+N123S+T274A, or N76D+V104A or other combinations of these mutations (V104N, S101G, K27R, V104Y, N123S, T274A, N76D, V104A), in combination with any one or more of the modification(s) mentioned above exhibit improved properties.
Even further subtilase variants of the main aspect(s) of the invention are preferably combined with one or more modification(s) in any of the positions 129, 131, 133 and 194, preferably as 129K, 131H, 133P, 133D and 194P modifications, and most preferably as P129K, P131H, A133P, A133D and A194P modifications. Any of those modifications) may give a higher expression level of a subtilase variant of the invention.
Method for Producing Mutations in Subtilase Genes
Many methods for cloning a subtilase of the invention and for introducing mutations into genes (e.g. subtilase genes) are well known in the art.
In general standard procedures for cloning of genes and introducing mutations (random and/or site directed) into said genes may be used in order to obtain a subtilase variant of the invention. For further description of suitable techniques reference is made to working examples herein (vide infra) and (Sambrook et al. (1989) Molecular cloning: A laboratory manual, Cold Spring Harbor lab., Cold Spring Harbor, N.Y.; Ausubel, F. M. et al. (eds.) “Current protocols in Molecular Biology”. John Wiley and Sons, 1995; Harwood, C. R., and Cutting, S. M. (eds.) “Molecular Biological Methods for Bacillus”. John Wiley and Sons, 1990); and WO 96/34946.
Expression Vectors
A recombinant expression vector comprising a DNA construct encoding the enzyme of the invention may be any vector which may conveniently be subjected to recombinant DNA procedures, and the choice of vector will often depend on the host cell into which it is to be introduced. Thus, the vector may be an autonomously replicating vector, i.e. a vector which exists as an extrachromosomal entity, the replication of which is independent of chromosomal replication, e.g. a plasmid. Alternatively, the vector may be one which, when introduced into a host cell, is integrated into the host cell genome in part or in its entirety and replicated together with the chromosome(s) into which it has been integrated.
The vector is preferably an expression vector in which the DNA sequence encoding the enzyme of the invention is operably linked to additional segments required for transcription of the DNA. In general, the expression vector is derived from plasmid or viral DNA, or may contain elements of both. The term, “operably linked” indicates that the segments are arranged so that they function in concert for their intended purposes, e.g. transcription initiates in a promoter and proceeds through the DNA sequence coding for the enzyme.
The promoter may be any DNA sequence which shows transcriptional activity in the host cell of choice and may be derived from genes encoding proteins either homologous or heterologous to the host cell.
Examples of suitable promoters for use in bacterial host cells include the promoter of the Bacillus stearothermophilus maltogenic amylase gene, the Bacillus licheniformis alpha-amylase gene, the Bacillus amyloliquefaciens alpha-amylase gene, the Bacillus subtilis alkaline protease gen, or the Bacillus pumilus xylosidase gene, or the phage Lambda P R or P L promoters or the E. coli lac, trp or tac promoters.
The DNA sequence encoding the enzyme of the invention may also, if necessary, be operably connected to a suitable terminator.
The recombinant vector of the invention may further comprise a DNA sequence enabling the vector to replicate in the host cell in question.
The vector may also comprise a selectable marker, e.g. a gene the product of which complements a defect in the host cell, or a gene encoding resistance to e.g. antibiotics like kanamycin, chloramphenicol, erythromycin, tetracycline, spectinomycine, or the like, or resistance to heavy metals or herbicides.
To direct an enzyme of the present invention into the secretory pathway of the host cells, a secretory signal sequence (also known as a leader sequence, prepro sequence or pre sequence) may be provided in the recombinant vector. The secretory signal sequence is joined to the DNA sequence encoding the enzyme in the correct reading frame. Secretory signal sequences are commonly positioned 5′ to the DNA sequence encoding the enzyme. The secretory signal sequence may be that normally associated with the enzyme or may be from a gene encoding another secreted protein.
The procedures used to ligate the DNA sequences coding for the present enzyme, the promoter and optionally the terminator and/or secretory signal sequence, respectively, or to assemble these sequences by suitable PCR amplification schemes, and to insert them into suitable vectors containing the information necessary for replication or integration, are well known to persons skilled in the art (cf., for instance, Sambrook et al., op.cit.).
Host Cell
The DNA sequence encoding the present enzyme introduced into the host cell may be either homologous or heterologous to the host in question. If homologous to the host cell, i.e. produced by the host cell in nature, it will typically be operably connected to another promoter sequence or, if applicable, another secretory signal sequence and/or terminator sequence than in its natural environment. The term “homologous” is intended to include a DNA sequence encoding an enzyme native to the host organism in question. The term “heterologous” is intended to include a DNA sequence not expressed by the host cell in nature. Thus, the DNA sequence may be from another organism, or it may be a synthetic sequence.
The host cell into which the DNA construct or the recombinant vector of the invention is introduced may be any cell which is capable of producing the present enzyme and includes bacteria, yeast, fungi and higher eukaryotic cells.
Examples of bacterial host cells which, on cultivation, are capable of producing the enzyme of the invention are gram-positive bacteria such as strains of Bacillus, such as strains of B. subtilis, B. licheniformis, B. lentus, B. brevis, B. stearothermophilus, B. alkalophilus, B. amyloliquefaciens, B. coagulans, B. circulans, B. lautus, B. megatherium or B. thuringiensis, or strains of Streptomyces, such as S. lividans or S. murinus, or gram-negative bacteria such as Echerichia coli. The transformation of the bacteria may be effected by protoplast transformation, electroporation, conjugation, or by using competent cells in a manner known per se (cf. Sambrook et al., supra).
When expressing the enzyme in bacteria such as E. coli, the enzyme may be retained in the cytoplasm, typically as insoluble granules (known as inclusion bodies), 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 after which the enzyme is refolded by diluting the denaturing agent. In the latter case, the enzyme may be recovered from the periplasmic space by disrupting the cells, e.g. by sonication or osmotic shock, to release the contents of the periplasmic space and recovering the enzyme.
When expressing the enzyme in gram-positive bacteria such as Bacillus or Streptomyces strains, the enzyme may be retained in the cytoplasm, or may be directed to the extracellular medium by a bacterial secretion sequence. In the latter case, the enzyme may be recovered from the medium as described below.
Method of Producing Subtilase
The present invention provides a method of producing an isolated enzyme according to the invention, wherein a suitable host cell, which has been transformed with a DNA sequence encoding the enzyme, is cultured under conditions permitting the production of the enzyme, and the resulting enzyme is recovered from the culture.
When an expression vector comprising a DNA sequence encoding the enzyme is transformed into a heterologous host cell it is possible to enable heterologous recombinant production of the enzyme of the invention.
Thereby it is possible to make a highly purified subtilase composition, characterized in being free from homologous impurities.
In this context homologous impurities means any impurities (e.g. other polypeptides than the enzyme of the invention) which originate from the homologous cell where the enzyme of the invention is originally obtained from.
The medium used to culture the transformed host cells may be any conventional medium suitable for growing the host cells in question. The expressed subtilase may conveniently be secreted into the culture medium and may be recovered therefrom by well-known procedures including separating the cells from the medium by centrifugation or filtration, precipitating proteinaceous components of the medium by means of a salt such as ammonium sulphate, followed by chromatographic procedures such as ion exchange chromatography, affinity chromatography, or the like.
Use of a Subtilase Variant of the Invention
A subtilase protease variant of the invention may be used for a number of industrial applications, in particular within the detergent industry.
Further the invention relates to an enzyme composition, which comprise a subtilase variant of the invention.
An summary of preferred industrial applications and corresponding preferred enzyme compositions are described below.
This summary is not in any way intended to be a complete list of suitable applications of a subtilase variant of the invention. A subtilase variants of the invention may be used in other industrial applications known in the art to include use of a protease, in particular a subtilase.
Detergent Compositions Comprising the Mutant Enzymes
The present invention comprises the use of the mutant enzymes of the invention in cleaning and detergent compositions and such compositions comprising the mutant subtilisin enzymes. Such cleaning and detergent compositions are well described in the art and reference is made to WO 96/34946; WO 97/07202; WO 95/30011 for further description of suitable cleaning and detergent compositions.
Further reference is made to workings example(s) herein showing wash performance improvements for a number of subtilase variants of the invention.
Detergent Disclosure and Examples
Surfactant System
The detergent compositions according to the present invention comprise a surfactant system, wherein the surfactant can be selected from nonionic and/or anionic and/or cationic and/or ampholytic and/or zwitterionic and/or semi-polar surfactants.
The surfactant is typically present at a level from 0.1% to 60% by weight.
The surfactant is preferably formulated to be compatible with enzyme components present in the composition. In liquid or gel compositions the surfactant is most preferably formulated in such a way that it promotes, or at least does not degrade, the stability of any enzyme in these compositions.
Preferred systems to be used according to the present inven-tion comprise as a surfactant one or more of the nonionic and/or anionic surfactants described herein.
Polyethylene, polypropylene, and polybutylene oxide condensates of alkyl phenols are suitable for use as the nonionic surfactant of the surfactant systems of the present inven-tion, with the polyethylene oxide condensates being pre-ferred. These compounds include the condensation products of alkyl phenols having an alkyl group containing from about 6 to about 14 carbon atoms, preferably from about 8 to about 14 carbon atoms, in either a straight chain or branched-chain configuration with the alkylene oxide. In a preferred embodiment, the ethylene oxide is present in an amount equal to from about 2 to about 25 moles, more preferably from about 3 to about 15 moles, of ethylene oxide per mole of alkyl phenol. Commercially available nonionic surfactants of this type include Igepal™ CO-630, marketed by the GAF Corporation; and Triton™ X-45, X-114, X-100 and X-102, all marketed by the Rohm & Haas Company. These surfactants are commonly referred to as alkylphenol alkoxylates (e.g., alkyl phenol ethoxylates).
The condensation products of primary and secondary aliphatic alcohols with about 1 to about 25 moles of ethylene oxide are suitable for use as the nonionic surfactant of the nonionic surfactant systems of the present invention. The alkyl chain of the aliphatic alcohol can either be straight or branched, primary or secondary, and generally contains from about 8 to about 22 carbon atoms. Preferred are the condensation products of alcohols having an alkyl group containing from about 8 to about 20 carbon atoms, more preferably from about 10 to about 18 carbon atoms, with from about 2 to about 10 moles of ethylene oxide per mole of alcohol. About 2 to about 7 moles of ethylene oxide and most preferably from 2 to 5 moles of ethylene oxide per mole of alcohol are present in said condensation products. Examples of commercially available nonionic surfactants of this type include Tergitol™ 15-S-9 (The condensation product of C 11 -C 15 linear alcohol with 9 moles ethylene oxide), Tergitol™ 24-L-6 NMW (the condensation product of C 12 -C 14 primary alcohol with 6 moles ethylene oxide with a narrow molecular weight distribution), both marketed by Union Carbide Corporation; Neodol™ 45-9 (the condensation product of C 14 -C 15 linear alcohol with 9 moles of ethylene oxide), Neodol™ 23-3 (the condensation product of C 12 -C 13 linear alcohol with 3.0 moles of ethylene oxide), Neodol™ 45-7 (the condensation product of C 14 -C 15 linear alcohol with 7 moles of ethylene oxide), Neodol™ 45-5 (the condensation product of C 14 -C 15 linear alcohol with 5 moles of ethylene oxide) marketed by Shell Chemical Company, Kyro™ EOB (the condensation product of C 13 -C 15 alcohol with 9 moles ethylene oxide), marketed by The Procter & Gamble Company, and Genapol LA 050 (the condensation product of C 12 -C 14 alcohol with 5 moles of ethylene oxide) marketed by Hoechst. Preferred range of HLB in these products is from 8-11 and most preferred from 8-10.
Also useful as the nonionic surfactant of the surfactant systems of the present invention are alkylpolysaccharides disclosed in U.S. Pat. No. 4,565,647, having a hydrophobic group containing from about 6 to about 30 carbon atoms, preferably from about 10 to about 16 carbon atoms and a polysaccharide, e.g. a polyglycoside, hydrophilic group containing from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7 saccharide units. Any reducing saccharide containing 5 or 6 carbon atoms can be used, e.g., glucose, galactose and galactosyl moieties can be substituted for the glucosyl moieties (optionally the hydrophobic group is attached at the 2-, 3-, 4-, etc. positions thus giving a glucose or galactose as opposed to a glucoside or galactoside). The intersaccharide bonds can be, e.g., between the one position of the additional saccharide units and the 2-, 3-, 4-, and/or 6-positions on the preceding saccharide units.
The preferred alkylpolyglycosides have the formula
R 2 O(C n H 2n O) t (glycosyl) x
wherein R 2 is selected from the group consisting of alkyl, alkylphenyl, hydroxyalkyl, hydroxyalkylphenyl, and mixtures thereof in which the alkyl groups contain from about 10 to about 18, preferably from about 12 to about 14, carbon atoms; n is 2 or 3, preferably 2; t is from 0 to about 10, pre-ferably 0; and x is from about 1.3 to about 10, preferably from about 1.3 to about 3, most preferably from about 1.3 to about 2.7. The glycosyl is preferably derived from glucose. To prepare these compounds, the alcohol or alkylpolyethoxy alcohol is formed first and then reacted with glucose, or a source of glucose, to form the glucoside (attachment at the 1-position). The additional glycosyl units can then be attached between their 1-position and the preceding glycosyl units 2-, 3-, 4-, and/or 6-position, preferably predominantly the 2-position.
The condensation products of ethylene oxide with a hydrophobic base formed by the condensation of propylene oxide with propylene glycol are also suitable for use as the additional nonionic surfactant systems of the present invention. The hydrophobic portion of these compounds will preferably have a molecular weight from about 1500 to about 1800 and will exhibit water insolubility. The addition of polyoxyethylene moieties to this hydrophobic portion tends to increase the water solubility of the molecule as a whole, and the liquid character of the product is retained up to the point where the polyoxyethylene content is about 50% of the total weight of the condensation product, which corresponds to condensation with up to about 40 moles of ethylene oxide. Examples of compounds of this type include certain of the commercially available Pluronic™ surfactants, marketed by BASF.
Also suitable for use as the nonionic surfactant of the nonionic surfactant system of the present invention, are the condensation products of ethylene oxide with the product resulting from the reaction of propylene oxide and ethylenediamine. The hydrophobic moiety of these products consists of the reaction product of ethylenediamine and excess propylene oxide, and generally has a molecular weight of from about 2500 to about 3000. This hydrophobic moiety is condensed with ethylene oxide to the extent that the condensation product contains from about 40% to about 80% by weight of polyoxyethylene and has a molecular weight of from about 5,000 to about 11,000. Examples of this type of nonionic surfactant include certain of the commercially available Tetronic™ compounds, marketed by BASF.
Preferred for use as the nonionic surfactant of the surfactant systems of the present invention are polyethylene oxide condensates of alkyl phenols, condensation products of primary and secondary aliphatic alcohols with from about 1 to about 25 moles of ethyleneoxide, alkylpolysaccharides, and mixtures hereof. Most preferred are C 8 -C 14 alkyl phenol ethoxylates having from 3 to 15 ethoxy groups and C 8 -C 18 alcohol ethoxylates (preferably C 10 avg.) having from 2 to 10 ethoxy groups, and mixtures thereof.
Highly preferred nonionic surfactants are polyhydroxy fatty acid amide surfactants of the formula
wherein R 1 is H, or R 1 is C 1-4 hydrocarbyl, 2-hydroxyethyl, 2-hydroxypropyl or a mixture thereof, R 2 is C 5-31 hydrocarbyl, and Z is a polyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3 hydroxyls directly connected to the chain, or an alkoxylated derivative thereof. Preferably, R 1 is methyl, R 2 is straight C 11-15 alkyl or C 16-18 alkyl or alkenyl chain such as coconut alkyl or mixtures thereof, and Z is derived from a reducing sugar such as glucose, fructose, maltose or lactose, in a reductive amination reaction.
Highly preferred anionic surfactants include alkyl alkoxylated sulfate surfactants. Examples hereof are water soluble salts or acids of the formula RO(A) m SO3M wherein R is an unsubstituted C 10 -C 24 alkyl or hydroxyalkyl group having a C 10 -C 24 alkyl component, preferably a C 12 -C 20 alkyl or hydro-xyalkyl, more preferably C 12 -C 18 alkyl or hydroxyalkyl, A is an ethoxy or propoxy unit, m is greater than zero, typically between about 0.5 and about 6, more preferably between about 0.5 and about 3, and M is H or a cation which can be, for example, a metal cation (e.g., sodium, potassium, lithium, calcium, magnesium, etc.), ammonium or substituted-ammonium cation. Alkyl ethoxylated sulfates as well as alkyl propoxylated sulfates are contemplated herein. Specific examples of substituted ammonium cations include methyl-dimethyl, trimethyl-ammonium cations and quaternary ammonium cations such as tetramethyl-ammonium and dimethyl piperdinium cations and those derived from alkylamines such as ethylamine, diethylamine, triethylamine, mixtures thereof, and the like. Exemplary surfactants are C 12 -C 18 alkyl polyethoxylate (1.0) sulfate (C 12 -C 18 E(1.0)M), C 12 -C 18 alkyl polyethoxylate (2.25) sulfate (C 12 -C 18 (2.25)M, and C 12 -C 18 alkyl polyethoxylate (3.0) sulfate (C 12 -C 18 E(3.0)M), and C 12 -C 18 alkyl polyethoxylate (4.0) sulfate (C 12 -C 18 E(4.0)M), wherein M is conveniently selected from sodium and potassium.
Suitable anionic surfactants to be used are alkyl ester sulfonate surfactants including linear esters of C 8 -C 20 carboxylic acids (i.e., fatty acids) which are sulfonated with gaseous SO 3 according to “The Journal of the American Oil Chemists Society”, 52 (1975), pp. 323-329. Suitable starting materials would include natural fatty substances as derived from tallow, palm oil, etc.
The preferred alkyl ester sulfonate surfactant, especially for laundry applications, comprise alkyl ester sulfonate surfactants of the structural formula:
wherein R 3 is a C 8 -C 20 hydrocarbyl, preferably an alkyl, or combination thereof, R 4 is a C 1 -C 6 hydrocarbyl, preferably an alkyl, or combination thereof, and M is a cation which forms a water soluble salt with the alkyl ester sulfonate. Suitable salt-forming cations include metals such as sodium, potassium, and lithium, and substituted or unsubstituted ammonium cations, such as monoethanolamine, diethonolamine, and triethanolamine. Preferably, R 3 is C 10 -C 16 alkyl, and R 4 is methyl, ethyl or isopropyl. Especially preferred are the methyl ester sulfonates wherein R 3 is C 10 -C 16 alkyl.
Other suitable anionic surfactants include the alkyl sulfate surfactants which are water soluble salts or acids of the formula ROSO 3 M wherein R preferably is a C 10 -C 24 hydrocarbyl, preferably an alkyl or hydroxyalkyl having a C 10 -C 20 alkyl component, more preferably a C 12 -C 18 alkyl or hydroxyalkyl, and M is H or a cation, e.g., an alkali metal cation (e.g. sodium, potassium, lithium), or ammonium or substituted ammonium (e.g. methyl-, dimethyl-, and trimethyl ammonium cations and quaternary ammonium cations such as tetramethyl-ammonium and dimethyl piperdinium cations and quaternary ammonium cations derived from alkylamines such as ethylamine, diethylamine, triethylamine, and mixtures thereof, and the like). Typically, alkyl chains of C 12 -C 16 are preferred for lower wash temperatures (e.g. below about 50° C.) and C 16 -C 18 alkyl chains are preferred for higher wash temperatures (e.g. above about 50° C.).
Other anionic surfactants useful for detersive purposes can also be included in the laundry detergent compositions of the present invention. Theses can include salts (including, for example, sodium, potassium, ammonium, and substituted ammonium salts such as mono- di- and triethanolamine salts) of soap, C 8 -C 22 primary or secondary alkanesulfonates, C 8 -C 24 olefinsulfonates, sulfonated polycarboxylic acids prepared by sulfonation of the pyrolyzed product of alkaline earth metal citrates, e.g., as described in British patent specification No. 1,082,179, C 8 -C 24 alkylpolyglycolethersulfates (containing up to 10 moles of ethylene oxide); alkyl glycerol sulfonates, fatty acyl glycerol sulfonates, fatty oleyl glycerol sulfates, alkyl phenol ethylene oxide ether sulfates, paraffin sulfonates, alkyl phosphates, isethionates such as the acyl isethionates, N-acyl taurates, alkyl succinamates and sulfosuccinates, monoesters of sulfosuccinates (especially saturated and unsaturated C 12 -C 18 monoesters) and diesters of sulfosuccinates (especially saturated and unsaturated C 6 -C 12 diesters), acyl sarcosinates, sulfates of alkylpolysaccharides such as the sulfates of alkylpolyglucoside (the nonionic nonsulfated compounds being described below), branched primary alkyl sulfates, and alkyl polyethoxy carboxylates such as those of the formula RO(CH 2 CH 2 O) k —CH 2 COO—M+ wherein R is a C 8 -C 22 alkyl, k is an integer from 1 to 10, and M is a soluble salt forming cation. Resin acids and hydrogenated resin acids are also suitable, such as rosin, hydrogenated rosin, and resin acids and hydrogenated resin acids present in or derived from tall oil.
Alkylbenzene sulfonates are highly preferred. Especially preferred are linear (straight-chain) alkyl benzene sulfonates (LAS) wherein the alkyl group preferably contains from 10 to 18 carbon atoms.
Further examples are described in “Surface Active Agents and Detergents” (Vol. I and II by Schwartz, Perrry and Berch). A variety of such surfactants are also generally disclosed in U.S. Pat. No. 3,929,678, (Column 23, line 58 through Column 29, line 23, herein incorporated by reference).
When included therein, the laundry detergent compositions of the present invention typically comprise from about 1 to about 40%, preferably from about 3% to about 20% by weight of such anionic surfactants.
The laundry detergent compositions of the present invention may also contain cationic, ampholytic, zwitterionic, and semi-polar surfactants, as well as the nonionic and/or anionic surfactants other than those already described herein.
Cationic detersive surfactants suitable for use in the laundry detergent compositions of the present invention are those having one long-chain hydrocarbyl group. Examples of such cationic surfactants include the ammonium surfactants such as alkyltrimethylammonium halogenides, and those surfactants having the formula:
[R 2 (OR 3 ) y ][R 4 (OR 3 ) y ] 2 R 5 N+X−
wherein R 2 is an alkyl or alkyl benzyl group having from about 8 to about 18 carbon atoms in the alkyl chain, each R 3 is selected from the group consisting of —CH 2 CH 2 —, —CH 2 CH(CH 3 )—, —CH 2 CH(CH 2 OH)—, —CH 2 CH 2 CH 2 —, and mixtures thereof; each R 4 is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 hydroxyalkyl, benzyl ring structures formed by joining the two R 4 groups, —CH 2 CHOHCHOHCOR 6 CHOHCH 2 OH, wherein R 6 is any hexose or hexose polymer having a molecular weight less than about 1000, and hydrogen when y is not 0; R 5 is the same as R 4 or is an alkyl chain, wherein the total number of carbon atoms or R 2 plus R 5 is not more than about 18; each y is from 0 to about 10, and the sum of the y values is from 0 to about 15; and X is any compatible anion.
Highly preferred cationic surfactants are the water soluble quaternary ammonium compounds useful in the present composition having the formula:
R 1 R 2 R 3 R 4 N + X − (i)
wherein R 1 is C 8 -C 16 alkyl, each of R 2 , R 3 and R 4 is independently C 1 -C 4 alkyl, C 1 -C 4 hydroxy alkyl, benzyl, and —(C 2 H 40 ) x H where x has a value from 2 to 5, and X is an anion. Not more than one of R 2 , R 3 or R 4 should be benzyl.
The preferred alkyl chain length for R 1 is C 12 -C 15 , particularly where the alkyl group is a mixture of chain lengths derived from coconut or palm kernel fat or is derived synthetically by olefin build up or OXO alcohols synthesis.
Preferred groups for R 2 R 3 and R 4 are methyl and hydroxyethyl groups and the anion X may be selected from halide, methosulphate, acetate and phosphate ions.
Examples of suitable quaternary ammonium compounds of formulae (i) for use herein are:
coconut trimethyl ammonium chloride or bromide;
coconut methyl dihydroxyethyl ammonium chloride or bromide;
decyl triethyl ammonium chloride;
decyl dimethyl hydroxyethyl ammonium chloride or bromide;
C 12 -C 15 dimethyl hydroxyethyl ammonium chloride or bromide;
coconut dimethyl hydroxyethyl ammonium chloride or bromide;
myristyl trimethyl ammonium methyl sulphate;
lauryl dimethyl benzyl ammonium chloride or bromide;
lauryl dimethyl (ethenoxy) 4 ammonium chloride or bromide;
choline esters (compounds of formula (i) wherein R 1 is
di-alkyl imidazolines [compounds of formula (i)].
Other cationic surfactants useful herein are also described in U.S. Pat. No. 4,228,044 and in EP 000 224.
When included therein, the laundry detergent compositions of the present invention typically comprise from. 0.2% to about 25%, preferably from about 1% to about 8% by weight of such cationic surfactants.
Ampholytic surfactants are also suitable for use in the laundry detergent compositions of the present invention. These surfactants can be broadly described as aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight- or branched-chain. One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g. carboxy, sulfonate, sulfate. See U.S. Pat. No. 3,929,678 (column 19, lines 18-35) for examples of ampholytic surfactants.
When included therein, the laundry detergent compositions of the present invention typically comprise from 0.2% to about 15%, preferably from about 1% to about 10% by weight of such ampholytic surfactants.
Zwitterionic surfactants are also suitable for use in laundry detergent compositions. These surfactants can be broadly described as derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds. See U.S. Pat. No. 3,929,678 (column 19, line 38 through column 22, line 48) for examples of zwitterionic surfactants.
When included therein, the laundry detergent compositions of the present invention typically comprise from 0.2% to about 15%, preferably from about 1% to about 10% by weight of such zwitterionic surfactants.
Semi-polar nonionic surfactants are a special category of nonionic surfactants which include water-soluble amine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; watersoluble phosphine oxides containing one alkyl moiety of from about 10 to about 18 carbon atoms and 2 moieties selected from the group consisting of alkyl groups and hydroxyalkyl groups containing from about 1 to about 3 carbon atoms; and water-soluble sulfoxides containing one alkyl moiety from about 10 to about 18 carbon atoms and a moiety selected from the group consisting of alkyl and hydroxyalkyl moieties of from about 1 to about 3 carbon atoms.
Semi-polar nonionic detergent surfactants include the amine oxide surfactants having the formula:
wherein R 3 is an alkyl, hydroxyalkyl, or alkyl phenyl group or mixtures thereof containing from about 8 to about 22 carbon atoms; R 4 is an alkylene or hydroxyalkylene group containing from about 2 to about 3 carbon atoms or mixtures thereof; x is from 0 to about 3: and each R 5 is an alkyl or hydroxyalkyl group containing from about 1 to about 3 carbon atoms or a polyethylene oxide group containing from about 1 to about 3 ethylene oxide groups. The R 5 groups can be attached to each other, e.g., through an oxygen or nitrogen atom, to form a ring structure.
These amine oxide surfactants in particular include C 10 -C 18 alkyl dimethyl amine oxides and C 8 -C 12 alkoxy ethyl dihydroxy ethyl amine oxides.
When included therein, the laundry detergent compositions of the present invention typically comprise from 0.2% to about 15%, preferably from about 1% to about 10% by weight of such semi-polar nonionic surfactants.
Builder System
The compositions according to the present invention may further comprise a builder system. Any conventional builder system is suitable for use herein including aluminosilicate materials, silicates, polycarboxylates and fatty acids, materials such as ethylenediamine tetraacetate, metal ion sequestrants such as aminopolyphosphonates, particularly ethylenediamine tetramethylene phosphonic acid and diethylene triamine pentamethylenephosphonic acid. Though less preferred for obvious environmental reasons, phosphate builders can also be used herein.
Suitable builders can be an inorganic ion exchange material, commonly an inorganic hydrated aluminosilicate material, more particularly a hydrated synthetic zeolite such as hydrated zeolite A, X, B, HS or MAP.
Another suitable inorganic builder material is layered silicate, e.g. SKS-6 (Hoechst). SKS-6 is a crystalline layered silicate consisting of sodium silicate (Na 2 Si 2 O 5 ).
Suitable polycarboxylates containing one carboxy group include lactic acid, glycolic acid and ether derivatives thereof as disclosed in Belgian Patent Nos. 831,368, 821,369 and 821,370. Polycarboxylates containing two carboxy groups include the water-soluble salts of succinic acid, malonic acid, (ethylenedioxy) diacetic acid, maleic acid, diglycollic acid, tartaric acid, tartronic acid and fumaric acid, as well as the ether carboxylates described in German Offenle-enschrift 2,446,686, and 2,446,487, U.S. Pat. No. 3,935,257 and the sulfinyl carboxylates described in Belgian Patent No. 840,623. Polycarboxylates containing three carboxy groups include, in particular, water-soluble citrates, aconitrates and citraconates as well as succinate derivatives such as the carboxymethyloxysuccinates described in British Patent No. 1,379,241, lactoxysuccinates described in Netherlands Application 7205873, and the oxypolycarboxylate materials such as 2-oxa-1,1,3-propane tricarboxylates described in British Patent No. 1,387,447.
Polycarboxylates containing four carboxy groups include oxydisuccinates disclosed in British Patent No. 1,261,829, 1,1,2,2,-ethane tetracarboxylates, 1,1,3,3-propane tetracarboxylates containing sulfo substituents include the sulfosuccinate derivatives disclosed in British Patent Nos. 1,398,421 and 1,398,422 and in U.S. Pat. No. 3,936,448, and the sulfonated pyrolysed citrates described in British Patent No. 1,082,179, while polycarboxylates containing phosphone substituents are disclosed in British Patent No. 1,439,000.
Alicyclic and heterocyclic polycarboxylates include cyclopentane-cis,cis-cis-tetracarboxylates, cyclopentadienide pentacarboxylates, 2,3,4,5-tetrahydro-furan-cis, cis, cis-tetracarboxylates, 2,5-tetrahydro-furan-cis, discarboxylates, 2,2,5,5,-tetrahydrofuran-tetracarboxylates, 1,2,3,4,5,6-hexane-hexacarboxylates and carboxymethyl derivatives of polyhydric alcohols such as sorbitol, mannitol and xylitol. Aromatic polycarboxylates include mellitic acid, pyromellitic acid and the phthalic acid derivatives disclosed in British Patent No. 1,425,343.
Of the above, the preferred polycarboxylates are hydroxy-carboxylates containing up to three carboxy groups per molecule, more particularly citrates.
Preferred builder systems for use in the present compositions include a mixture of a water-insoluble aluminosilicate builder such as zeolite A or of a layered silicate (SKS-6), and a water-soluble carboxylate chelating agent such as citric acid.
A suitable chelant for inclusion in the detergent composi-ions in accordance with the invention is ethylenediamine-N,N′-disuccinic acid (EDDS) or the alkali metal, alkaline earth metal, ammonium, or substituted ammonium salts thereof, or mixtures thereof. Preferred EDDS compounds are the free acid form and the sodium or magnesium salt thereof. Examples of such preferred sodium salts of EDDS include Na 2 EDDS and Na 4 EDDS. Examples of such preferred magnesium salts of EDDS include MgEDDS and Mg 2 EDDS. The magnesium salts are the most preferred for inclusion in compositions in accordance with the invention.
Preferred builder systems include a mixture of a water-insoluble aluminosilicate builder such as zeolite A, and a water soluble carboxylate chelating agent such as citric acid.
Other builder materials that can form part of the builder system for use in granular compositions include inorganic materials such as alkali metal carbonates, bicarbonates, silicates, and organic materials such as the organic phosphonates, amino polyalkylene phosphonates and amino polycarboxylates.
Other suitable water-soluble organic salts are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid comprises at least two carboxyl radicals separated form each other by not more than two carbon atoms.
Polymers of this type are disclosed in GB-A-1,596,756. Examples of such salts are polyacrylates of MW 2000-5000 and their copolymers with maleic anhydride, such copolymers having a molecular weight of from 20,000 to 70,000, especially about 40,000.
Detergency builder salts are normally included in amounts of from 5% to 80% by weight of the composition. Preferred levels of builder for liquid detergents are from 5% to 30%.
Enzymes
Preferred detergent compositions, in addition to the enzyme preparation of the invention, comprise other enzyme(s) which provides cleaning performance and/or fabric care benefits.
Such enzymes include other proteases, lipases, cutinases, amylases, cellulases, peroxidases, oxidases (e.g. laccases).
Proteases: Any other protease suitable for use in alkaline solutions can be used. Suitable proteases include those of animal, vegetable or microbial origin. Microbial origin is preferred. Chemically or genetically modified mutants are included. The protease may be a serine protease, preferably an alkaline microbial protease or a trypsin-like protease. Examples of alkaline proteases are subtilisins, especially those derived from Bacillus, e.g., subtilisin Novo, subtilisin Carlsberg, subtilisin 309, subtilisin 147 and subtilisin 168 (described in WO 89/06279). Examples of trypsin-like proteases are trypsin (e.g. of porcine or bovine origin) and the Fusarium protease described in WO 89/06270.
Preferred commercially available protease enzymes include those sold under the trade names Alcalase, Savinase, Primase, Durazym, and Esperase by Novo Nordisk A/S (Denmark), those sold under the tradename Maxatase, Maxacal, Maxapem, Properase, Purafect and Purafect OXP by Genencor International, and those sold under the tradename opticlean and Optimase by Solvay Enzymes. Protease enzymes may be incorporated into the compositions in accordance with the invention at a level of from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level of from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level of from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level of from 0.01% to 0.2% of enzyme protein by weight of the composition.
Lipases: Any lipase suitable for use in alkaline solutions can be used. Suitable lipases include those of bacterial or fungal origin. Chemically or genetically modified mutants are included.
Examples of useful lipases include a Humicola lanuginosa lipase, e.g., as described in EP 258 068 and EP 305 216, a Rhizomucor miehei lipase, e.g., as described in EP 238 023, a Candida lipase, such as a C. antarctica lipase, e.g., the C. antarctica lipase A or B described in EP 214 761, a Pseudomonas lipase such as a P. alcaligenes and P. pseudoalcaligenes lipase, e.g., as described in EP 218 272, a P. cepacia lipase, e.g., as described in EP 331 376, a P. stutzeri lipase, e.g., as disclosed in GB 1,372,034, a P. fluorescens lipase, a Bacillus lipase, e.g., a B. subtilis lipase (Dartois et al., (1993), Biochemica et Biophysica acta 1131, 253-260), a B. stearothermophilus lipase (JP 64/744992) and a B. pumilus lipase (WO 91/16422).
Furthermore, a number of cloned lipases may be useful, including the Penicillium camembertii lipase described by Yamaguchi et al., (1991), Gene 103, 61-67), the Geotricum candidum lipase (Schimada, Y. et al., (1989), J. Biochem., 106, 383-388), and various Rhizopus lipases such as a R. delemar lipase (Hass, M. J et al., (1991), Gene 109, 117-113), a R. niveus lipase (Kugimiya et al., (1992), Biosci. Biotech. Biochem. 56, 716-719) and a R. oryzae lipase.
Other types of lipolytic enzymes such as cutinases may also be useful, e.g., a cutinase derived from Pseudomonas mendocina as described in WO 88/09367, or a cutinase derived from Fusarium solani pisi (e.g. described in WO 90/09446).
Especially suitable lipases are lipases such as M1 Lipase™, Luma fast™ and Lipomax™ (Genencor), Lipolase™ and Lipolase Ultra™ (Novo Nordisk A/S), and Lipase P “Amano” (Amano Pharmaceutical Co. Ltd.).
The lipases are normally incorporated in the detergent composition at a level of from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level of from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level of from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level of from 0.01% to 0.2% of enzyme protein by weight of the composition.
Amylases: Any amylase (α and/or β) suitable for use in alkaline solutions can be used. Suitable amylases include those of bacterial or fungal origin. Chemically or genetically modified mutants are included. Amylases include, for example, α-amylases obtained from a special strain of B. licheniformis, described in more detail in GB 1,296,839. Commercially available amylases are Duramyl™, Termamyl™, Fungamyl™ and BAN™ (available from Novo Nordisk A/S) and Rapidase™ and Maxamyl P™ (available from Genencor).
The amylases are normally incorporated in the detergent composition at a level of from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level of from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level of from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level of from 0.01% to 0.2% of enzyme protein by weight of the composition.
Cellulases: Any cellulase suitable for use in alkaline solutions can be used. Suitable cellulases include those of bacterial or fungal origin. Chemically or genetically modified mutants are included. Suitable cellulases are disclosed in U.S. Pat. No. 4,435,307, which discloses fungal cellulases produced from Humicola insolens. Especially suitable cellulases are the cellulases having colour care benefits. Examples of such cellulases are cellulases described in European patent application No. 0 495 257.
Commercially available cellulases include Celluzyme™ produced by a strain of Humicola insolens, (Novo Nordisk A/S), and KAC-500(B)™ (Kao Corporation).
Cellulases are normally incorporated in the detergent composition at a level of from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level of from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level of from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level of from 0.01% to 0.2% of enzyme protein by weight of the composition.
Peroxidases/Oxidases: Peroxidase enzymes are used in combination with hydrogen peroxide or a source thereof (e.g. a percarbonate, perborate or persulfate). Oxidase enzymes are used in combination with oxygen. Both types of enzymes are used for “solution bleaching”, i.e. to prevent transfer of a textile dye from a dyed fabric to another fabric when said fabrics are washed together in a wash liquor, preferably together with an enhancing agent as described in e.g. WO 94/12621 and WO 95/01426. Suitable peroxidases/oxidases include those of plant, bacterial or fungal origin. Chemically or genetically modified mutants are included.
Peroxidase and/or oxidase enzymes are normally incorporated in the detergent composition at a level of from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level of from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level of from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level of from 0.01% to 0.2% of enzyme protein by weight of the composition.
Mixtures of the above mentioned enzymes are encompassed herein, in particular a mixture of a protease, an amylase, a lipase and/or a cellulase.
The enzyme of the invention, or any other enzyme incorporated in the detergent composition, is normally incorporated in the detergent composition at a level from 0.00001% to 2% of enzyme protein by weight of the composition, preferably at a level from 0.0001% to 1% of enzyme protein by weight of the composition, more preferably at a level from 0.001% to 0.5% of enzyme protein by weight of the composition, even more preferably at a level from 0.01% to 0.2% of enzyme protein by weight of the composition.
Bleaching agents: Additional optional detergent ingredients that can be included in the detergent compositions of the present invention include bleaching agents such as PB1, PB4 and percarbonate with a particle size of 400-800 microns. These bleaching agent components can include one or more oxygen bleaching agents and, depending upon the bleaching agent chosen, one or more bleach activators. When present oxygen bleaching compounds will typically be present at levels of from about 1% to about 25%. In general, bleaching compounds are optional added components in non-liquid formulations, e.g. granular detergents.
The bleaching agent component for use herein can be any of the bleaching agents useful for detergent compositions including oxygen bleaches as well as others known in the art.
The bleaching agent suitable for the present invention can be an activated or non-activated bleaching agent.
One category of oxygen bleaching agent that can be used encompasses percarboxylic acid bleaching agents and salts thereof. Suitable examples of this class of agents include magnesium monoperoxyphthalate hexahydrate, the magnesium salt of meta-chloro perbenzoic acid, 4-nonylamino-4-oxoperoxybutyric acid and diperoxydodecanedioic acid. Such bleaching agents are disclosed in U.S. Pat. Nos. 4,483,781, 740,446, EP 0 133 354 and U.S Pat. No. 4,412,934. Highly preferred bleaching agents also include 6-nonylamino-6-oxoperoxycaproic acid as described in U.S. Pat. No. 4,634,551.
Another category of bleaching agents that can be used encompasses the halogen bleaching agents. Examples of hypohalite bleaching agents, for example, include trichloro isocyanuric acid and the sodium and potassium dichloroisocyanurates and N-chloro and N-bromo alkane sulphonamides. Such materials are normally added at 0.5-10% by weight of the finished product, preferably 1-5% by weight.
The hydrogen peroxide releasing agents can be used in combination with bleach activators such as tetra-acetylethylenediamine (TAED), nonanoyloxybenzenesulfonate (NOBS, described in U.S. Pat. No. 4,412,934), 3,5-trimethyl-hexsanoloxybenzenesulfonate (ISONOBS, described in EP 120 591) or pentaacetylglucose (PAG), which are perhydrolyzed to form a peracid as the active bleaching species, leading to improved bleaching effect. In addition, very suitable are the bleach activators C8(6-octanamido-caproyl) oxybenzene-sulfonate, C9(6-nonanamido caproyl) oxybenzenesulfonate and C10 (6-decanamido caproyl) oxybenzenesulfonate or mixtures thereof. Also suitable activators are acylated citrate esters such as disclosed in European Patent Application No. 91870207.7.
Useful bleaching agents, including peroxyacids and bleaching systems comprising bleach activators and peroxygen bleaching compounds for use in cleaning compositions according to the invention are described in application U.S. Ser. No. 08/136,626.
The hydrogen peroxide may also be present by adding an enzymatic system (i.e. an enzyme and a substrate therefore) which is capable of generation of hydrogen peroxide at the beginning or during the washing and/or rinsing process. Such enzymatic systems are disclosed in European Patent Application EP 0 537 381.
Bleaching agents other than oxygen bleaching agents are also known in the art and can be utilized herein. One type of non-oxygen bleaching agent of particular interest includes photoactivated bleaching agents such as the sulfonated zinc and/or aluminium phthalocyanines. These materials can be deposited upon the substrate during the washing process. Upon irradiation with light, in the presence of oxygen, such as by hanging clothes out to dry in the daylight, the sulfonated zinc phthalocyanine is activated and, consequently, the substrate is bleached. Preferred zinc phthalocyanine and a photoactivated bleaching process are described in U.S. Pat. No. 4,033,718. Typically, detergent composition will contain about 0.025% to about 1.25%, by weight, of sulfonated zinc phthalocyanine.
Bleaching agents may also comprise a manganese catalyst. The manganese catalyst may, e.g., be one of the compounds described in “Efficient manganese catalysts for low-temperature bleaching”, Nature 369, 1994, pp. 637-639.
Suds suppressors: Another optional ingredient is a suds suppressor, exemplified by silicones, and silica-silicone mixtures. Silicones can generally be represented by alkylated polysiloxane materials, while silica is normally used in finely divided forms exemplified by silica aerogels and xerogels and hydrophobic silicas of various types. Theses materials can be incorporated as particulates, in which the suds suppressor is advantageously releasably incorporated in a water-soluble or waterdispersible, substantially non surface-active detergent impermeable carrier. Alternatively the suds suppressor can be dissolved or dispersed in a liquid carrier and applied by spraying on to one or more of the other components.
A preferred silicone suds controlling agent is disclosed in U.S. Pat. No. 3,933,672. Other particularly useful suds suppressors are the self-emulsifying silicone suds suppressors, described in German Patent Application DTOS 2,646,126. An example of such a compound is DC-544, commercially available form Dow Corning, which is a siloxane-glycol copolymer. Especially preferred suds controlling agent are the suds suppressor system comprising a mixture of silicone oils and 2-alkyl-alkanols. Suitable 2-alkyl-alkanols are 2-butyl-octanol which are commercially available under the trade name Isofol 12 R.
Such suds suppressor system are described in European Patent Application EP 0 593 841.
Especially preferred silicone suds controlling agents are described in European Patent Application No. 92201649.8. Said compositions can comprise a silicone/silica mixture in combination with fumed nonporous silica such as Aerosil R .
The suds suppressors described above are normally employed at levels of from 0.001% to 2% by weight of the composition, preferably from 0.01% to 1% by weight.
Other components: Other components used in detergent compositions may be employed such as soil-suspending agents, soil-releasing agents, optical brighteners, abrasives, bactericides, tarnish inhibitors, coloring agents, and/or encapsulated or nonencapsulated perfumes.
Especially suitable encapsulating materials are water soluble capsules which consist of a matrix of polysaccharide and polyhydroxy compounds such as described in GB 1,464,616.
Other suitable water soluble encapsulating materials comprise dextrins derived from ungelatinized starch acid esters of substituted dicarboxylic acids such as described in U.S. Pat. No. 3,455,838. These acid-ester dextrins are, preferably, prepared from such starches as waxy maize, waxy sorghum, sago, tapioca and potato. Suitable examples of said encapsulation materials include N-Lok manufactured by National Starch. The N-Lok encapsulating material consists of a modified maize starch and glucose. The starch is modified by adding monofunctional substituted groups such as octenyl succinic acid anhydride.
Antiredeposition and soil suspension agents suitable herein include cellulose derivatives such as methylcellulose, carboxymethylcellulose and hydroxyethylcellulose, and homo- or co-polymeric polycarboxylic acids or their salts. Polymers of this type include the polyacrylates and maleic anhydride-acrylic acid copolymers previously mentioned as builders, as well as copolymers of maleic anhydride with ethylene, methylvinyl ether or methacrylic acid, the maleic anhydride constituting at least mole percent of the copolymer. These materials are normally used at levels of from 0.5% to 10% by weight, more preferably form 0.75% to 8%, most preferably from 1% to 6% by weight of the composition.
Preferred optical brighteners are anionic in character, examples of which are disodium 4,4′-bis-(2-diethanolamino-4-anilino-s-triazin-6-ylamino)stilbene-2:2′ disulphonate, disodium 4,-4′-bis-(2-morpholino-4-anilino-s-triazin-6-ylamino-stilbene-2:2′-disulphonate, disodium 4,4′-bis-(2,4-dianilino-s-triazin-6-ylamino)stilbene-2:2′-disulphonate, monosodium 4′,4″-bis-(2,4-dianilino-s-tri-azin-6 ylamino)stilbene-2-sulphonate, disodium 4,4′-bis-(2-anilino-4-(N-methyl-N-2-hydroxyethylamino)-s-triazin-6-ylamino)stilbene-2,2′-disulphonate, di-sodium 4,4′-bis-(4-phenyl-2,1,3-triazol-2-yl)-stilbene-2,2′ disulphonate, di-so-dium 4,4′bis(2-anilino-4-(1-methyl-2-hydroxyethylamino)-s-triazin-6-ylami-no)stilbene-2,2′disulphonate, sodium 2(stilbyl-4″-(naphtho-1′,2′:4,5)-1,2,3,-triazole-2″-sulphonate and 4,4″-bis(2-sulphostyryl)biphenyl.
Other useful polymeric materials are the polyethylene glycols, particularly those of molecular weight 1000-10000, more particularly 2000 to 8000 and most preferably about 4000. These are used at levels of from 0.20% to 5% more preferably from 0.25% to 2.5% by weight. These polymers and the previously mentioned homo- or co-polymeric poly-carboxylate salts are valuable for improving whiteness maintenance, fabric ash deposition, and cleaning performance on clay, proteinaceous and oxidizable soils in the presence of transition metal impurities.
Soil release agents useful in compositions of the present invention are conventionally copolymers or terpolymers of terephthalic acid with ethylene glycol and/or propylene glycol units in various arrangements. Examples of such polymers are disclosed in U.S. Pat. Nos. 4,116,885 and 4,711,730 and EP 0 272 033. A particular preferred polymer in accordance with EP 0 272 033 has the formula:
(CH 3 (PEG) 43 ) 0.75 (POH) 0.25 [T—PO) 2.8 (T—PEG) 0.4 ]T(POH) 0.25 ((PEG) 43 —CH 3 ) 0.75
where PEG is —(OC 2 H 4 )O—, PO is (OC 3 H 6 O) and T is (POOC 6 H 4 CO).
Also very useful are modified polyesters as random copolymers of dimethyl terephthalate, dimethyl sulfoisophthalate, ethylene glycol and 1,2-propanediol, the end groups consisting primarily of sulphobenzoate and secondarily of mono esters of ethylene glycol and/or 1,2-propanediol. The target is to obtain a polymer capped at both end by sulphobenzoate groups, “primarily”, in the present context most of said copolymers herein will be endcapped by sulphobenzoate groups. However, some copolymers will be less than fully capped, and therefore their end groups may consist of monoester of ethylene glycol and/or 1,2-propanediol, thereof consist “secondarily” of such species.
The selected polyesters herein contain about 46% by weight of dimethyl terephthalic acid, about 16% by weight of 1,2-propanediol, about 10% by weight ethylene glycol, about 13% by weight of dimethyl sulfobenzoic acid and about 15% by weight of sulfoisophthalic acid, and have a molecular weight of about 3.000. The polyesters and their method of preparation are described in detail in EP 311 342.
Softening agents: Fabric softening agents can also be incorporated into laundry detergent compositions in accordance with the present invention. These agents may be inorganic or organic in type. Inorganic softening agents are exemplified by the smectite clays disclosed in GB-A-1 400898 and in U.S. Pat. No. 5,019,292. Organic fabric softening agents include the water insoluble tertiary amines as disclosed in GB-A1 514 276 and EP 0 011 340 and their combination with mono C 12 -C 14 quaternary ammonium salts are disclosed in EP-B-0 026 528 and di-long-chain amides as disclosed in EP 0 242 919. Other useful organic ingredients of fabric softening systems include high molecular weight polyethylene oxide materials as disclosed in EP 0 299 575 and 0 313 146.
Levels of smectite clay are normally in the range from 5% to 15%, more preferably from 8% to 12% by weight, with the material being added as a dry mixed component to the remainder of the formulation. Organic fabric softening agents such as the water-insoluble tertiary amines or dilong chain amide materials are incorporated at levels of from 0.5% to 5% by weight, normally from 1% to 3% by weight whilst the high molecular weight polyethylene oxide materials and the water soluble cationic materials are added at levels of from 0.1% to 2%, normally from 0.15% to 1.5% by weight. These materials are normally added to the spray dried portion of the composition, although in some instances it may be more convenient to add them as a dry mixed particulate, or spray them as molten liquid on to other solid components of the composition.
Polymeric dye-transfer inhibiting agents: The detergent compositions according to the present invention may also comprise from 0.001% to 10%, preferably from 0.01% to 2%, more preferably form 0.05% to 1% by weight of polymeric dye-transfer inhibiting agents. Said polymeric dye-transfer inhibiting agents are normally incorporated into detergent compositions in order to inhibit the transfer of dyes from colored fabrics onto fabrics washed therewith. These polymers have the ability of complexing or adsorbing the fugitive dyes washed out of dyed fabrics before the dyes have the opportunity to become attached to other articles in the wash.
Especially suitable polymeric dye-transfer inhibiting agents are polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinylpyrrolidone polymers, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof.
Addition of such polymers also enhances the performance of the enzymes according the invention.
The detergent composition according to the invention can be in liquid, paste, gels, bars or granular forms.
Non-dusting granulates may be produced, e.g., as disclosed in U.S. Pat. Nos. 4,106,991 and 4,661,452 (both to Novo Industri A/S) and may optionally be coated by methods known in the art. Examples of—waxy coating materials are poly(ethylene oxide) products (polyethyleneglycol, PEG) with mean molecular weights of 1000 to 20000; ethoxylated nonylphenols having from 16 to 50 ethylene oxide units; ethoxylated fatty alcohols in which the alcohol contains from 12 to 20 carbon atoms and in which there are 15 to 80 ethylene oxide units; fatty alcohols; fatty acids; and mono- and di- and triglycerides of fatty acids. Examples of film-forming coating materials suitable for application by fluid bed techniques are given in GB 1483591.
Granular compositions according to the present invention can also be in “compact form”, i.e. they may have a relatively higher density than conventional granular detergents, i.e. form 550 to 950 g/l; in such case, the granular detergent compositions according to the present invention will contain a lower amount of “Inorganic filler salt”, compared to conventional granular detergents; typical filler salts are alkaline earth metal salts of sulphates and chlorides, typically sodium sulphate; “Compact” detergent typically comprise not more than 10% filler salt. The liquid compositions according to the present invention can also be in “concentrated form”, in such case, the liquid detergent compositions according to the present invention will contain a lower amount of water, compared to conventional liquid detergents. Typically, the water content of the concentrated liquid detergent is less than 30%, more preferably less than 20%, most preferably less than 10% by weight of the detergent compositions.
The compositions of the invention may for example, be formulated as hand and machine laundry detergent compositions including laundry additive compositions and compositions suitable for use in the pretreatment of stained fabrics, rinse added fabric softener compositions, and compositions for use in general household hard surface cleaning operations and dishwashing operations.
The following examples are meant to exemplify compositions for the present invention, but are not necessarily meant to limit or otherwise define the scope of the invention.
In the detergent compositions, the abbreviated component identifications have the following meanings:
LAS: Sodium linear C 12 alkyl benzene sulphonate
TAS: Sodium tallow alkyl sulphate
XYAS: Sodium C 1X —C 1Y alkyl sulfate
SS: soap surfactant of formula 2-butyl octanoic
acid
25EY: A C 12 —C 15 predominantly linear primary alcohol
condensed with an average of Y moles of ethylene oxide
45EY: A C 14 —C 15 predominantly linear primary alcohol
condensed with an average of Y moles of ethylene oxide
XYEZS: C 1X —C 1Y sodium alkyl sulfate condensed with an
average of Z moles of ethylene oxide per mole
Nonionic: C 13 —C 15 mixed ethoxylated/propoxylated fatty alcohol
with an average degree of ethoxylation of 3.8 and an average
degree of propoxylation of 4.5 sold under the tradename Plurafax
LF404 by BASF Gmbh
CFAA: C 12 —C 14 alkyl N-methyl glucamide
TFAA: C 16 —C 18 alkyl N-methyl glucamide
Silicate: Amorphous Sodium Silicate (SiO 2 :Na 2 O ratio = 2.0)
NaSKS-6: Crystalline layered silicate of formula δ-Na 2 Si 2 O 5
Carbonate: Anhydrous sodium carbonate
Phosphate: Sodium tripolyphosphate
MA/AA: Copolymer of 1:4 maleic/acrylic acid, average
molecular weight about 80,000
Polyacrylate: Polyacrylate homopolymer with an average
molecular weight of 8,000 sold under the tradename PA30 by BASF
Gmbh
Zeolite A: Hydrated Sodium Aluminosilicate of formula
Na 12 (AlO 2 SiO 2 ) 12 . 27H 2 O
having a primary particle size in the range
from 1 to 10 micrometers
Citrate: Tri-sodium citrate dihydrate
Citric: Citric Acid
Perborate: Anhydrous sodium perborate monohydrate bleach,
empirical formula NaBO 2 . H 2 O 2
PB4: Anhydrous sodium perborate tetrahydrate
Percarbonate: Anhydrous sodium percarbonate bleach of
empirical formula 2Na 2 CO 3 . 3H 2 O 2
TAED: Tetraacetyl ethylene diamine
CMC: Sodium carboxymethyl cellulose
DETPMP: Diethylene triamine penta (methylene phosphonic
acid), marketed by Monsanto under the Tradename
Dequest 2060
PVP: Polyvinylpyrrolidone polymer
EDDS: Ethylenediamine-N, N′-disuccinic acid, [S,S]
isomer in the form of the sodium salt
Suds 25% paraffin wax Mpt 50° C., 17% hydrophobic
silica, 58% Suppressor: paraffin oil
Granular Suds 12% Silicone/silica, 18% stearyl alcohol, 70%
suppressor: starch in granular form
Sulphate: Anhydrous sodium sulphate
HMWPEO: High molecular weight polyethylene oxide
TAE 25: Tallow alcohol ethoxylate (25)
Detergent Example I
A granular fabric cleaning composition in accordance with the invention may be prepared as follows:
Sodium linear C 12 alkyl
6.5
benzene sulfonate
Sodium sulfate
15.0
Zeolite A
26.0
Sodium nitrilotriacetate
5.0
Enzyme of the invention
0.1
PVP
0.5
TAED
3.0
Boric acid
4.0
Perborate
18.0
Phenol sulphonate
0.1
Minors
Up to 100
Detergent Example II
A compact granular fabric cleaning composition (density 800 g/l) in accord with the invention may be prepared as follows:
45AS
8.0
25E3S
2.0
25E5
3.0
25E3
3.0
TFAA
2.5
Zeolite A
17.0
NaSKS-6
12.0
Citric acid
3.0
Carbonate
7.0
MA/AA
5.0
CMC
0.4
Enzyme of the invention
0.1
TAED
6.0
Percarbonate
22.0
EDDS
0.3
Granular suds suppressor
3.5
water/minors
Up to 100%
Detergent Example III
Granular fabric cleaning compositions in accordance with the invention which are especially useful in the laundering of coloured fabrics were prepared as follows:
LAS
10.7
—
TAS
2.4
—
TFAA
—
4.0
45AS
3.1
10.0
45E7
4.0
—
25E3S
—
3.0
68E11
1.8
—
25E5
—
8.0
Citrate
15.0
7.0
Carbonate
—
10
Citric acid
2.5
3.0
Zeolite A
32.1
25.0
Na-SKS-6
—
9.0
MA/AA
5.0
5.0
DETPMP
0.2
0.8
Enzyme of the invention
0.10
0.05
Silicate
2.5
—
Sulphate
5.2
3.0
PVP
0.5
—
Poly (4-vinylpyridine)-N-
—
0.2
Oxide/copolymer of vinyl-
imidazole and vinyl-
pyrrolidone
Perborate
1.0
—
Phenol sulfonate
0.2
—
Water/Minors
Up to 100%
Detergent Example IV
Granular fabric cleaning compositions in accordance with the invention which provide “Softening through the wash” capability may be prepared as follows:
45AS
—
10.0
LAS
7.6
—
68AS
1.3
—
45E7
4.0
—
25E3
—
5.0
Coco-alkyl-dimethyl hydroxy-
1.4
1.0
ethyl ammonium chloride
Citrate
5.0
3.0
Na-SKS-6
—
11.0
Zeolite A
15.0
15.0
MA/AA
4.0
4.0
DETPMP
0.4
0.4
Perborate
15.0
—
Percarbonate
—
15.0
TAED
5.0
5.0
Smectite clay
10.0
10.0
HMWPEO
—
0.1
Enzyme of the invention
0.10
0.05
Silicate
3.0
5.0
Carbonate
10.0
10.0
Granular suds suppressor
1.0
4.0
CMC
0.2
0.1
Water/Minors
Up to 100%
Detergent Example V
Heavy duty liquid fabric cleaning compositions in accordance with the invention may be prepared as follows:
I
II
LAS acid form
—
25.0
Citric acid
5.0
2.0
25AS acid form
8.0
—
25AE2S acid form
3.0
—
25AE7
8.0
—
CFAA
5
—
DETPMP
1.0
1.0
Fatty acid
8
—
Oleic acid
—
1.0
Ethanol
4.0
6.0
Propanediol
2.0
6.0
Enzyme of the invention
0.10
0.05
Coco-alkyl dimethyl
—
3.0
hydroxy ethyl ammonium
chloride
Smectite clay
—
5.0
PVP
2.0
—
Water/Minors
Up to 100%
Leather Industry Applications
A subtilase of the invention may be used in the leather industry, in particular for use in depilation of skins.
In said application a subtilase variant of the invention is preferably used in an enzyme composition which further comprise another protease.
For a more detailed description of suitable other proteases see section relating to suitable enzymes for use in a detergent composition (vide supra).
Wool Industry Applications
A subtilase of the invention may be used in the wool industry, in particular for use in cleaning of clothes comprising wool.
In said application a subtilase variant of the invention is preferably used in an enzyme composition which further comprise another protease.
For a more detailed description of suitable other proteases see section relating to suitable enzymes for use in a detergent composition (vide supra).
The invention is described in further detail in the following examples which are not in any way intended to limit the scope of the invention as claimed.
Materials and Methods
Strains
B. subtilis DN1885 (Diderichsen et al., 1990).
B. lentus 309 and 147 are specific strains of Bacillus lentus, deposited with the NCIB and accorded the accession numbers NCIB 10309 and 10147, and described in U.S. Pat. No. 3,723,250 incorporated by reference herein.
E. coli MC 1000 (M. J. Casadaban and S. N. Cohen (1980); J. Mol. Biol. 138 179-207), was made r − ,m + by conventional methods and is also described in U.S. patent application Ser. No. 039,298.
Plasmids
pJS3: E. coli - B. subtilis shuttle vector containing a synthetic gene encoding for subtilase 309. (Described by Jacob Schiødt et al. in Protein and Peptide letters 3:39-44 (1996)).
pSX222: B. subtilis expression vector (Described in WO 96/34946).
General Molecular Biology Methods
Unless otherwise mentioned the DNA manipulations and transformations were performed using standard methods of molecular biology (Sambrook et al. (1989) Molecular cloning: A laboratory manual, Cold Spring Harbor lab., Cold Spring Harbor, N.Y.; Ausubel, F. M. et al. (eds.) “Current protocols in Molecular Biology”. John Wiley and Sons, 1995; Harwood, C. R., and Cutting, S. M. (eds.) “Molecular Biological Methods for Bacillus”. John Wiley and Sons, 1990).
Enzymes for DNA manipulations were used according to the specifications of the suppliers.
Enzymes for DNA Manipulations
Unless otherwise mentioned all enzymes for DNA manipulations, such as e.g. restiction endonucleases, ligases etc., are obtained from New England Biolabs, Inc.
Proteolytic Activity
In the context of this invention proteolytic activity is expressed in Kilo NOVO Protease Units (KNPU). The activity is determined relatively to an enzyme standard (SAVINASEÔ), and the determination is based on the digestion of a dimethyl casein (DMC) solution by the proteolytic enzyme at standard conditions, i.e. 50° C., pH 8.3, 9 min. reaction time, 3 min. measuring time. A folder AF 220/1 is available upon request to Novo Nordisk A/S, Denmark, which folder is hereby included by reference.
A GU is a Glycine Unit, defined as the proteolytic enzyme activity which, under standard conditions, during a 15-minutes' incubation at 40 deg C., with N-acetyl casein as substrate, produces an amount of NH 2 -group equivalent to 1 mmole of glycine.
Enzyme activity can also be measured using the PNA assay, according to reaction with the soluble substrate succinyl-alanine-alanine-proline-phenyl-alanine-para-nitrophenol, which is described in the Journal of American Oil Chemists Society, Rothgeb, T. M., Goodlander, B. D., Garrison, P. H., and Smith, L. A., (1988).
Fermentation
Fermentation of subtilase enzymes were performed at 300° C. on a rotary shaking table (300 r.p.m.) in 500 ml baffled Erlenmeyer flasks containing 100 ml BPX medium for 5 days.
Consequently in order to make an e.g 2 liter broth 20 Erlenmeyer flasks were fermented simultaneously.
Media:
BPX: Composition (per liter)
Potato starch
100
g
Ground barley
50
g
Soybean flour
20
g
Na 2 HPO 4 X 12 H 2 O
9
g
Pluronic
0.1
g
Sodium caseinate
10
g
The starch in the medium is liquified with α-amylase and the medium is sterilized by heating at 120° C. for 45 minutes. After sterilization the pH of the medium is adjusted to 9 by addition of NaHCO 3 to 0.1 M.
EXAMPLES
Example 1
Construction and Expression of Enzyme Variants:Construction and Expression of Enzyme Variants:Construction and Expression of Enzyme Variants:Construction and Expression of Enzyme Variants:Construction and Expression of Enzyme Variants:Construction and Expression of Enzyme Variants
Site-directed mutagenesis:
Subtilase 309 site-directed variants was made by the “Unique site elimination (USE)” or the “Uracil-USE” technique described respectively by Deng et al. (Anal. Biochem. 200:81-88 (1992)) and Markvardsen et al. (BioTechniques 18(3):371-372 (1995)).
The template plasmid was pJS3, or a analogue of this containing a variant of Subtilase 309, e.g. USE mutagenesis was performed on pJS3 analogue containing a gene encoding the T134A variant with a oligonucleotide directed to the construct Q137L variant resulting in a final T134A+Q137L Subtilase 309 variant.
The in pJS3 constructed Subtilase 309 variants was then subcloned into the B.subtilis pSX222 expression plasmid, using the restriction enzymes KpnI and MluI.
Localized Random mutagenesis:
The overall strategy to used to perform localized random mutagenesis was:
a mutagenic primer (oligonucleotide) was synthesized which corresponds to the part of the DNA sequence to be mutagenized except for the nucleotide(s) corresponding to amino acid codon(s) to be mutagenized.
Subsequently, the resulting mutagenic primer was used in a PCR reaction with a suitable opposite primer. The resulting PCR fragment was purified and digested and cloned into a E.coli - B.subtilis shuttle vector.
Alternatively and if necessary, the resulting PCR fragment is used in a second PCR reaction as a primer with a second suitable opposite primer so as to allow digestion and cloning of the mutagenized region into the shuttle vector. The PCR reactions are performed under normal conditions.
Following this strategy a localized random library was constructed in SAVINASE wherein both position T134 and Q137 was completely randomized.
One oligonucleotide was synthesized with 25% of each of the four bases (N) in the first and the second base at amino acid codons wanted to be mutagenized. The third nucleotide (the wobble base) in codons were synthesized with 50%G/50%C (S) to avoid two (TAA, TGA) of the three stop-codons.
The mutagenic primer (5′-G AAC GCC TCT AGA AGT CGC GCT ATT AAC AGC SNN CTC GAG SNN GGC ACT TGG CGA AGG GCT TCC-3′ (anti-sense (SEQ ID NO: 11)) were used in a PCR reaction with a suitab opposite primer (e.g. 5′ GAA CTC GAT CCA GCG ATT TC 3′ (sense)(SEQ ID NO:12)) and the plasmid pJS3 as template. This resulting PCR product was cloned into the pJS3 shuttle vector by using the restriction enzymes HindIII and XbaI.
The in pJS3 constructed localized random library was then subcloned into the B.subtilis pSX222 expression plasmid, using the restriction enzymes KpnI and MluI.
The library prepared contained approximately 100,000 individual clones/library.
Ten randomly chosen colonies were sequenced to confirm the mutations designed.
In order to purify a subtilase variant of the invention the B.subtilis pSX222 expression plasmid comprising a variant of the invention was transformed into a competent B. subtilis strain and was fermented as described above in a medium containing 10 μg/ml Chloramphenicol (CAM).
EXAMPLE 2
Purification of Enzyme Variants: Purification of Enzyme Variants:Purification of Enzyme Variants:Purification of Enzyme Variants:Purification of Enzyme Variants:Purification of Enzyme Variants
This procedure relates to purification of a 2 liter scale fermentation of the Subtilisin 147 enzyme, the Subtilisin 309 enzyme or mutants thereof.
Approximately 1.6 liters of fermentation broth were centrifuged at 5000 rpm for 35 minutes in 1 liter beakers. The supernatants were adjusted to pH 6.5 using 10% acetic acid and filtered on Seitz Supra S100 filter plates.
The filtrates were concentrated to approximately 400 ml using an Amicon CH2A UF unit equipped with an Amicon S1Y10 UF cartridge. The UF concentrate was centrifuged and filtered prior to absorption at room temperature on a Bacitracin affinity column at pH 7. The protease was eluted from the Bacitracin column at room temperature using 25% 2-propanol and 1 M sodium chloride in a buffer solution with 0.01 dimethylglutaric acid, 0.1 M boric acid and 0.002 M calcium chloride adjusted to pH 7.
The fractions with protease activity from the Bacitracin purification step were combined and applied to a 750 ml Sephadex G25 column (5 cm dia.) equilibrated with a buffer containing 0.01 dimethylglutaric acid, 0.2 M boric acid and 0.002 m calcium chloride adjusted to pH 6.5.
Fractions with proteolytic activity from the Sephadex G25 column were combined and applied to a 150 ml CM Sepharose CL 6B cation exchange column (5 cm dia.) equilibrated with a buffer containing 0.01 M dimethylglutaric acid, 0.2 M boric acid, and 0.002 M calcium chloride adjusted to pH 6.5.
The protease was eluted using a linear gradient of 0-0.1 M sodium chloride in 2 liters of the same buffer (0-0.2 M sodium chloride in case of Subtilisin 147).
In a final purification step protease containing fractions from the CM Sepharose column were combined and concentrated in an Amicon ultrafiltration cell equipped with a GR81PP membrane (from the Danish Sugar Factories Inc.).
By using the techniques of Example 1 for the construction and the above isolation procedure the following subtilisin 309 variants were produced and isolated:
T134A+Q137L
T134S+Q137L
T134A+Q137E
Q137F
Q137L
T134V+Q137T
T134V+Q137L
T134C+Q137S
T134A+Q137C
Q137C; and
Q137D.
EXAMPLE 3
Wash Performance of Detergent Compositions Comprising Enzyme VariantsWash Performance of Detergent Compositions Comprising Enzyme VariantsWash Performance of Detergent Compositions Comprising Enzyme VariantsWash Performance of Detergent Compositions Comprising Enzyme VariantsWash Performance of Detergent Compositions Comprising Enzyme VariantsWash Performance of Detergent Compositions Comprising Enzyme Variants
The following examples provide results from a number of washing tests that were conducted under the conditions indicated
Experimental Conditions
TABLE IV
Experimental conditions for evaluation of Subtilisin
309 variants.
Detergent
Protease Model Detergent 95
Detergent dose
3.0 g/l
pH
10.5
Wash time
10 min.
Temperature
15° C.
Water hardness
6°dH
Enzymes
Subtilisin 309 variants as
listed below
Enzyme conc.
10 nM
Test system
150 ml glass beakers with a
stirring rod
Textile/volume
5 textile pieces (Ø 2.5 cm)
in 50 ml detergent
Test material
EMPA117 from Center for
Testmaterials, Holland
The detergent used is a simple model formulation. pH is adjusted to 10.5 which is within the normal range for a powder detergent. The composition of model detergent 95 is as follows:
25%
STP (Na 5 P 3 O 10 )
25%
Na 2 SO 4
10%
Na 2 CO 3
20%
LAS (Nansa 80S)
5.0%
Nonionic tenside (Dobanol 25-7)
5.0%
Na 2 Si 2 O 5
0.5%
Carboxymethylcellulose (CMC)
9.5%
Water
Water hardness was adjusted by adding CaCl 2 and MgCl 2 (Ca 2+ :Mg 2+ =2:1) to deionized water (see also Surfactants in Consumer Products—Theory, Technology and Application, Springer Verlag 1986). pH of the detergent solution was adjusted to pH 10.5 by addition of HCl.
Measurement of reflectance (R) on the test material was done at 460 nm using a Macbeth ColorEye 7000 photometer (Macbeth, Division of Kollmorgen Instruments Corporation, Germany). The measurements were done according to the manufacturers protocol.
The wash performance of the Subtilisin 309 variants was evaluated by calculating a performance factor: P = R Variant - R Blank R Savinase - R Blank
P: Performance factor
R Variant : Reflectance of test material washed with variant
R Savinase : Reflectance of test material washed with Savinase®
R Blank : Reflectance of test material washed with no enzyme
The claimed Subtilisin 309 variants all have improved wash performance compared to Savinase®—i.e. P>1.
The variants are divided into improvement classes designated with capital letters:
Class A: 1<P≦1.5
Class B: 1.5<P≦2
Class C: P>2
TABLE V
Subtilisin 309 variants and improvement classes.
Improvement class
Variants
A
T134A + Q137L
T134S + Q137L
T134A + Q137E
Q137F
Q137L
T134V + Q137T
T134V + Q137L
T134C + Q137S
T134A + Q137C
Q137C
Q137D
B
C
12
1
275
PRT
Bacillus
1
Ala Gln Ser Val Pro Tyr Gly Val Ser Gln Ile Lys Ala Pro Ala Leu
1 5 10 15
His Ser Gln Gly Tyr Thr Gly Ser Asn Val Lys Val Ala Val Ile Asp
20 25 30
Ser Gly Ile Asp Ser Ser His Pro Asp Leu Lys Val Ala Gly Gly Ala
35 40 45
Ser Met Val Pro Ser Glu Thr Asn Pro Phe Gln Asp Asn Asn Ser His
50 55 60
Gly Thr His Val Ala Gly Thr Val Ala Ala Leu Asn Asn Ser Ile Gly
65 70 75 80
Val Leu Gly Val Ala Pro Ser Ala Ser Leu Tyr Ala Val Lys Val Leu
85 90 95
Gly Ala Asp Gly Ser Gly Gln Tyr Ser Trp Ile Ile Asn Gly Ile Glu
100 105 110
Trp Ala Ile Ala Asn Asn Met Asp Val Ile Asn Met Ser Leu Gly Gly
115 120 125
Pro Ser Gly Ser Ala Ala Leu Lys Ala Ala Val Asp Lys Ala Val Ala
130 135 140
Ser Gly Val Val Val Ala Ala Ala Ala Gly Asn Glu Gly Thr Ser Gly
145 150 155 160
Ser Ser Ser Thr Val Gly Tyr Pro Gly Lys Tyr Pro Ser Val Ile Ala
165 170 175
Val Gly Ala Val Asp Ser Ser Asn Gln Arg Ala Ser Phe Ser Ser Val
180 185 190
Gly Pro Glu Leu Asp Val Met Ala Pro Gly Val Ser Ile Gln Ser Thr
195 200 205
Leu Pro Gly Asn Lys Tyr Gly Ala Tyr Asn Gly Thr Ser Met Ala Ser
210 215 220
Pro His Val Ala Gly Ala Ala Ala Leu Ile Leu Ser Lys His Pro Asn
225 230 235 240
Trp Thr Asn Thr Gln Val Arg Ser Ser Leu Glu Asn Thr Thr Thr Lys
245 250 255
Leu Gly Asp Ser Phe Tyr Tyr Gly Lys Gly Leu Ile Asn Val Gln Ala
260 265 270
Ala Ala Gln
275
2
268
PRT
Bacillus
2
Gln Thr Val Pro Trp Gly Ile Ser Phe Ile Asn Thr Gln Gln Ala His
1 5 10 15
Asn Arg Gly Ile Phe Gly Asn Gly Ala Arg Val Ala Val Leu Asp Thr
20 25 30
Gly Ile Ala Ser His Pro Asp Leu Arg Ile Ala Gly Gly Ala Ser Phe
35 40 45
Ile Ser Ser Glu Pro Ser Tyr His Asp Asn Asn Gly His Gly Thr His
50 55 60
Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly Val Leu Gly
65 70 75 80
Val Arg Pro Ser Ala Asp Leu Tyr Ala Leu Lys Val Leu Asp Arg Asn
85 90 95
Gly Ser Gly Ser Leu Ala Ser Val Ala Gln Gly Ile Glu Trp Ala Ile
100 105 110
Asn Asn Asn Met His Ile Ile Asn Met Ser Leu Gly Ser Thr Ser Gly
115 120 125
Ser Ser Thr Leu Glu Leu Ala Val Asn Arg Ala Asn Asn Ala Gly Ile
130 135 140
Leu Leu Val Gly Ala Ala Gly Asn Thr Gly Arg Gln Gly Val Asn Tyr
145 150 155 160
Pro Ala Arg Tyr Ser Gly Val Met Ala Val Ala Ala Val Asp Gln Asn
165 170 175
Gly Gln Arg Ala Ser Phe Ser Thr Tyr Gly Pro Glu Ile Glu Ile Ser
180 185 190
Ala Pro Gly Val Asn Val Asn Ser Thr Tyr Thr Gly Asn Arg Tyr Val
195 200 205
Ser Leu Ser Gly Thr Ser Met Ala Thr Pro His Val Ala Gly Val Ala
210 215 220
Ala Leu Val Lys Ser Arg Tyr Pro Ser Tyr Thr Asn Asn Gln Ile Arg
225 230 235 240
Gln Arg Ile Asn Gln Thr Ala Thr Tyr Leu Gly Ser Pro Ser Leu Tyr
245 250 255
Gly Asn Gly Leu Val His Ala Gly Arg Ala Thr Gln
260 265
3
268
PRT
Bacillus
3
Gln Thr Val Pro Trp Gly Ile Asn Arg Val Gln Ala Pro Ile Ala Gln
1 5 10 15
Ser Arg Gly Phe Thr Gly Thr Gly Val Arg Val Ala Val Leu Asp Thr
20 25 30
Gly Ile Ser Asn His Ala Asp Leu Arg Ile Arg Gly Gly Ala Ser Phe
35 40 45
Val Pro Gly Glu Pro Asn Ile Ser Asp Gly Asn Gly His Gly Thr Gln
50 55 60
Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly Val Leu Gly
65 70 75 80
Val Ala Pro Asn Val Asp Leu Tyr Gly Val Lys Val Leu Gly Ala Ser
85 90 95
Gly Ser Gly Ser Ile Ser Gly Ile Ala Gln Gly Leu Gln Trp Ala Ala
100 105 110
Asn Asn Gly Met His Ile Ala Asn Met Ser Leu Gly Ser Ser Ala Gly
115 120 125
Ser Ala Thr Met Glu Gln Ala Val Asn Gln Ala Thr Ala Ser Gly Val
130 135 140
Leu Val Val Ala Ala Ser Gly Asn Ser Gly Ala Gly Asn Val Gly Phe
145 150 155 160
Pro Ala Arg Tyr Ala Asn Ala Met Ala Val Gly Ala Thr Asp Gln Asn
165 170 175
Asn Asn Arg Ala Thr Phe Ser Gln Tyr Gly Ala Gly Leu Asp Ile Val
180 185 190
Ala Pro Gly Val Gly Val Gln Ser Thr Val Pro Gly Asn Gly Tyr Ala
195 200 205
Ser Phe Asn Gly Thr Ser Met Ala Thr Pro His Val Ala Gly Val Ala
210 215 220
Ala Leu Val Lys Gln Lys Asn Pro Ser Trp Ser Asn Val Gln Ile Arg
225 230 235 240
Asn His Leu Lys Asn Thr Ala Thr Asn Leu Gly Asn Thr Thr Gln Phe
245 250 255
Gly Ser Gly Leu Val Asn Ala Glu Ala Ala Thr Arg
260 265
4
269
PRT
Bacillus
4
Ala Gln Ser Val Pro Trp Gly Ile Ser Arg Val Gln Ala Pro Ala Ala
1 5 10 15
His Asn Arg Gly Leu Thr Gly Ser Gly Val Lys Val Ala Val Leu Asp
20 25 30
Thr Gly Ile Ser Thr His Pro Asp Leu Asn Ile Arg Gly Gly Ala Ser
35 40 45
Phe Val Pro Gly Glu Pro Ser Thr Gln Asp Gly Asn Gly His Gly Thr
50 55 60
His Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly Val Leu
65 70 75 80
Gly Val Ala Pro Asn Ala Glu Leu Tyr Ala Val Lys Val Leu Gly Ala
85 90 95
Ser Gly Ser Gly Ser Val Ser Ser Ile Ala Gln Gly Leu Glu Trp Ala
100 105 110
Gly Asn Asn Gly Met His Val Ala Asn Leu Ser Leu Gly Ser Pro Ser
115 120 125
Pro Ser Ala Thr Leu Glu Gln Ala Val Asn Ser Ala Thr Ser Arg Gly
130 135 140
Val Leu Val Val Ala Ala Ser Gly Asn Ser Gly Ala Gly Ser Ile Ser
145 150 155 160
Tyr Pro Ala Arg Tyr Ala Asn Ala Met Ala Val Gly Ala Thr Asp Gln
165 170 175
Asn Asn Asn Arg Ala Ser Phe Ser Gln Tyr Gly Ala Gly Leu Asp Ile
180 185 190
Val Ala Pro Gly Val Asn Val Gln Ser Thr Tyr Pro Gly Ser Thr Tyr
195 200 205
Ala Ser Leu Asn Gly Thr Ser Met Ala Thr Pro His Val Ala Gly Ala
210 215 220
Ala Ala Leu Val Lys Gln Lys Asn Pro Ser Trp Ser Asn Val Gln Ile
225 230 235 240
Arg Asn His Leu Lys Asn Thr Ala Thr Ser Leu Gly Ser Thr Asn Leu
245 250 255
Tyr Gly Ser Gly Leu Val Asn Ala Glu Ala Ala Thr Arg
260 265
5
274
PRT
Bacillus
5
Ala Gln Thr Val Pro Tyr Gly Ile Pro Leu Ile Lys Ala Asp Lys Val
1 5 10 15
Gln Ala Gln Gly Tyr Lys Gly Ala Asn Val Lys Val Gly Ile Ile Asp
20 25 30
Thr Gly Ile Ala Ala Ser His Thr Asp Leu Lys Val Val Gly Gly Ala
35 40 45
Ser Phe Val Ser Gly Glu Ser Tyr Asn Thr Asp Gly Asn Gly His Gly
50 55 60
Thr His Val Ala Gly Thr Val Ala Ala Leu Asp Asn Thr Thr Gly Val
65 70 75 80
Leu Gly Val Ala Pro Asn Val Ser Leu Tyr Ala Ile Lys Val Leu Asn
85 90 95
Ser Ser Gly Ser Gly Thr Tyr Ser Ala Ile Val Ser Gly Ile Glu Trp
100 105 110
Ala Thr Gln Asn Gly Leu Asp Val Ile Asn Met Ser Leu Gly Gly Pro
115 120 125
Ser Gly Ser Thr Ala Leu Lys Gln Ala Val Asp Lys Ala Tyr Ala Ser
130 135 140
Gly Ile Val Val Val Ala Ala Ala Gly Asn Ser Gly Ser Ser Gly Ser
145 150 155 160
Gln Asn Thr Ile Gly Tyr Pro Ala Lys Tyr Asp Ser Val Ile Ala Val
165 170 175
Gly Ala Val Asp Ser Asn Lys Asn Arg Ala Ser Phe Ser Ser Val Gly
180 185 190
Ala Glu Leu Glu Val Met Ala Pro Gly Val Ser Val Tyr Ser Thr Tyr
195 200 205
Pro Ser Asn Thr Tyr Thr Ser Leu Asn Gly Thr Ser Met Ala Ser Pro
210 215 220
His Val Ala Gly Ala Ala Ala Leu Ile Leu Ser Lys Tyr Pro Thr Leu
225 230 235 240
Ser Ala Ser Gln Val Arg Asn Arg Leu Ser Ser Thr Ala Thr Asn Leu
245 250 255
Gly Asp Ser Phe Tyr Tyr Gly Lys Gly Leu Ile Asn Val Glu Ala Ala
260 265 270
Ala Gln
6
279
PRT
Bacillus
6
Tyr Thr Pro Asn Asp Pro Tyr Phe Ser Ser Arg Gln Tyr Gly Pro Gln
1 5 10 15
Lys Ile Gln Ala Pro Gln Ala Trp Asp Ile Ala Glu Gly Ser Gly Ala
20 25 30
Lys Ile Ala Ile Val Asp Thr Gly Val Gln Ser Asn His Pro Asp Leu
35 40 45
Ala Gly Lys Val Val Gly Gly Trp Asp Phe Val Asp Asn Asp Ser Thr
50 55 60
Pro Gln Asn Gly Asn Gly His Gly Thr His Cys Ala Gly Ile Ala Ala
65 70 75 80
Ala Val Thr Asn Asn Ser Thr Gly Ile Ala Gly Thr Ala Pro Lys Ala
85 90 95
Ser Ile Leu Ala Val Arg Val Leu Asp Asn Ser Gly Ser Gly Thr Trp
100 105 110
Thr Ala Val Ala Asn Gly Ile Thr Tyr Ala Ala Asp Gln Gly Ala Lys
115 120 125
Val Ile Ser Leu Ser Leu Gly Gly Thr Val Gly Asn Ser Gly Leu Gln
130 135 140
Gln Ala Val Asn Tyr Ala Trp Asn Lys Gly Ser Val Val Val Ala Ala
145 150 155 160
Ala Gly Asn Ala Gly Asn Thr Ala Pro Asn Tyr Pro Ala Tyr Tyr Ser
165 170 175
Asn Ala Ile Ala Val Ala Ser Thr Asp Gln Asn Asp Asn Lys Ser Ser
180 185 190
Phe Ser Thr Tyr Gly Ser Val Val Asp Val Ala Ala Pro Gly Ser Trp
195 200 205
Ile Tyr Ser Thr Tyr Pro Thr Ser Thr Tyr Ala Ser Leu Ser Gly Thr
210 215 220
Ser Met Ala Thr Pro His Val Ala Gly Val Ala Gly Leu Leu Ala Ser
225 230 235 240
Gln Gly Arg Ser Ala Ser Asn Ile Arg Ala Ala Ile Glu Asn Thr Ala
245 250 255
Asp Lys Ile Ser Gly Thr Gly Thr Tyr Trp Ala Lys Gly Arg Val Asn
260 265 270
Ala Tyr Lys Ala Val Gln Tyr
275
7
269
PRT
Bacillus
7
Ala Gln Ser Val Pro Trp Gly Ile Ser Arg Val Gln Ala Pro Ala Ala
1 5 10 15
His Asn Arg Gly Leu Thr Gly Ser Gly Val Lys Val Ala Val Leu Asp
20 25 30
Thr Gly Ile Ser Thr His Pro Asp Leu Asn Ile Arg Gly Gly Ala Ser
35 40 45
Phe Val Pro Gly Glu Pro Ser Thr Gln Asp Gly Asn Gly His Gly Thr
50 55 60
His Val Ala Gly Thr Ile Ala Ala Leu Asn Asn Ser Ile Gly Val Leu
65 70 75 80
Gly Val Ala Pro Ser Ala Glu Leu Tyr Ala Val Lys Val Leu Gly Ala
85 90 95
Ser Gly Ser Gly Ser Val Ser Ser Ile Ala Gln Gly Leu Glu Trp Ala
100 105 110
Gly Asn Asn Gly Met His Val Ala Asn Leu Ser Leu Gly Ser Pro Ser
115 120 125
Pro Ser Ala Thr Leu Glu Gln Ala Val Asn Ser Ala Thr Ser Arg Gly
130 135 140
Val Leu Val Val Ala Ala Ser Gly Asn Ser Gly Ala Gly Ser Ile Ser
145 150 155 160
Tyr Pro Ala Arg Tyr Ala Asn Ala Met Ala Val Gly Ala Thr Asp Gln
165 170 175
Asn Asn Asn Arg Ala Ser Phe Ser Gln Tyr Gly Ala Gly Leu Asp Ile
180 185 190
Val Ala Pro Gly Val Asn Val Gln Ser Thr Tyr Pro Gly Ser Thr Tyr
195 200 205
Ala Ser Leu Asn Gly Thr Ser Met Ala Thr Pro His Val Ala Gly Ala
210 215 220
Ala Ala Leu Val Lys Gln Lys Asn Pro Ser Trp Ser Asn Val Gln Ile
225 230 235 240
Arg Asn His Leu Lys Asn Thr Ala Thr Ser Leu Gly Ser Thr Asn Leu
245 250 255
Tyr Gly Ser Gly Leu Val Asn Ala Glu Ala Ala Thr Arg
260 265
8
307
PRT
Bacillus
8
Met Asn Gly Glu Ile Arg Leu Ile Pro Tyr Val Thr Asn Glu Gln Ile
1 5 10 15
Met Asp Val Asn Glu Leu Pro Glu Gly Ile Lys Val Ile Lys Ala Pro
20 25 30
Glu Met Trp Ala Lys Gly Val Lys Gly Lys Asn Ile Lys Val Ala Val
35 40 45
Leu Asp Thr Gly Cys Asp Thr Ser His Pro Asp Leu Lys Asn Gln Ile
50 55 60
Ile Gly Gly Lys Asn Phe Ser Asp Asp Asp Gly Gly Lys Glu Asp Ala
65 70 75 80
Ile Ser Asp Tyr Asn Gly His Gly Thr His Val Ala Gly Thr Ile Ala
85 90 95
Ala Asn Asp Ser Asn Gly Gly Ile Ala Gly Val Ala Pro Glu Ala Ser
100 105 110
Leu Leu Ile Val Lys Val Leu Gly Gly Glu Asn Gly Ser Gly Gln Tyr
115 120 125
Glu Trp Ile Ile Asn Gly Ile Asn Tyr Ala Val Glu Gln Lys Val Asp
130 135 140
Ile Ile Ser Met Ser Leu Gly Gly Pro Ser Asp Val Pro Glu Leu Glu
145 150 155 160
Glu Ala Val Lys Asn Ala Val Lys Asn Gly Val Leu Val Val Cys Ala
165 170 175
Ala Gly Asn Glu Gly Asp Gly Asp Glu Arg Thr Glu Glu Leu Ser Tyr
180 185 190
Pro Ala Ala Tyr Asn Glu Val Ile Ala Val Gly Ser Val Ser Val Ala
195 200 205
Arg Glu Leu Ser Glu Phe Ser Asn Ala Asn Lys Glu Ile Asp Leu Val
210 215 220
Ala Pro Gly Glu Asn Ile Leu Ser Thr Leu Pro Asn Lys Lys Tyr Gly
225 230 235 240
Lys Leu Thr Gly Thr Ser Met Ala Ala Pro His Val Ser Gly Ala Leu
245 250 255
Ala Leu Ile Lys Ser Tyr Glu Glu Glu Ser Phe Gln Arg Lys Leu Ser
260 265 270
Glu Ser Glu Val Phe Ala Gln Leu Ile Arg Arg Thr Leu Pro Leu Asp
275 280 285
Ile Ala Lys Thr Leu Ala Gly Asn Gly Phe Leu Tyr Leu Thr Ala Pro
290 295 300
Asp Glu Leu
305
9
281
PRT
Bacillus
9
Ser Asp Gly Thr Asp Thr Ser Asp Asn Phe Glu Gln Trp Asn Leu Glu
1 5 10 15
Pro Ile Gln Val Lys Gln Ala Trp Lys Ala Gly Leu Thr Gly Lys Asn
20 25 30
Ile Lys Ile Ala Val Ile Asp Ser Gly Ile Ser Pro His Asp Asp Leu
35 40 45
Ser Ile Ala Gly Gly Tyr Ser Ala Val Ser Tyr Thr Ser Ser Tyr Lys
50 55 60
Asp Asp Asn Gly His Gly Thr His Val Ala Gly Ile Ile Gly Ala Lys
65 70 75 80
His Asn Gly Tyr Gly Ile Asp Gly Ile Ala Pro Glu Ala Gln Ile Tyr
85 90 95
Ala Val Lys Ala Leu Asp Gln Asn Gly Ser Gly Asp Leu Gln Ser Leu
100 105 110
Leu Gln Gly Ile Asp Trp Ser Ile Ala Asn Arg Met Asp Ile Val Asn
115 120 125
Met Ser Leu Gly Thr Thr Ser Asp Ser Lys Ile Leu His Asp Ala Val
130 135 140
Asn Lys Ala Tyr Glu Gln Gly Val Leu Leu Val Ala Ala Ser Gly Asn
145 150 155 160
Asp Gly Asn Gly Lys Pro Val Asn Tyr Pro Ala Ala Tyr Ser Ser Val
165 170 175
Val Ala Val Ser Ala Thr Asn Glu Lys Asn Gln Leu Ala Ser Phe Ser
180 185 190
Thr Thr Gly Asp Glu Val Glu Phe Ser Ala Pro Gly Thr Asn Ile Thr
195 200 205
Ser Thr Tyr Leu Asn Gln Tyr Tyr Ala Thr Gly Ser Gly Thr Ser Gln
210 215 220
Ala Thr Pro His Ala Ala Ala Met Phe Ala Leu Leu Lys Gln Arg Asp
225 230 235 240
Pro Ala Glu Thr Asn Val Gln Leu Arg Glu Glu Met Arg Lys Asn Ile
245 250 255
Val Asp Leu Gly Thr Ala Gly Arg Asp Gln Gln Phe Gly Tyr Gly Leu
260 265 270
Ile Gln Tyr Lys Ala Gln Ala Thr Asp
275 280
10
345
PRT
Bacillus
10
Leu Arg Gly Leu Glu Gln Ile Ala Gln Tyr Ala Thr Asn Asn Asp Val
1 5 10 15
Leu Tyr Val Thr Pro Lys Pro Glu Tyr Glu Val Leu Asn Asp Val Ala
20 25 30
Arg Gly Ile Val Lys Ala Asp Val Ala Gln Asn Asn Phe Gly Leu Tyr
35 40 45
Gly Gln Gly Gln Ile Val Ala Val Ala Asp Thr Gly Leu Asp Thr Gly
50 55 60
Arg Asn Asp Ser Ser Met His Glu Ala Phe Arg Gly Lys Ile Thr Ala
65 70 75 80
Leu Tyr Ala Leu Gly Arg Thr Asn Asn Ala Asn Asp Pro Asn Gly His
85 90 95
Gly Thr His Val Ala Gly Ser Val Leu Gly Asn Ala Thr Asn Lys Gly
100 105 110
Met Ala Pro Gln Ala Asn Leu Val Phe Gln Ser Ile Met Asp Ser Gly
115 120 125
Gly Gly Leu Gly Gly Leu Pro Ala Asn Leu Gln Thr Leu Phe Ser Gln
130 135 140
Ala Tyr Ser Ala Gly Ala Arg Ile His Thr Asn Ser Trp Gly Ala Pro
145 150 155 160
Val Asn Gly Ala Tyr Thr Thr Asp Ser Arg Asn Val Asp Asp Tyr Val
165 170 175
Arg Lys Asn Asp Met Thr Ile Leu Phe Ala Ala Gly Asn Glu Gly Pro
180 185 190
Gly Ser Gly Thr Ile Ser Ala Pro Gly Thr Ala Lys Asn Ala Ile Thr
195 200 205
Val Gly Ala Thr Glu Asn Leu Arg Pro Ser Phe Gly Ser Tyr Ala Asp
210 215 220
Asn Ile Asn His Val Ala Gln Phe Ser Ser Arg Gly Pro Thr Arg Asp
225 230 235 240
Gly Arg Ile Lys Pro Asp Val Met Ala Pro Gly Thr Tyr Ile Leu Ser
245 250 255
Ala Arg Ser Ser Leu Ala Pro Asp Ser Ser Phe Trp Ala Asn His Asp
260 265 270
Ser Lys Tyr Ala Tyr Met Gly Gly Thr Ser Met Ala Thr Pro Ile Val
275 280 285
Ala Gly Asn Val Ala Gln Leu Arg Glu His Phe Val Lys Asn Arg Gly
290 295 300
Val Thr Pro Lys Pro Ser Leu Leu Lys Ala Ala Leu Ile Ala Gly Ala
305 310 315 320
Ala Asp Val Gly Leu Gly Phe Pro Asn Gly Asn Gln Gly Trp Gly Arg
325 330 335
Val Thr Leu Asp Lys Ser Leu Asn Val
340 345
11
64
DNA
Artificial Sequence
Primer
11
gaacgcctct agaagtcgcg ctattaacag csnnctcgag snnggcactt ggcgaagggc 60
ttcc 64
12
20
DNA
Artificial sequence
Primer
12
gaactcgatc cagcgatttc 20
|
Enzymes produced by mutating the genes for a number of subtilases and expressing the mutated genes in suitable hosts are presented.
The enzymes exhibit improved wash performance in any detergent in comparison to their wild type parent enzymes.
| 2
|
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments disclosed herein relate generally to a thermoplastic foam shock absorbing layer. In another aspect, embodiments described herein relate to a synthetic turf including a thermoplastic foam shock absorbing layer, where the foam may be recyclable.
[0003] 2. Background
[0004] Artificial turf consists of a multitude of artificial grass tufts extending upward from a sheet substrate. The turf is usually laid upon a prepared, flat ground surface to form a game playing field intended to simulate a natural grass playing field surface.
[0005] For some types of games, a resilient underpad is placed beneath the turf and upon the firm ground support surface to provide a shock absorbing effect. Also, in some instances, a layer of sand or other particulate material is placed upon the upper surface of the carpet base sheet and around the strands. An example of this type of construction is shown in U.S. Pat. No. 4,389,435 issued Jun. 21, 1983 to Frederick T. Haas, Jr. Another example is shown in U.S. Pat. No. 4,637,942 issued Jan. 20, 1987 to Seymour A. Tomarin.
[0006] Further, examples of artificial turfs which are formed with the grass-like carpet placed upon a resilient underpad are disclosed in U.S. Pat. No. 3,551,263 issued Dec. 29, 1970 to Carter et al., which discloses a polyurethane foam underpad; U.S. Pat. No. 3,332,828 issued Jul. 25, 1967 to Faria et al., which discloses a PVC foam plastic or polyurethane foam plastic underpad; U.S. Pat. No. 4,637,942 issued Jan. 20, 1987 to Seymour A. Tomarin which discloses a rubber-like underpad; U.S. Pat. No. 4,882,208 issued Nov. 21, 1989 to Hans-Urich Brietschidel, which illustrates a closed cell crosslinked polyethylene foam underpad; U.S. Pat. No. 3,597,297 issued Aug. 3, 1971 to Theodore Buchholz et al., which discloses a polyurethane underpad having voids; and U.S. Pat. No. 4,505,960 issued Mar. 19, 1985 to James W. Leffingwell, which discloses shock absorbing pads made from elastomer foams of polyvinyl chloride, polyethylene, polyurethane, polypropylene, etc.
[0007] Shock absorbing layers may, of course, be more broadly used in other applications, such as in energy dampening in floors, for example. What is still needed, therefore, are improved materials and methods for forming shock absorbing layers, including recyclable shock absorbing layers.
SUMMARY OF INVENTION
[0008] In one aspect, embodiments disclosed herein relate to a synthetic turf surface comprising a synthetic grass carpet having a flexible base sheet, and a shock absorbing pad, wherein the shock absorbing pad comprises a non-crosslinked polyolefin foam.
[0009] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF FIGURES
[0010] FIG. 1 illustrates instrumentation and experimentation for a shock absorption test using FIFA standards.
[0011] FIGS. 2 and 2 c compare results of the compressive stress-strain behavior analyses of foams according to embodiments disclosed herein to those of crosslinked polyethylene foams.
[0012] FIGS. 3 and 3 c compare compressive strain versus time test results for foams according to embodiments disclosed herein to those of crosslinked polyethylene foams.
[0013] FIG. 4 compare compressive creep behavior test results for foams according to embodiments disclosed herein to those of crosslinked polyethylene foams.
[0014] FIG. 5 illustrates synthetic turf that may be formed using embodiments of the non-crosslinked polyolefin foams described herein.
DETAILED DESCRIPTION
[0015] General Definitions and Measurement Methods:
[0016] The following terms shall have the given meaning for the purposes of this invention:
[0017] “Polymer” means a substance composed of molecules with large molecular mass consisting of repeating structural units, or monomers, connected by covalent chemical bonds. The term ‘polymer’ generally includes, but is not limited to, homopolymers, copolymers such as block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Further, unless otherwise specifically limited, the term ‘polymer’ shall include all possible geometrical configurations of the molecular structure. These configurations include isotactic, syndiotactic, random configurations, and the like.
[0018] “Interpolymer” means a polymer prepared by the polymerization of at least two different types of monomers. The generic term “interpolymer” includes the term “copolymer” (which is usually employed to refer to a polymer prepared from two different monomers) as well as the term “terpolymer” (which is usually employed to refer to a polymer prepared from three different types of monomers). The class of materials known as “interpolymers” also encompasses polymers made by polymerizing four or more types of monomers.
[0019] Density of resins and compositions is measured according to ASTM D792.
[0020] Density of foams is measured according to ASTM D3575/W/B.
[0021] “Melt Index (I2)” is determined according to ASTM D1238 using a weight of 2.16 kg at 190° C. for polymers comprising ethylene as the major component in the polymer. “Melt Flow Rate (MFR)” is determined according to ASTM D1238 using a weight of 2.16 kg at 230° C. for polymers comprising propylene as the major component in the polymer.
[0022] Molecular weight distribution of the polymers is determined using gel permeation chromatography (GPC) on a Polymer Laboratories PL-GPC-220 high temperature chromatographic unit equipped with four linear mixed bed columns (Polymer Laboratories (20-micron particle size)). The oven temperature is at 160° C. with the autosampler hot zone at 160° C. and the warm zone at 145° C. The solvent is 1,2,4-trichlorobenzene containing 200 ppm 2,6-di-t-butyl-4-methylphenol. The flow rate is 1.0 milliliter/minute and the injection size is 100 microliters. About 0.2% by weight solutions of the samples are prepared for injection by dissolving the sample in nitrogen purged 1,2,4-trichlorobenzene containing 200 ppm 2,6-di-t-butyl-4-methylphenol for 2.5 hrs at 160° C. with gentle mixing.
[0023] The molecular weight determination is deduced by using ten narrow molecular weight distribution polystyrene standards (from Polymer Laboratories, EasiCal PS1 ranging from 580-7,500,000 g/mole) in conjunction with their elution volumes. The equivalent polypropylene molecular weights are determined by using appropriate Mark-Houwink coefficients for polypropylene (as described by Th. G. Scholte, N. L. J. Meijerink, H. M. Schoffeleers, and A.M.G. Brands, J. Appl. Polym. Sci., 29, 3763-3782 (1984)) and polystyrene (as described by E. P. Otocka, R. J. Roe, N. Y. Hellman, P. M. Muglia, Macromolecules, 4, 507 (1971)) in the Mark-Houwink equation:
[0000] {N}=KM a where K pp =1.90E-04, a pp =0.725 and K ps =1.26E-04, a ps =0.702.
[0000] “Molecular weight distribution” or MWD is measured by conventional GPC per the procedure described by Williams, T.; Ward, I. M. Journal of Polymer Science, Polymer Letters Edition (1968), 6(9), 621-624. Coefficient B is 1. Coefficient A is 0.4316.
[0024] The term high pressure low density type resin is defined to mean that the polymer is partly or entirely homopolymerized or copolymerized in autoclave or tubular reactors at pressures above 14,500 psi (100 MPa) with the use of free-radical initiators, such as peroxides (see for example U.S. Pat. No. 4,599,392, herein incorporated by reference) and includes “LDPE” which may also be referred to as “high pressure ethylene polymer” or “highly branched polyethylene”. The cumulative detector fraction (CDF) of these materials is greater than about 0.02 for molecular weight greater than 1000000 g/mol as measured using light scattering. CDF may be determined as described in WO2005/023912 A2, which is herein incorporated by reference for its teachings regarding CDF. The preferred high pressure low density polyethylene material (LDPE) has a melt index MI (I2) of less than about 20, more preferably less than about 15, most preferably less than 10, and greater than about 0.1, more preferably greater than about 0.2, most preferably more than 0.3 g/10 min. The preferred LDPE will have a density between about 0.915 g/cm3 and 0.930 g/cm 3 , with less than 0.925 g/cm 3 being more preferred.
[0025] “Crystallinity” means atomic dimension or structural order of a polymer composition. Crystallinity is often represented by a fraction or percentage of the volume of the material that is crystalline or as a measure of how likely atoms or molecules are to be arranged in a regular pattern, namely into a crystal. Crystallinity of polymers can be adjusted fairly precisely and over a very wide range by heat treatment. A “crystalline” “semi-crystalline” polymer possesses a first order transition or crystalline melting point (Tm) as determined by differential scanning calorimetry (DSC) or equivalent technique. The term may be used interchangeably with the term “semicrystalline”. The term “amorphous” refers to a polymer lacking a crystalline melting point as determined by differential scanning calorimetry (DSC) or equivalent technique.
[0026] Differential Scanning Calorimetry (DSC) is a common technique that can be used to examine the melting and crystallization of semi-crystalline polymers. General principles of DSC measurements and applications of DSC to studying semi-crystalline polymers are described in standard texts (e.g., E. A. Turi, ed., Thermal Characterization of Polymeric Materials, Academic Press, 1981). DSC is a method suitable for determining the melting characteristics of a polymer.
[0027] DSC analysis was done using a model Q1000 DSC from TA Instruments, Inc. DSC is calibrated by the following method. First, a baseline is obtained by running the DSC from −90° C. to 290° C. without any sample in the aluminum DSC pan. Then 7 milligrams of a fresh indium sample is analyzed by heating the sample to 180° C., cooling the sample to 140° C. at a cooling rate of 10° C./min followed by keeping the sample isothermally at 140° C. for 1 minute, followed by heating the sample from 140° C. to 180° C. at a heating rate of 10° C./min. The heat of fusion and the onset of melting of the indium sample are determined and checked to be within 0.5° C. to 156.6° C. for the onset of melting and within 0.5 J/g to 28.71 J/g for the heat of fusion. Then deionized water is analyzed by cooling a small drop of flesh sample in the DSC pan from 25° C. to −30° C. at a cooling rate of 10° C./min. The sample is kept isothermally at −30° C. for 2 minutes and heated to 30° C. at a heating rate of 10° C./min. The onset of melting is determined and checked to be within 0.5° C. to 0° C.
[0028] Polymer samples were pressed into a thin film at an initial temperature of 190° C. (designated as the ‘initial temperature’). About 5 to 8 mg of sample is weighed out and placed in the DSC pan. The lid is crimped on the pan to ensure a closed atmosphere. The DSC pan is placed in the DSC cell and then heated at a rate of about 100° C./min to a temperature (T o ) of about 60° C. above the melt temperature of the sample. The sample is kept at this temperature for about 3 minutes. Then the sample is cooled at a rate of 10° C./min to −40° C., and kept isothermally at that temperature for 3 minutes. Consequently the sample is heated at a rate of 10° C./min until complete melting. Enthalpy curves resulting from this experiment are analyzed for peak melt temperature, onset and peak crystallization temperatures, heat of fusion and heat of crystallization, and any other DSC analyses of interest.
[0029] For a polymer comprising polypropylene crystallinity is analyzed, T o is 230° C. T o is 190° C. when polyethylene crystallinity is present and no polypropylene crystallinity is present in the sample.
[0030] Percent crystallinity by weight is calculated according to the following formula:
[0000]
Crystallinity
(
wt
.
%
)
=
Δ
H
Δ
H
o
×
100
%
[0000] such that the heat of fusion (ΔH) is divided by the heat of fusion for the perfect polymer crystal (ΔH o ) and then multiplied by 100%. For ethylene crystallinity, ΔH o is taken to be 290 J/g. For example, an ethylene-octene copolymer which upon melting of its polyethylene crystallinity is measured to have a heat of fusion of 29 J/g; the corresponding crystallinity is 10% by weight. For propylene crystallinity, ΔH o is taken to be 165 J/g. For example, a propylene-ethylene copolymer which upon melting of its propylene crystallinity is measured to have a heat of fusion of 20 J/g; the corresponding crystallinity is 12.1% by weight.
[0031] “Non crosslinked” As used herein, the term non-crosslinked refers to polymers that have between 0-10% gel, more preferably, 0-5%, and more preferably 0-1%. It should not be construed that absolutely zero crosslinking is present, as some crosslinking may inevitably occur during processing, but that the crosslinking should be kept to a minimum to allow for recyclability.
Foam Shock Absorbing Layer
[0032] In one aspect, embodiments described herein relate to a thermoplastic foam shock absorbing layer. In another aspect, embodiments described herein relate to a synthetic turf including a thermoplastic foam shock absorbing layer. In selected applications, embodiments described herein relate to a thermoplastic non-crosslinked polymer foam shock absorption layer having the following characteristics:
[0033] 1) Foam thickness: between 8 and 30 mm;
[0034] 2) Foam density: between 30 and 150 kg/m3;
[0035] 3) Foam cell size: between 0.2 and 3 mm; and
[0036] 4) % Open cell volume is low, so as to avoid water uptake: typically less than 35%.
[0037] Polymer
[0038] The thermoplastic polymer used to form the shock absorbing layer may vary depending upon the particular application and the desired result. In one embodiment, for instance, the polymer is an olefin polymer. As used herein, an olefin polymer, in general, refers to a class of polymers fanned from hydrocarbon monomers having the general formula C n H 2n . The olefin polymer may be present as a copolymer, such as an interpolymer, a block copolymer, or a multi-block interpolymer or copolymer.
[0039] In one particular embodiment, for instance, the olefin polymer may comprise an alpha-olefin interpolymer of ethylene with at least one comonomer selected from the group consisting of a C 3 -C 20 linear, branched or cyclic diene, or an ethylene vinyl compound, such as vinyl acetate, and a compound represented by the formula H 2 C═CHR wherein R is a C 1 -C 20 linear, branched or cyclic alkyl group or a C 6 -C 20 aryl group. Examples of comonomers include propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1-decene, and 1-dodecene.
[0040] In other embodiments, the polymer may be an alpha-olefin interpolymer of propylene with at least one comonomer selected from the group consisting of ethylene, a C 4 -C 20 linear, branched or cyclic diene, and a compound represented by the formula H 2 C═CHR wherein R is a C 1 -C 20 linear, branched or cyclic alkyl group or a C 6 -C 20 aryl group. Examples of comonomers include ethylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1-decene, and 1-dodecene. In some embodiments, the comonomer is present at about 5% by weight to about 25% by weight of the interpolymer. In one embodiment, a propylene-ethylene interpolymer is used.
[0041] Other examples of polymers which may be used in the present disclosure include homopolymers and copolymers (including elastomers) of an olefin such as ethylene, propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1-decene, and 1-dodecene as typically represented by polyethylene, polypropylene, poly-1-butene, poly-3-methyl-1-butene, poly-3-methyl-1-pentene, poly-4-methyl-1-pentene, ethylene-propylene copolymer, ethylene-1-butene copolymer, and propylene-1-butene copolymer; copolymers (including elastomers) of an alpha-olefin with a conjugated or non-conjugated diene as typically represented by ethylene-butadiene copolymer and ethylene-ethylidene norbornene copolymer; and polyolefins (including elastomers) such as copolymers of two or more alpha-olefins with a conjugated or non-conjugated diene as typically represented by ethylene-propylene-butadiene copolymer, ethylene-propylene-dicyclopentadiene copolymer, ethylene-propylene-1,5-hexadiene copolymer, and ethylene-propylene-ethylidene norbornene copolymer; ethylene-vinyl compound copolymers such as ethylene-vinyl acetate copolymers with N-methylol functional comonomers, ethylene-vinyl alcohol copolymers with N-methylol functional comonomers, ethylene-vinyl chloride copolymer, ethylene acrylic acid or ethylene-(meth)acrylic acid copolymers, and ethylene-(meth)acrylate copolymer; styrenic copolymers (including elastomers) such as polystyrene, ABS, acrylonitrile-styrene copolymer, methylstyrene-styrene copolymer; and styrene block copolymers (including elastomers) such as styrene-butadiene copolymer and hydrate thereat, and styrene-isoprene-styrene triblock copolymer; polyvinyl compounds such as polyvinyl chloride, polyvinylidene chloride, vinyl chloride-vinylidene chloride copolymer, polymethyl acrylate, and polymethyl methacrylate; polyamides such as nylon 6, nylon 6,6, and nylon 12; thermoplastic polyesters such as polyethylene terephthalate and polybutylene terephthalate; polycarbonate, polyphenylene oxide, and the like. These resins may be used either alone or in combinations of two or more.
[0042] In particular embodiments, polyolefins such as polypropylene, polyethylene, and copolymers thereof and blends thereof, as well as ethylene-propylene-diene terpolymers may be used. In some embodiments, the olefinic polymers include homogeneous polymers described in U.S. Pat. No. 3,645,992 by Elston; high density polyethylene (HDPE) as described in U.S. Pat. No. 4,076,698 to Anderson; heterogeneously branched linear low density polyethylene (LLDPE); heterogeneously branched ultra low linear density (ULDPE); homogeneously branched, linear ethylene/alpha-olefin copolymers; homogeneously branched, substantially linear ethylene/alpha-olefin polymers which can be prepared, for example, by a process disclosed in U.S. Pat. Nos. 5,272,236 and 5,278,272, the disclosure of which process is incorporated herein by reference; heterogeneously branched linear ethylene/alpha olefin polymers; and high pressure, free radical polymerized ethylene polymers and copolymers such as low density polyethylene (LDPE).
[0043] In another embodiment, the polymers may include an ethylene-carboxylic acid copolymer, such as, ethylene-vinyl acetate (EVA) copolymers, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers such as, for example, those available under the tradenames PRIMACOR™ from the Dow Chemical Company, NUCREL™ from DuPont, and ESCOR™ from ExxonMobil, and described in U.S. Pat. Nos. 4,599,392, 4,988,781, and 59,384,373, each of which is incorporated herein by reference in its entirety. Exemplary polymers include polypropylene, (both impact modifying polypropylene, isotactic polypropylene, atactic polypropylene, and random ethylene/propylene copolymers), various types of polyethylene, including high pressure, free-radical LDPE, Ziegler Natta LLDPE, metallocene PE, including multiple reactor PE (“in reactor”) blends of Ziegler-Natta PE and metallocene PE, such as products disclosed in U.S. Pat. Nos. 6,545,088, 6,538,070, 6,566,446, 5,844,045, 5,869,575, and 6,448,341. Homogeneous polymers such as olefin plastomers and elastomers, ethylene and propylene-based copolymers (for example polymers available under the trade designation VERSIFY™ available from The Dow Chemical Company and VISTAMAXX™ available from ExxonMobil) may also be useful in some embodiments. Of course, blends of polymers may be used as well. In some embodiments, the blends include two different Ziegler-Natta polymers. In other embodiments, the blends may include blends of a Ziegler-Natta and a metallocene polymer. In still other embodiments, the thermoplastic resin used herein may be a blend of two different metallocene polymers.
[0044] In one particular embodiment, the polymer may comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene, such as 1-octene. The ethylene and octene copolymer may be present alone or in combination with another polymer, such as ethylene-acrylic acid copolymer. When present together, the weight ratio between the ethylene and octene copolymer and the ethylene-acrylic acid copolymer may be from about 1:10 to about 10:1, such as from about 3:2 to about 2:3. The polymer, such as the ethylene-octene copolymer, may have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer may be from 5 to 35 percent. In other embodiments, the crystallinity may range from 7 to 20 percent.
[0045] In one particular embodiment, the polymer may comprise at least one low density polyethylene (LDPE). The polymer may comprise LDPE made in autoclave processes or tubular processes. Suitable LDPE for this embodiment is defined elsewhere in this document.
[0046] In one particular embodiment, the polymer may comprise at least two low density polyethylenes. The polymer may comprise LDPE made in autoclave processes, tubular processes, or combinations thereof. Suitable LDPEs for this embodiment are defined elsewhere in this document.
[0047] In one particular embodiment, the polymer may comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene, such as 1-octene. The ethylene and octene copolymer may be present alone or in combination with another polymer, such as a low density polyethylene (LDPE). When present together, the weight ratio between the ethylene and octene copolymer and the LDPE may be from about 60:40 to about 97:3, such as from about 80:20 to about 96:4. The polymer, such as the ethylene-octene copolymer, may have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer may be from 5 to 35 percent. In other embodiments, the crystallinity may range from 7 to 20 percent. Suitable LDPEs for this embodiment are defined elsewhere in this document.
[0048] In one particular embodiment, the polymer may comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene, such as 1-octene. The ethylene and octene copolymer may be present alone or in combination with at least two other polymers from the group: low density polyethylene, medium density polyethylene, and high density polyethylene (HDPE). When present together, the weight ratio between the ethylene and octene copolymer, the LDPE, and the HDPE are such that the composition comprises one component from 3 to 97% by weight of the total composition and the remainder comprises the other two components. The polymer, such as the ethylene-octene copolymer, may have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer may be from 5 to 35 percent. In other embodiments, the crystallinity may range from 7 to 20 percent.
[0049] Embodiments disclosed herein may also include a polymeric component that may include at least one multi-block olefin interpolymer. Suitable multi-block olefin interpolymers may include those described in U.S. Provisional Patent Application No. 60/818,911, for example. The term “multi-block copolymer” or refers to a polymer comprising two or more chemically distinct regions or segments (referred to as “blocks”) preferably joined in a linear manner, that is, a polymer comprising chemically differentiated units which are joined end-to-end with respect to polymerized ethylenic functionality, rather than in pendent or grafted fashion. In certain embodiments, the blocks differ in the amount or type of comonomer incorporated therein, the density, the amount of crystallinity, the crystallite size attributable to a polymer of such composition, the type or degree of tacticity (isotactic or syndiotactic), regio-regularity or regio-irregularity, the amount of branching, including long chain branching or hyper-branching, the homogeneity, or any other chemical or physical property. The multi-block copolymers are characterized by unique distributions of polydispersity index (PDI or M w /M n ), block length distribution, and/or block number distribution due to the unique process making of the copolymers. More specifically, when produced in a continuous process, embodiments of the polymers may possess a PDI ranging from about 1.7 to about 8; from about 1.7 to about 3.5 in other embodiments; from about 1.7 to about 2.5 in other embodiments; and from about 1.8 to about 2.5 or from about 1.8 to about 2.1 in yet other embodiments. When produced in a batch or semi-batch process, embodiments of the polymers may possess a PDI ranging from about 1.0 to about 2.9; from about 1.3 to about 2.5 in other embodiments; from about 1.4 to about 2.0 in other embodiments; and from about 1.4 to about 1.8 in yet other embodiments.
[0050] One example of the multi-block olefin interpolymer is an ethylene/α-olefin block interpolymer. Another example of the multi-block olefin interpolymer is a propylene/α-olefin interpolymer. The following description focuses on the interpolymer as having ethylene as the majority monomer, but applies in a similar fashion to propylene-based multi-block interpolymers with regard to general polymer characteristics.
[0051] The ethylene/α-olefin multi-block interpolymers may comprise ethylene and one or more co-polymerizable α-olefin comonomers in polymerized form, characterized by multiple (i.e., two or more) blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (block interpolymer), preferably a multi-block interpolymer. In some embodiments, the multi-block interpolymer may be represented by the following formula:
[0000] (AB) n
[0000] where n is at least 1, preferably an integer greater than 1, such as 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, or higher; “A” represents a hard block or segment; and “B” represents a soft block or segment. Preferably, A′ s and B′ s are linked in a linear fashion, not in a branched or a star fashion. “Hard” segments refer to blocks of polymerized units in which ethylene is present in an amount greater than 95 weight percent in some embodiments, and in other embodiments greater than 98 weight percent. In other words, the comonomer content in the hard segments is less than 5 weight percent in some embodiments, and in other embodiments, less than 2 weight percent of the total weight of the hard segments. In some embodiments, the hard segments comprise all or substantially all ethylene. “Soft” segments, on the other hand, refer to blocks of polymerized units in which the comonomer content is greater than 5 weight percent of the total weight of the soft segments in some embodiments, greater than 8 weight percent, greater than 10 weight percent, or greater than 15 weight percent in various other embodiments. In some embodiments, the comonomer content in the soft segments may be greater than 20 weight percent, greater than 25 eight percent, greater than 30 weight percent, greater than 35 weight percent, greater than 40 weight percent, greater than 45 weight percent, greater than 50 weight percent, or greater than 60 weight percent in various other embodiments.
[0052] In some embodiments, A blocks and B blocks are randomly distributed along the polymer chain. In other words, the block copolymers do not have a structure like:
[0000] AAA-AA-BBB-BB
[0053] In other embodiments, the block copolymers do not have a third block. In still other embodiments, neither block A nor block B comprises two or more segments (or sub-blocks), such as a tip segment.
[0054] The multi-block interpolymers may be characterized by an average block index, ABI, ranging from greater than zero to about 1.0 and a molecular weight distribution, M w /M n , greater than about 1.3. The average block index, ABI, is the weight average of the block index (“BI”) for each of the polymer fractions obtained in preparative TREF from 20° C. and 110° C., with an increment of 5° C.:
[0000] ABI=Σ( w i BI i )
[0000] where BI i is the block index for the i th fraction of the multi-block interpolymer obtained in preparative TREF, and w i is the weight percentage of the i th fraction.
[0055] Similarly, the square root of the second moment about the mean, hereinafter referred to as the second moment weight average block index, may be defined as follows:
[0000]
2
nd
moment
weight
average
B
I
=
Σ
(
w
i
(
B
I
i
-
ABI
)
2
)
(
N
-
1
)
Σ
w
i
N
[0056] For each polymer fraction, BI is defined by one of the two following equations (both of which give the same BI value):
[0000]
B
I
=
1
/
T
X
-
1
/
T
XO
1
/
T
A
-
1
/
T
AB
or
B
I
=
-
Ln
P
X
-
Ln
P
XO
Ln
P
A
-
Ln
P
AB
[0000] where T x is the analytical temperature rising elution fractionation (ATREF) elution temperature for the i th fraction (preferably expressed in Kelvin), P x is the ethylene mole fraction for the i th fraction, which may be measured by NMR or IR as described below. P AB is the ethylene mole fraction of the whole ethylene/α-olefin interpolymer (before fractionation), which also may be measured by NMR or IR. T A and P A are the ATREF elution temperature and the ethylene mole fraction for pure “hard segments” (which refer to the crystalline segments of the interpolymer). As an approximation or for polymers where the “hard segment” composition is unknown, the T A and P A values are set to those for high density polyethylene homopolymer.
[0057] T AB is the ATREF elution temperature for a random copolymer of the same composition (having an ethylene mole fraction of P AB ) and molecular weight as the multi-block interpolymer. T AB may be calculated from the mole fraction of ethylene (measured by NMR) using the following equation:
[0000] Ln P AB =α/T AB +β
[0000] where α and β are two constants which may be determined by a calibration using a number of well characterized preparative TREF fractions of a broad composition random copolymer and/or well characterized random ethylene copolymers with narrow composition. It should be noted that α and β may vary from instrument to instrument. Moreover, one would need to create an appropriate calibration curve with the polymer composition of interest, using appropriate molecular weight ranges and comonomer type for the preparative TREF fractions and/or random copolymers used to create the calibration. There is a slight molecular weight effect. If the calibration curve is obtained from similar molecular weight ranges, such effect would be essentially negligible. In some embodiments, random ethylene copolymers and/or preparative TREF fractions of random copolymers satisfy the following relationship:
[0000] Ln P=− 237.83 /T ATREF +0.639
[0058] The above calibration equation relates the mole fraction of ethylene, P, to the analytical TREF elution temperature, T ATREF , for narrow composition random copolymers and/or preparative TREF fractions of broad composition random copolymers. T XO is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of P x . T XO may be calculated from Ln P X =α/T XO +β. Conversely, P XO is the ethylene mole fraction for a random copolymer of the same composition and having an ATREF temperature of T X , which may be calculated from Ln P XO =α/T X +β
[0059] Once the block index (BI) for each preparative TREF fraction is obtained, the weight average block index, ABI, for the whole polymer may be calculated. In some embodiments, ABI is greater than zero but less than about 0.4 or from about 0.1 to about 0.3. In other embodiments, ABI is greater than about 0.4 and up to about 1.0. Preferably, ABI should be in the range of from about 0.4 to about 0.7, from about 0.5 to about 0.7, or from about 0.6 to about 0.9. In some embodiments, ABI is in the range of from about 0.3 to about 0.9, from about 0.3 to about 0.8, or from about 0.3 to about 0.7, from about 0.3 to about 0.6, from about 0.3 to about 0.5, or from about 0.3 to about 0.4. In other embodiments, ABI is in the range of from about 0.4 to about 1.0, from about 0.5 to about 1.0, or from about 0.6 to about 1.0, from about 0.7 to about 1.0, from about 0.8 to about 1.0, or from about 0.9 to about 1.0.
[0060] Another characteristic of the multi-block interpolymer is that the interpolymer may comprise at least one polymer fraction which may be obtained by preparative TREF, wherein the fraction has a block index greater than about 0.1 and up to about 1.0 and the polymer having a molecular weight distribution, M w /M n , greater than about 1.3. In some embodiments, the polymer fraction has a block index greater than about 0.6 and up to about 1.0, greater than about 0.7 and up to about 1.0, greater than about 0.8 and up to about 1.0, or greater than about 0.9 and up to about 1.0. In other embodiments, the polymer fraction has a block index greater than about 0.1 and up to about 1.0, greater than about 0.2 and up to about 1.0, greater than about 0.3 and up to about 1.0, greater than about 0.4 and up to about 1.0, or greater than about 0.4 and up to about 1.0. In still other embodiments, the polymer fraction has a block index greater than about 0.1 and up to about 0.5, greater than about 0.2 and up to about 0.5, greater than about 0.3 and up to about 0.5, or greater than about 0.4 and up to about 0.5. In yet other embodiments, the polymer fraction has a block index greater than about 0.2 and up to about 0.9, greater than about 0.3 and up to about 0.8, greater than about 0.4 and up to about 0.7, or greater than about 0.5 and up to about 0.6.
[0061] Ethylene α-olefin multi-block interpolymers used in embodiments of the invention may be interpolymers of ethylene with at least one C 3 -C 20 α-olefin. The interpolymers may further comprise C 4 -C 18 diolefin and/or alkenylbenzene. Suitable unsaturated comonomers useful for polymerizing with ethylene include, for example, ethylenically unsaturated monomers, conjugated or non-conjugated dienes, polyenes, alkenylbenzenes, etc. Examples of such comonomers include C 3 -C 20 α-olefins such as propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene, and the like. 1-Butene and 1-octene are especially preferred. Other suitable monomers include styrene, halo- or alkyl-substituted styrenes, vinylbenzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and naphthenics (such as cyclopentene, cyclohexene, and cyclooctene, for example).
[0062] The multi-block interpolymers disclosed herein may be differentiated from conventional, random copolymers, physical blends of polymers, and block copolymers prepared via sequential monomer addition, fluxional catalysts, and anionic or cationic living polymerization techniques. In particular, compared to a random copolymer of the same monomers and monomer content at equivalent crystallinity or modulus, the interpolymers have better (higher) heat resistance as measured by melting point, higher TMA penetration temperature, higher high-temperature tensile strength, and/or higher high-temperature torsion storage modulus as determined by dynamic mechanical analysis. Properties of infill may benefit from the use of embodiments of the multi-block interpolymers, as compared to a random copolymer containing the same monomers and monomer content, the multi-block interpolymers have lower compression set, particularly at elevated temperatures, lower stress relaxation, higher creep resistance, higher tear strength, higher blocking resistance, faster setup due to higher crystallization (solidification) temperature, higher recovery (particularly at elevated temperatures), better abrasion resistance, higher refractive force, and better oil and filler acceptance.
[0063] Other olefin interpolymers include polymers comprising monovinylidene aromatic monomers including styrene, o-methyl styrene, p-methyl styrene, t-butylstyrene, and the like. In particular, interpolymers comprising ethylene and styrene may be used. In other embodiments, copolymers comprising ethylene, styrene and a C 3 -C 20 α olefin, optionally comprising a C 4 -C 20 diene, may be used.
[0064] Suitable non-conjugated diene monomers may include straight chain, branched chain or cyclic hydrocarbon diene having from 6 to 15 carbon atoms. Examples of suitable non-conjugated dienes include, but are not limited to, straight chain acyclic dienes, such as 1,4-hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, branched chain acyclic dienes, such as 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene, single ring alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene; 1,5-cyclooctadiene and 1,5-cyclododecadiene, and multi-ring alicyclic fused and bridged ring dienes, such as tetrahydroindene, methyl tetrahydroindene, dicyclopentadiene, bicyclo-(2,2,1)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene (MNB); 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene. Of the dienes typically used to prepare EPDMs, the particularly preferred dienes are 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB), and dicyclopentadiene (DCPD).
[0065] One class of desirable polymers that may be used in accordance with embodiments disclosed herein includes elastomeric interpolymers of ethylene, a C 3 -C 20 α-olefin, especially propylene, and optionally one or more diene monomers. Preferred α-olefins for use in this embodiment are designated by the formula CH 2 ═CHR*, where R* is a linear or branched alkyl group of from 1 to 12 carbon atoms. Examples of suitable α-olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene. A particularly preferred α-olefin is propylene. The propylene based polymers are generally referred to in the art as EP or EPDM polymers. Suitable dienes for use in preparing such polymers, especially multi-block EPDM type polymers include conjugated or non-conjugated, straight or branched chain-, cyclic- or polycyclic-dienes comprising from 4 to 20 carbons. Preferred dienes include 1,4-pentadiene, 1,4-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene, cyclohexadiene, and 5-butylidene-2-norbornene. A particularly preferred diene is 5-ethylidene-2-norbornene.
[0066] The polymers (homopolymers, copolymers, interpolymers and multi-block interpolymers) described herein may have a melt index, I 2 , from 0.01 to 2000 g/10 minutes in some embodiments; from 0.01 to 1000 g/10 minutes in other embodiments; from 0.01 to 500 g/10 minutes in other embodiments; and from 0.01 to 100 g/10 minutes in yet other embodiments. In certain embodiments, the polymers may have a melt index, I 2 , from 0.01 to 10 g/10 minutes, from 0.5 to 50 g/10 minutes, from 1 to 30 g/10 minutes, from 1 to 6 g/10 minutes or from 0.3 to 10 g/10 minutes. In certain embodiments, the melt index for the polymers may be approximately 1 g/10 minutes, 3 g/10 minutes or 5 g/10 minutes. In other embodiments, the polymers may have a melt index greater than 20 dg/min; greater than 40 dg/min in other embodiments; and greater than 60 dg/min in yet other embodiments.
[0067] The polymers described herein may have molecular weights, M w , from 1,000 g/mole to 5,000,000 g/mole in some embodiments; from 1000 g/mole to 1,000,000 in other embodiments; from 10,000 g/mole to 500,000 g/mole in other embodiments; and from 10,000 g/mole to 300,000 g/mole in yet other embodiments. The density of the polymers described herein may be from 0.80 to 0.99 g/cm 3 in some embodiments; for ethylene containing polymers from 0.85 g/cm 3 to 0.97 g/cm 3 ; in some embodiments between 0.87 g/cm 3 and 0.94 g/cm 3 .
[0068] In some embodiments, the polymers described herein may have a tensile strength above 10 MPa; a tensile strength >11 MPa in other embodiments; and a tensile strength >13 MPa in yet other embodiments. In some embodiments, the polymers described herein may have an elongation at break of at least 600 percent at a crosshead separation rate of 11 cm/minute; at least 700 percent in other embodiments; at least 800 percent in other embodiments; and at least 900 percent in yet other embodiments.
[0069] In some embodiments, the polymers described herein may have a storage modulus ratio, G′(25° C.)/G′(100° C.), from 1 to 50; from 1 to 20 in other embodiments; and from 1 to 10 in yet other embodiments. In some embodiments, the polymers may have a 70° C. compression set of less than 80 percent; less than 70 percent in other embodiments; less than 60 percent in other embodiments; and, less than 50 percent, less than 40 percent, down to a compression set of 0 percent in yet other embodiments.
[0070] In some embodiments, the ethylene/α-olefin interpolymers may have a heat of fusion of less than 85 J/g. In other embodiments, the ethylene/α-olefin interpolymer may have a pellet blocking strength of equal to or less than 100 pounds/foot 2 (4800 Pa); equal to or less than 50 lbs/ft 2 (2400 Pa) in other embodiments; equal to or less than 5 lbs/ft 2 (240 Pa), and as low as 0 lbs/ft 2 (0 Pa) in yet other embodiments.
[0071] In some embodiments, block polymers made with two catalysts incorporating differing quantities of comonomer may have a weight ratio of blocks formed thereby ranging from 95:5 to 5:95. The elastomeric interpolymers, in some embodiments, have an ethylene content of from 20 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 80 percent, based on the total weight of the polymer. In other embodiments, the multi-block elastomeric polymers have an ethylene content of from 60 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 40 percent, based on the total weight of the polymer. In other embodiments, the interpolymer may have a Mooney viscosity (ML (1+4) 125° C.) ranging from 1 to 250. In other embodiments, such polymers may have an ethylene content from 65 to 75 percent, a diene content from 0 to 6 percent, and an α-olefin content from 20 to 35 percent.
[0072] In certain embodiments, the polymer may be a propylene-ethylene copolymer or interpolymer having an ethylene content between 5 and 20% by weight and a melt flow rate (230° C. with 2.16 kg weight) from 0.5 to 300 g/10 min. In other embodiments, the propylene-ethylene copolymer or interpolymer may have an ethylene content between 9 and 12% by weight and a melt flow rate (230° C. with 2.16 kg weight) from 1 to 100 g/10 min.
[0073] In some particular embodiments, the polymer is a propylene-based copolymer or interpolymer. In some embodiments, a propylene/ethylene copolymer or interpolymer is characterized as having substantially isotactic propylene sequences. The term “substantially isotactic propylene sequences” and similar terms mean that the sequences have an isotactic triad (mm) measured by 13 C NMR of greater than about 0.85, preferably greater than about 0.90, more preferably greater than about 0.92 and most preferably greater than about 0.93. Isotactic triads are well-known in the art and are described in, for example, U.S. Pat. No. 5,504,172 and WO 00/01745, which refer to the isotactic sequence in terms of a triad unit in the copolymer molecular chain determined by 13 C NMR spectra. In other particular embodiments, the ethylene-α olefin copolymer may be ethylene-butene, ethylene-hexene, or ethylene-octene copolymers or interpolymers. In other particular embodiments, the propylene-α olefin copolymer may be a propylene-ethylene or a propylene-ethylene-butene copolymer or interpolymer.
[0074] The polymers described herein (homopolymers, copolymers, interpolymers, multi-block interpolymers) may be produced using a single site catalyst and may have a weight average molecular weight of from about 15,000 to about 5 million, such as from about 20,000 to about 1 million. The molecular weight distribution of the polymer may be from about 1.01 to about 80, such as from about 1.5 to about 40, such as from about 1.8 to about 20.
[0075] In some embodiments, the polymer may have a Shore A hardness from 30 to 100. In other embodiments, the polymer may have a Shore A hardness from 40 to 90; from 30 to 80 in other embodiments; and from 40 to 75 in yet other embodiments.
[0076] The olefin polymers, copolymers, interpolymers, and multi-block interpolymers may be functionalized by incorporating at least one functional group in its polymer structure. Exemplary functional groups may include, for example, ethylenically unsaturated mono- and di-functional carboxylic acids, ethylenically unsaturated mono- and di-functional carboxylic acid anhydrides, salts thereof and esters thereof. Such functional groups may be grafted to an olefin polymer, or it may be copolymerized with ethylene and an optional additional comonomer to form an interpolymer of ethylene, the functional comonomer and optionally other comonomer(s). Means for grafting functional groups onto polyethylene are described for example in U.S. Pat. Nos. 4,762,890, 4,927,888, and 4,950,541, the disclosures of which are incorporated herein by reference in their entirety. One particularly useful functional group is maleic anhydride.
[0077] The amount of the functional group present in the functional polymer may vary. The functional group may be present in an amount of at least about 1.0 weight percent in some embodiments; at least about 5 weight percent in other embodiments; and at least about 7 weight percent in yet other embodiments. The functional group may be present in an amount less than about 40 weight percent in some embodiments; less than about 30 weight percent in other embodiments; and less than about 25 weight percent in yet other embodiments.
[0078] The foam sheets according to embodiments disclosed herein may include a single layer or multiple layers as desired. The foam articles may be produced in any manner so as to result in at least one foam layer. The foam layers described herein may be made by a pressurized melt processing method such as an extrusion method. The extruder may be a tandem system, a single screw extruder, a twin screw extruder, etc. The extruder may be equipped with multilayer annular dies, flat film dies and feedblocks, multi-layer feedblocks such as those disclosed in U.S. Pat. No. 4,908,278 (Bland et al.), multi-vaned or multi-manifold dies such as a 3-layer vane die available from Cloeren, Orange, Tex. A foamable composition may also be made by combining a chemical blowing agent and polymer at a temperature below the decomposition temperature of the chemical blowing agent, and then later foamed. In some embodiments, the foam may be coextruded with one or more barrier layers.
[0079] One method of producing the foams described herein is by using an extruder, as mentioned above. In this case, the foamable mixture (polymer+blowing agent) is extruded. As the mixture exits an extruder die and upon exposure to reduced pressure, the fugitive gas nucleates and forms cells within the polymer to create a foam article. The resulting foam article may then be deposited onto a temperature-controlled casting drum. The casting drum speed (i.e., as produced by the drum RPM) can affect the overall thickness of the foam article. As the casting roll speed increases, the overall thickness of the foam article can decrease. However, the barrier layer thickness at the die exit, which is where foaming occurs, is the diffusion length for the system. As the foam article is stretched and quenched on the casting drum, the barrier layer thickness may decrease until the foam article solidifies. In other words, it is the barrier layer diffusion length (i.e., thickness) at the die exit that is the important factor in controlling the diffusion of the fugitive gas.
[0080] Blowing agents suitable for use in forming the foams described herein may be physical blowing agents, which are typically the same material as the fugitive gas, e.g., CO 2 , or a chemical blowing agent, which produces the fugitive gas. More than one physical or chemical blowing agent may be used and physical and chemical blowing agents may be used together.
[0081] Physical blowing agents useful in the present invention include any naturally occurring atmospheric material which is a vapor at the temperature and pressure at which the foam exits the die. The physical blowing agent may be introduced, i.e., injected into the polymeric material as a gas, a supercritical fluid, or liquid, preferably as a supercritical fluid or liquid, most preferably as a liquid. The physical blowing agents used will depend on the properties sought in the resulting foam articles. Other factors considered in choosing a blowing agent are its toxicity, vapor pressure profile, ease of handling, and solubility with regard to the polymeric materials used. Non-flammable, non-toxic, non-ozone depleting blowing are preferred because they are easier to use, e.g., fewer environmental and safety concerns, and are generally less soluble in thermoplastic polymers. Suitable physical blowing agents include, e.g., carbon dioxide, nitrogen, SF.sub.6, nitrous oxide, perfluorinated fluids, such as C 2 F 6 , argon, helium, noble gases, such as xenon, air (nitrogen and oxygen blend), and blends of these materials.
[0082] Chemical blowing agents that may be used in the present invention include, e.g., a sodium bicarbonate and citric acid blend, dinitrosopentamethylenetetramine, p-toluenesulfonyl hydrazide, 4-4 1 -oxybis(benzenesulfonyl hydrazide, azodicarbonamide (1,1′-azobisformamide), p-toluenesulfonyl semicarbazide, 5-phenyltetrazole, 5-phenyltetrazole analogues, diisopropylhydrazodicarboxylate, 5-phenyl-3,6-dihydro-1,3,4-oxadiazin-2-one, and sodium borohydride. Preferably, the blowing agents are, or produce, one or more fugitive gases having a vapor pressure of greater than 0.689 MPa at 0° C.
[0083] The total amount of the blowing agent used depends on conditions such as extrusion-process conditions at mixing, the blowing agent being used, the composition of the extrudate, and the desired density of the foamed article. The extrudate is defined herein as including the blowing agent blend, a polyolefin resin(s), and any additives. For a foam having a density of from about 1 to about 15 lb/ft 3 , the extrudate typically comprises from about 18 to about 1 wt of blowing agent. In other embodiments, 1% to 10% of blowing agent may be used.
[0084] The blowing agent blend used in the present invention comprises less than about 99 mol % isobutane. The blowing agent blend generally comprises from about 10 mol % to about 60 or 75 mol % isopentane. The blowing agent blend more typically comprises from about 15 mol % to about 40 mol % isopentane. More specifically, the blowing agent blend comprises from about 25 or 30 mol % to about 40 mol % isobutane. The blowing agent blend generally comprises at least about 15 or 30 mol % of co-blowing agent(s). More specifically, the blowing agent blend comprises from about 40 to about 85 or 90 mol % of co-blowing agent(s). The blowing agent blend more typically comprises from about 60 mol % to about 70 or 75 mol % of co-blowing agent(s).
[0085] A nucleating agent or combination of such agents may be employed in the present invention for advantages, such as its capability for regulating cell formation and morphology. A nucleating agent, or cell size control agent, may be any conventional or useful nucleating agent(s). The amount of nucleating agent used depends upon the desired cell size, the selected blowing agent blend, and the desired foam density. The nucleating agent is generally added in amounts from about 0.02 to about 20 wt % of the polyolefin resin composition.
[0086] Some contemplated nucleating agents include inorganic materials (in small particulate form), such as clay, talc, silica, and diatomaceous earth. Other contemplated nucleating agents include organic nucleating agents that decompose or react at the heating temperature within an extruder to evolve gases, such as carbon dioxide, water, and/or nitrogen. One example of an organic nucleating agent is a combination of an alkali metal salt of a polycarboxylic acid with a carbonate or bicarbonate. Some examples of alkali metal salts of a polycarboxylic acid include, but are not limited to, the monosodium salt of 2,3-dihydroxy-butanedioic acid (commonly referred to as sodium hydrogen tartrate), the monopotassium salt of butanedioic acid (commonly referred to as potassium hydrogen succinate), the trisodium and tripotassium salts of 2-hydroxy-1,2,3-propanetricarboxylic acid (commonly referred to as sodium and potassium citrate, respectively), and the disodium salt of ethanedioic acid (commonly referred to as sodium oxalate), or polycarboxylic acid such as 2-hydroxy-1,2,3-propanetricarboxylic acid. Some examples of a carbonate or a bicarbonate include, but are not limited to, sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, and calcium carbonate.
[0087] It is contemplated that mixtures of different nucleating agents may be added in the present invention. Some more desirable nucleating agents include talc, crystalline silica, and a stoichiometric mixture of citric acid and sodium bicarbonate (the stoichiometric mixture having a 1 to 100 percent concentration where the carrier is a suitable polymer such as polyethylene). Talc may be added in a carrier or in a powder form.
[0088] Gas permeation agents or stability control agents may be employed in the present invention to assist in preventing or inhibiting collapsing of the foam. The stability control agents suitable for use in the present invention may include the partial esters of long-chain fatty acids with polyols described in U.S. Pat. No. 3,644,230, saturated higher alkyl amines, saturated higher fatty acid amides, complete esters of higher fatty acids such as those described in U.S. Pat. No. 4,214,054, and combinations thereof described in U.S. Pat. No. 5,750,584.
[0089] The partial esters of fatty acids that may be desired as a stability control agent include the members of the generic class known as surface active agents or surfactants. A preferred class of surfactants includes a partial ester of a fatty acid having 12 to 18 carbon atoms and a polyol having three to six hydroxyl groups. More preferably, the partial esters of a long chain fatty acid with a polyol component of the stability control agent are glycerol monostearate, glycerol distearate or mixtures thereof. It is contemplated that other gas permeation agents or stability control agents may be employed in the present invention to assist in preventing or inhibiting collapsing of the foam.
[0090] Additives
[0091] If desired, fillers, colorants, light and heat stabilizers, anti-oxidants, acid scavengers, flame retardants, processing aids, extrusion aids, and foaming additives may be used in making the foam. The foam of the invention may contain filler materials in amounts, depending on the application for which they are designed, ranging from about 2-100 percent (dry basis) of the weight of the polymer component. These optional ingredients may include, but are not limited to, calcium carbonate, titanium dioxide powder, polymer particles, hollow glass spheres, polymeric fibers such as polyolefin based staple monofilaments and the like.
[0092] In selected embodiments, foams useful for disclosed embodiments may have thickness between 1 and 500 mm, and in some embodiments, 5 to 100 mm, and in some embodiments 8 and 30 mm. In selected embodiments foams may have a density between about 20 and 600 kg/m 3 , preferably 25 to 300 kg/m 3 , and more preferably, 30 to 150 kg/m 3 . In selected embodiments, foams may have a cell size between about 0.1 to 6 mm, preferably 0.2 to 4.5 mm, and more preferably 0.2 to 3 mm.
[0093] In some embodiments, the foam layer may be perforated in order to facilitate drainage, so that in the event of rain, water may drain off of the playing surface.
[0094] In some embodiments, the above described foams may be used as a shock absorbing layer in a synthetic turf. Additionally, tests may be performed to analyze temperature performance and aging, as well as the bounce and spin properties of the resulting turf. Briefly, the significant tests & desired results for artificial turf performance as specified by the FIFA Quality Concept Manual (March 2006 Edition) are shown in the below table. Those having ordinary skill in the art will appreciate that this is but one use of the foams described herein, and that the artificial turf and foams described herein may be useful in a number of other applications an a number of other sports, such as rugby and field hockey, for example.
[0000]
LABORATORY TESTS - BALL/SURFACE INTERACTION
Requirements
FIFA
Test
Test
Test Conditions
Recommended**
FIFA
Property
Method
Method
Preparation
Temp
Condition
(best ranking)
Recommended*
Vertical ball
FIFA
Pre-
23° C.
Dry
0.60 m-0.85 m
0.60 m-1 m
rebound
01/05-01 &
conditioning
Wet
—
FIFA
Simulated
23° C.
Dry
0.60 m-1 m
09/05-01
Wear
Shock
FIFA
Flat foot
Pre-
23° C.
Dry
60%-70%
55%-70%
absorption
04/05-01 &
Mean
conditioning
Wet
—
FIFA
2 nd /3 rd
Simulated
23° C.
Dry
55%-70%
10/05-01
impact
Wear
—
40° C.
Dry
—
Flat Foot
—
−5° C.
Frozen
60%-70%
—
1 st
impact
Vertical
FIFA
Flat foot
Pre-
23° C.
Dry
4 mm-8 mm
4 mm-9 mm
deformation
05/05-01 &
Mean
conditioning
Wet
—
FIFA
2 nd /3 rd
Simulated
23° C.
Dry
4 mm-9 mm
10/05-01
impact
Wear
[0095] Shock Absorption
[0096] Principle: A mass (20 Kgs) falls, as discussed in the FIFA Quality Concept Manual (March 2006 Edition), which is incorporated by reference in its entirety. The maximum force applied is recorded. The % reduction in this force relative to the maximum force measured on a concrete surface is reported as ‘Force Reduction’.
[0097] FIFA Requirement:
[0098] FIFA 2 Star: 60%-70%
[0099] FIFA 1 Star: 55%-70%
[0100] Vertical Deformation
[0101] Principle A mass is allowed to fall onto a spring that rests and the maximum deformation of the surface is determined.
[0102] FIFA Requirement:
[0103] FIFA 2 Star: 4 mm-8 mm
[0104] FIFA 1 Star: 4 mm-9 mm
EXAMPLES
[0105] The usefulness of polyolefin resins having selected foam densities and thicknesses is investigated. Specifically, a number of polyethylene resins, commercially available from The Dow Chemical Company, Midland, Mich. are studied. Table 1 and Table 2 show a number of the compounds used. In Table 1, the performance of crosslinked polyethylene (comparative examples 1c-4c) versus non-crosslinked polyethylene (examples 1-4) is investigated. Specifically, with respect to Table 1, (LDPE 300E, and LDPE PG 7004 , and blends thereof, LDPE 6201, and XU 60021.24 are used to generate the data. The formulations used in creating the Table are shown below.
[0000]
Resin
Foam
Thick-
Density
Density
ness
Cross-
Example
Resin A/B
(kg/m 3 )
(kg/m 3 )
(mm)
linked
1
XU 60021.24*
0.922
33
10
No
2
90/10 (LDPE 300E/
0.923
45
10
No
LDPE PG7004)
3
70/30 (LDPE 300E/
0.923
64
10
No
LDPE PG7004)
4
LDPE 620I
0.923
144
51
No
[0000]
TABLE 1
Resin A
Resin B
Density
Density
(g/cm 3)
(g/cm 3 )
Foam
Polymer
(ASTM
I 2
Polymer
(ASTM
I 2
Density
Thickness
Example
(wt. %)
Type
D792)
(g/10 min)
(wt. %)
Type
D792)
(g/10 min)
(kg/m 3 )
(mm)
Crosslinked
1
100
LDPE
0.922
3.3
—
—
—
—
33
10
No
2
90
LDPE
0.9235
0.8
10
LDPE
0.9215
4.1
45
10
No
3
70
LDPE
0.9235
0.8
30
LDPE
0.9215
4.1
64
10
No
4
100
LDPE
0.9239
1.85
—
—
—
—
144
51
No
Comparative Examples.
Foam
Comparative
Density
Thickness
Crosslinked
Example
Designation
(kg/m 3 )
(mm)
(yes/no)
1c
Qycell T-20*
33
10
yes
2c
Qycell T-30*
45
10
yes
3c
Qycell T-40*
64
10
yes
4c
Qycell T-80*
119
11.5
no
‘*’ denotes foam commercially available from Qycell Corporation (Ontario, California, USA)
[0106] Turning to the shock absorption, vertical deformation, and energy restitution, the performance of non-crosslinked polyethylene foams of Table 1, which are commercially available from The Dow Chemical Company, Midland, Mich. was investigated. The results of this investigation are summarized in FIG. 1 . With respect to Table 1, the compressive stress-strain, compressive creep, and compressive stress-strain behavior is analyzed using an Instron Model 5565 Universal Testing Machine (Norwood, Mass.) fitted with compression plates and a 2 kN load cell. When the tests are performed at 65° C., an Instron environmental chamber (Model 3119-405-21) is also used.
[0107] Samples 2.5 to 5 cm wide by 5 cm deep are cut from sheets of the foam. To measure compressive stress-strain behavior, the samples are inserted between the centers of the compressive plates. The thickness direction of the foam is aligned parallel to crosshead movement. A pre-load of 2.5 N was applied at 5 mm/min, and the crosshead position is re-zeroed. The sample is then compressed at 10 mm/min until the load approached the capacity of the load cell. Stress is calculated by dividing the measured compressive force by the product of the width and depth of the foam. Stress is quantified in units of megapascals (MPa). Strain in terms of percent is calculated by dividing the crosshead displacement by the starting thickness of the foam and multiplying by one hundred. Results for the compressive stress-strain behavior tests are illustrated in FIGS. 2 and 2 c (comparative samples).
[0108] To measure the compressive hysteresis behavior, a foam sample is loaded into the Instron in the same manner as above. A pre-load of 2.5N is applied at 5 mm/min, and the crosshead position is re-zeroed. Then the sample is compressed at 10 mm/min until the stress reaches 0.38 MPA, designated as the compression step. Immediately, the crosshead is then reversed until a load of 0.0038 MPa is reached, designated as decompression. Without interruption, the sample is compressed and decompressed for 10 cycles.
[0109] To measure the compressive creep behavior, a foam sample is loaded into the Instron in the same manner as above, except that the environmental chamber is in place and preheated to a temperature of 65° C. The sample is placed in between the compression plates, at 65° C. After allowing the foam sample to equilibrate inside the chamber for one hour, a pre-load of 2.5 N is applied at 5 mm/min, and the crosshead position is re-zeroed. Load is then applied at 0.16 MPa. Crosshead position is then adjusted automatically by the Instron computer, to maintain a stress of 0.16 MPa for 12 hours. Compressive strain versus time is measured, the results of which are presented in FIGS. 3 and 3 c . After 12 hours, the crosshead returns to its starting position. After another two hours, the foam is removed and allowed to cool to ambient conditions (20° C., 50% relative humidity). The foam thickness is then remeasured. The corresponding strain is designated “strain at release, 2 hr.” The compressive creep behavior test results are presented in FIG. 4 .
[0110] To measure the energy absorption behavior of the foams FIFA quality concept methodology as described in the “March 2006 FIFA Quality Concept Requirements for Artificial Turf Surfaces,” the FIFA handbook of test methods and requirements for artificial football turf; which is fully incorporated herein by reference. These foams are tested according to this methodology and it is found that foams having a density of 144 kg/m 3 , as an example, perform acceptably. More detailed test results on shock absorption are provided below. Returning to compressive performance, the below graphs illustrate that the performance of the foam is not compromised by the elimination of crosslinking. In addition, embodiments of the present invention may be useful for any field that may use artificial turf, such as rugby and field hockey.
[0111] FIGS. 3 , 3 c , and 4 illustrate that essentially the same compressive creep performance and subsequent recovery may be achieved despite the elimination of crosslinking.
[0112] Synthetic turf, using embodiments of the present invention, is shown in FIG. 5 . Specifically, a non-crosslinked polythene foam is provided as a shock absorption layer, which may be bonded to a backing. Artificial grass is attached to the backing, and the spaces between the grass may be filled with an infill.
[0113] Embodiments using non-crosslinked polyethylene may be advantageous as non-crosslinked polyethylene is recyclable, and, thus, there are no environmental issues. Embodiments of the polymer foams described herein may also be useful as heavy layers for noise and vibration dampening, among others.
[0114] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
[0115] All priority documents are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted. Further, all documents cited herein, including testing procedures, are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted to the extent such disclosure is consistent with the description of the present invention.
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A synthetic turf surface including a synthetic grass carpet having a flexible base sheet, and a shock absorbing pad, wherein the shock absorbing pad includes a non-crosslinked polyolefin foam is shown and described. The foam may be recyclable, as it is non-crosslinked.
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This application is a divisional of application No. 08/179,954, filed Jan. 11, 1994.
FIELD OF THE INVENTION
The present invention relates to duplex communication systems for cellular radiotelephone systems for simultaneous two way voice communications. The present invention is also relevant to certain simplex systems, for example, landmobile radio systems that provide "press-to-talk" communications facilities between a plurality of correspondents in a radio net. The present invention is also relevant to satellite communications with portable or mobile terminals.
BACKGROUND OF THE INVENTION
The prior art contains several examples of duplex radio communications using Frequency Division Multiple Access (FDMA) in which different radio telephones each have a unique pair of frequencies for transmissions in the transmit and receive directions, for example, the U.S. AMPS cellular telephone system. The prior art also discloses duplex radio communication systems using Time Division Multiple Access (TDMA) in which each radio telephone has a unique time slot on a first shared frequency for communication in one direction, and a second unique time slot on a second shared frequency for communication in the other direction, for example, the European GSM digital system or the U.S. Digital Cellular standard IS-54. In these systems, the time slots in the respective directions are furthermore offset in time from each other so that the portable radiotelephones do not need to transmit and receive simultaneously. This eliminates the need for a transmit/receive duplexing filter which is required by a radiotelephone operating in a FDMA system. Instead, a so-called "time duplex" phone, as envisioned in the prior European Cellular System GSM, uses a simpler transmit/receive switch to couple the antenna alternately to the receiver or the transmitter.
In certain applications, neither TDMA nor FDMA provides an optimal solution. The TDMA system requires higher peak transmitter power to compensate for compressing the transmission into a time slot that is only a fraction of the total time, since it is the mean power that governs the range and quality of the communication. This is not an issue for a base station that in any case must have enough transmitter power to support all mobile stations, and the total power is the same for FDMA and TDMA solutions. It is simpler and cheaper for the TDMA base stations to have one high power transmitter and one antenna which can be timeshared between all base/mobile links using Time Division Multiplexing (TDM). However, it is often inconvenient for TDMA mobile stations to generate high peak power. 0n the other hand, it is inconvenient for FDMA mobiles to use antenna duplexing filters. Therefore, the present invention seeks to provide a method of using TDM on the base-to-mobile link (downlink) combined with FDMA on the mobile-to-base link (uplink), while avoiding the need for a duplexer.
The prior art discloses examples of mixed TDM/FDMA systems, such as the British Army's PTARMIGAN Single Channel Radio Access System (SCRA). The SCRA system is in fact a military radiotelephone system, and uses TDM on the downlink on a first frequency band while using FDMA on the uplink by allocating a separate frequency in a second frequency band to each mobile uplink. The SCRA system, however, requires either separate antennas for the uplink and downlink, respectively, or a duplexing filter to permit simultaneous transmission and reception through one antenna.
FIG. 1 illustrate the prior art transmission format described in the U.S. Digital Cellular standard IS-54. A base station transmits information continuously in frames of data which are 20 ms long. The data in question is composed of digitized speech information generated by a digital speech compression algorithm interspersed with synchronization, signalling and control symbols. Each 20 ms frame of data is divided into three time slots and each time slot contains information destined for one of three mobile stations. Thus, a particular mobile station only needs to turn on its receiver for one-third of the time since the data for the particular mobile station is confined to one of three time slots that make up the frame. In the reverse direction, the 20 ms frame is likewise divided into three time slots. Each mobile transmitter uses only one of the two time slots in which it is not receiving, which leaves the other third of the time which can be utilized to scan other base station frequencies to see if another base station is received more strongly. These signal strength measurements are reported over the uplink channel to the current base station, which makes a decision on whether to hand off communications with that mobile station to a stronger base station. Utilizing signal strength measurements performed by mobile stations in making handoff decisions is called "Mobile Assisted Handover" (MAHO).
In this prior art system, it can be seen that a mobile transmits for only one-third of the available time and therefore has to use three times the peak power that otherwise might have been sufficient if continuous transmission had been employed. If continuous transmission had been employed, all three mobile transmissions would be overlapping in time and would therefore have to be given different frequency channels as in the British Army's PTARMIGAN SCRA system. Furthermore, transmit/receive duplexing filters would be needed to allow simultaneous transmission and reception in the mobile station.
SUMMARY OF THE DISCLOSURE
The present invention relates to a radio access method for facilitating communication between at least one first station and a plurality of second stations. First, each signal intended for transmission is buffered at a first station. The signals are then divided into equal length segments. The signal segments intended for a particular one of the second stations is transmitted using a corresponding time slot in a regularly repeating time multiplex frame. The signal segments transmitted by the first station are received at at least one of the second stations and the signal segments are assembled from successive corresponding time slots to reconstruct said intended signal. A transmit frequency channel uniquely associated with the corresponding receive time slot is determined at the second station. Finally, a signal intended for transmission to the first station is buffered in the second station and compressed for transmission using the transmit frequency channel during substantially the entire time period that the second station is not receiving.
The present invention also discloses a radio transmitter/receiver for communicating in both directions with a radio network. The radio transmitter/receiver comprises a timing control unit for sequencing transmit and receive functions. An antenna switch alternately connects an antenna to the receiver and transmitter under the control of the timing control unit. A receiver portion controlled by the timing control unit receives a signal from the radio network during an allocated time slot in the time division multiplex frame period. Finally, a transmitter portion capable of being controlled by the timing control unit transmits during the rest of the time division multiplex frame period when the receiver portion is not receiving.
The present invention also discloses a method of communication for providing telephone communications between at least one outstation and a subscriber in a public switched telephone network comprising at least one orbiting satellite and at least one ground control station in communication with the satellite and the public switched telephone network. First, a signal from the satellite bearing time division multiplex information comprised of time slots in a repetitive TDMA frame period is transmitted, wherein each time slot is allocated for reception by one of the outstations. After receiving signal bursts from the satellite, the outstations determine a transmit frequency channel uniquely associated with said allocated time slot. Finally, the outstation transmits signal bursts using the transmit frequency channel to the satellite using substantially all of the remaining TDM frame during which the outstation is not receiving.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in more detail with reference to preferred embodiments of the invention, given only by way of example, and illustrated in the accompanying drawings in which:
FIG. 1 illustrates a prior art TDMA format;
FIG. 2 illustrates a TDM/FDMA format with overlapping mobile transmissions according to one embodiment of the present invention;
FIG. 3 illustrates a TDM/FDMA hybrid format according to one embodiment of the present invention;
FIG. 4 illustrates a TDM/FDMA hybrid format according to one embodiment of the present invention;
FIG. 5 illustrates the application of the present invention to satellite communications with a large number of time slots;
FIG. 6 illustrates a 3-cell frequency re-use plan;
FIG. 7 illustrates a block diagram of a portable radio according to one embodiment of the present invention;
FIG. 8 illustrates a base station for one embodiment of the present invention;
FIG. 9 illustrates satellite/mobile communications in one embodiment of the present invention;
FIG. 10 illustrates a hub-to-mobile satellite transponder; and
FIG. 11 illustrates a mobile-to-hub satellite transponder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a 3-slot TDMA communication system where the Mobile Assisted Handover feature is not required, but where simultaneous transmitting and receiving is to be avoided so as to eliminate the transmit/receive duplex filter, the present invention extends the transmit duty factor from one-third to two-thirds, thus halving the peak power requirement. The uplink and downlink formats according to the present invention are illustrated in FIG. 2.
As illustrated in FIG. 2, two of the three mobile transmissions overlap at any one time. In order to permit them to overlap in time, they must be made orthogonal, i.e., non-interfering, in some other domain such as the frequency domain. Since using twice the time for transmission allows the transmission data rate to be halved, it is possible to accommodate two transmissions within the same bandwidth by arranging that one of the transmissions uses the top half of an allocated bandwidth while the other transmission uses the bottom half, or vice versa. For example, a first mobile station may use the upper half of the channel bandwidth and halfway through its two-thirds transmit period a second mobile station can start transmitting in the lower half of the channel. Then, after a further one-third of the frame period, the first mobile station will finish using the upper half of the channel and a third mobile station can begin transmitting in the upper half channel. After a further one-third period, the second mobile station will finish using the lower half channel, and the first mobile station can start transmitting again. However, the first mobile station will be operating on the lower half channel instead of the upper half channel it originally operated on. This problem arises only when an odd number of time slot are used in combination with channel bandwidth division by an even number, and may be solved by either of the two methods described below.
The solution in which two mobiles use the upper and lower half channels respectively for two-thirds of the time while a third mobile station uses the upper half channel for its first third of the time and then switches to the lower half channel for its second-third of the time is avoided since the aim of any solution should be that all mobiles function identically independent of time slot. It is preferable, if frequency switching midway through the transmit burst is to take place in any mobile station that it takes place in all mobiles so that the system has a uniform design.
FIG. 3 illustrates one embodiment of the present invention in which a first mobile station receives a first third of the base station transmission and then transmits to the base station using the upper half of the uplink channel for the first one-third of its two-thirds transmit period. After the first third transmit period, the first mobile station switches frequency so as to use the lower half channel for its second one-third transmission period. Meanwhile, a second mobile station has received the second third of the base station's 40 ms frame and starts transmitting in the upper half channel when the first mobile switches to the lower half channel. Then, when the second mobile station switches to the lower half channel midway through its transmit burst, a third mobile station begins transmission in the upper half channel. When the third mobile station switches to the lower half channel, the first mobile station begins transmitting again in the upper half channel. The mid-burst frequency switch from the upper to lower half channel is preferably accomplished not by means of a fast switching frequency synthesizer, but rather by means of applying a systematic phase rotation to the transmitted signal in order to provide a plus or minus frequency offset from the center of the channel. This can be performed within the digital signal processing used for generating the modulation waveforms as will be discussed below.
A second embodiment of the present invention, which avoids a mid-burst frequency shift, is illustrated in FIG. 4. Here, a first mobile station first transmits in the upper half channel and halfway through its two-third transmit frame a second mobile station starts transmitting using the lower half channel. Midway through the second mobile station's transmit period, the first mobile station finishes transmission and a third mobile station begins transmitting using the upper half channel. Midway through the third mobile station's transmit period, the second mobile station finishes its transmission on the lower half channel. At this time, the first mobile station begins transmitting again on the lower half channel which is opposite from the channel it initially used. In this embodiment, every mobile functions identically but alternates between transmitting in the upper and lower half channels on successive bursts. In this system, the one-third receive period of 13.3 ms between successive bursts is available for changing the transmit frequency, which can be accomplished by using a frequency synthesizer with a modest frequency changing speed.
It will be appreciated that the invention is not limited to a system with three time slots. When an even number of time slots is used, for example four, and the mobile transmit time is three-fourths of a frame, the transmissions of three mobile stations overlap in frequency at one time. In such a situation, the channel bandwidth can be divided into three, and each mobile station can then use the three subbands in sequence. Alternatively, one mobile can transmit for 2/4 of the time in 1/2 of the bandwidth, while the other three use the other combinations of half-frame period and half-channel-bandwidth.
The above described solutions are in general characterized by dividing the uplink channel bandwidth into a number of subbands which is at least one less than the number of downlink timeslots `N`. For example, the three-timeslot case divides the channel into upper and lower halves, while the four-timeslot case divides the channel into three subbands. This is compatible with the reduction in bit rate by the factor (N-1) when the transmitter operates for N-1 timeslots instead of just one timeslot. When N is small, it is difficult to divide the number into N sub-bands without also reducing the bit rate by N instead of only N-1. For example, in the three-timeslot system, it would be difficult to accommodate a half-bit rate transmission, obtained by transmitting only 2/3rds of the time instead of 1/3rd, in only 1/3rd of the bandwidth. This difficulty however disappears when N is large.
FIG. 5 illustrates one embodiment of the present invention which may be advantageous for satellite-mobile communications. In this embodiment, a 512-slot TDM downlink is combined with a 512-subband FDMA uplink. To avoid using a duplex filter in the mobile station, the signal for transmission is compressed into 511/512ths of the time remaining over after the mobile has received its 1/512th of the downlink TDM format. However, the 0.2% increase in the information rate does not hinder it from being accommodated in 1/512th of the bandwidth. Without this signalling format, either the mobile would have to transmit and receive at the same time, necessitating a duplex filter which results in undesirable signal losses, or else use TDMA on the uplink involving the mobile transmitting, for example, for 1/512th of the time using 512 times the peak power which results in an undesirable increase in the peak power and current requirements from the power supply. The present invention may, of course, also in such a case permit transmission for 510/512 of the time or even less, without severe difficulties, the compression of the information not being restricted to clearing one timeslot for receiving if there are other demands on time, such as providing guard times between transmit and receive.
It can also be advantageous to consider other hybrids of TDMA and FDMA and even CDMA for the uplink in the case of satellite communications. Satellites orbiting at altitudes which are lower than the geostationary altitude exhibit significant velocities relative to stationary or mobile terminals on the ground. This can result in the Doppler shifts of the frequency received at the satellite from the ground terminals that are significant compared with the narrow transmission bandwidths of a pure FDMA uplink. It is therefore sometimes desirable to increase the uplink bandwidth to make Doppler shift relatively insignificant, without reducing the capacity of the system. A small factor increase, such as 2,4 or 8 may often suffice. One method of accomplishing a 2:1 increase in bandwidth while accommodating the same number of transmitters would be for each uplink transmission to be compressed into 256/512ths of the time on one of 256 available subbands; two transmissions in each subband would then be accommodated by TDMA through a first mobile station's transmitter using the 1/512th timeslots numbered 1 to 256 and a second mobile station's transmitter using timeslots 257 to 512. The first mobile station receives on timeslot 257, while the second mobile station receives, for example, on timeslot 1, thus avoiding the need for being able to simultaneously transmit and receive. This principle may be extended to 4 timeslots on each of 128 subbands, or 8 timeslots on each of 64 subbands, and so on. However, The mobile station's peak transmitter power must be increased as its duty factor is reduced by using more TDMA and less FDMA on the uplink.
The bandwidth may instead be expanded by the use of Code Divisional Multiple Access (CDMA) on the uplink. In CDMA, each of the original information bits is transmitted a number of times with or without a polarity inversion according to the bits of an access code. For example, a four-times increase in bandwidth is achieved by using the access code 1100 and transmitting, in place of the original bit B1, the sequence B1B1B1B1; B2 is also replaced by B2B2B2B2 and so on, giving a fourfold increase in bit rate. Another mobile transmission may be allowed to overlap this by use of a different access code, preferably an orthogonal code such as 1001. The other mutually orthogonal codes are 1111 and 1010, resulting in four, overlapping, non-interfering transmissions sharing a four times wider subband. This achieves a fourfold increase in uplink signal bandwidth which is desired to render Doppler shift relatively insignificant while preserving capacity without requiring higher peak transmitter powers from the mobile station.
The capacity in a cellular telephone system or in a mobile-satellite communications system, depends on being able to re-use the limited number of allocated frequencies for more than one conversation. The service area to be covered is usually divided into a number of cells each served by a base station (or illuminated by a satellite antenna spot-beam). Ideally, it should be possible to utilize the whole of the allocated spectrum immediately in each adjacent cell, however this is not conventionally possible due to the interference of neighboring cells used in the same frequencies. As a result, a frequency re-use plan must be employed to control interference levels. For example, a so-called 3-cell frequency re-use plan may be employed, as illustrated in FIG. 6. A 3-cell frequency re-use plan guarantees a certain minimum desired Signal-to-Interference (C/I) ratio that may suffice if adequate error-correction coding is employed on the transmitted signal. In general, the C/I is better for a 3-cell reuse plan in the satellite case than in the ground cellular case, due to the sidelobes of the satellite's cell illumination profile tapering off more rapidly out-of-cell than the signal strength reduction with increasing distance in ground propagation.
A problem can arise in applying frequency re-use plans to a TDM downlink. A limited allocated frequency spectrum has to be divided into three to permit a 3-cell re-use plan. As a result, the bandwidth of a full TDM solution can no longer be accommodated. This problem is solved according to an aspect of the present invention, by using a time-reuse plan instead of a frequency reuse plan on the TDM downlink, combined with a corresponding frequency reuse plan on the FDMA uplink.
In the time-reuse plan, cells designated `1` in FIG. 6 are illuminated from the satellite or from their respective ground base stations using the first 1/3rd of the timeslots in the TDM format, using the full available frequency spectrum. The cells labelled `2` then receive illumination during the second 1/3rd of the TDM format, and so-on. In this way, adjacent cells are not illuminated with the same frequencies at the same time, but the full TDM signal bandwidth is still transmitted. For example, in a 512 timeslot TDM format, cells numbered `1` are illuminated for the first 170 time slots. Each mobile terminal, after receiving its respective 1/512th time slot may transmit for the remaining 511/512ths of the frame using a designated one of the first 170 out of 512 uplink FDMA channels. The cells numbered `2` are then illuminated for the second 170 out of the 512 timeslots, and corresponding mobiles in those cells reply using FDMA and respective uplink channel frequencies 171 to 340. The cells numbered `3` then become illuminated for the third 170 out of 512 timeslots, and their mobiles reply on uplink frequencies 341 to 510. The remaining two timeslots can be reserved for illuminating all cells with a special signal used for paging and call set-up. Likewise, the two correspondingly unused uplink channel frequencies can be reserved for mobiles wishing to initiate contact with the system by performing a so-called random access.
By using the above system of time re-use plans on the downlink combined with a matching frequency reuse plan on the uplink, the described TDM/FDMA hybrid access method can be employed while controlling the interference levels between adjacent cells.
As previously disclosed, it can be desirable to widen the uplink channel bandwidths by employing TDMA or CDMA on the otherwise FDMA uplink and reducing the number of FDMA channels commensurately, in order to correct for Doppler shifts. It will be appreciated by those of ordinary skill in the art that the actual numbers used above are exemplary and do not imply a restriction of the present invention to those examples.
FIG. 7 illustrated a preferred implementation of a mobile or portable radio suitable for use in the present invention. An antenna 10 which operates at both the uplink and downlink frequencies is connected alternately to receiver 30 and transmit power amplifier 120 by means of a T/R switch 20, which is controlled by TDM timing generator 50. In the alternative, transmit/receive duplexing filters can be used if uplink and downlink frequencies are sufficiently separated to permit simple filters with low loss. When uplink and downlink frequencies are widely separated, a single antenna may not be efficient, in which case separate transmit and receive antennas may be necessary. This does not, however, change the principle of the present invention, which is to avoid having the transmitter active during receiving instances.
The timing generator supplies timing and control pulses to the switch 20, the receiver 30 and the digital demodulator and decoder 40 in order to provide them with power to select the signal in allocated timeslots on the downlink. The receiver 30 has sufficient bandwidth to receive the entire TDM downlink signal spectrum, but only one timeslot per 40 ms frame of this bit rate stream is selected for processing in the digital demodulator and decoder 40. During this selected timeslot, the signal from the receiver is digitized in A to D converter 31 and recorded in a buffer memory contained in the demodulator 40. The digitization technique preferably preserves the complex vector nature of the signal, for example, by splitting the real(I) and imaginary (Q) parts by means of a quadrature mixer, and then digitizing each part. An alternative to this so-called I, Q, or Cartesian method is the LOGPOLAR method described in U.S. Pat. No. 5,048,059 which is assigned to the same assignee and is hereby incorporated by reference. Another alternative technique is the co-called homodyne or zero-IF receiver such as described in U.S. Pat. No. 5,241,702 which is hereby incorporated by reference.
The complex vectors recorded in the buffer memory are then processed by the digital demodulator and decoder 40 during the rest of the frame time before collection of the next timeslot's complex signal samples. The demodulation stage of the processing can involve channel equalization or echo-cancelling to mitigate the effects of multipath propagation. Typical algorithms suitable for this are disclosed in U.S. Pat. application Ser. No. 07/964,848 now U.S. Pat. No. 5,295,112 and U.S. Pat. No. 5,331,666 assigned to the same assignee which are incorporated herein by reference.
To help bridge fading, error-correction encoded data frames may be spread over more than one timeslot by means of interleaving, so that a number of timeslots have to be collected and deinterleaved before the first frame of speech data is error-correction decoded. The demodulation of the signal samples in each timeslot should preferably be optimized together with the error-correction decoding algorithm for best performance at low signal-to-noise ratios, for example, by passing soft-decision information from the demodulator to the decoder, or by combining demodulation with decoding in a so-called decodulator.
After demodulation and error correction decoding, using for example, a soft-decision based convolutional decoder, a frame's worth of error-correction decoded speech data is passed to the speech coder/decoder 60, where it is turned into PCM speech samples at 8 kilo samples/second using a decoder that matches the encoder at the originating transmitter. The speech coding/decoding technique can for example be Residual Pulse Excited Linear Predictive Coding (RELP) or Code Book Excited Linear Predictive Coding (CELP) which compresses an 8 kilo sample/second PCM voice signal down to 4.2 kilobits/second at the transmitter, and conversely expands the 4.2 kilobits/second signal from the decoder 40 to 8 kilobits/second PCM signal again for D to A conversion in D to A convertor 130 and audio amplification for driving an earphone 132.
In principle, the receiver only needs to receive a single frequency on which all signals from all mobiles are multiplexed and modulated. As a result, the receiver does not have to tune to alternative frequencies, but rather, selects between all available timeslots. The control microprocessor 110 receives information on a calling/paging slot during call set-up designating the slot to be used for the call. The control microprocessor 110 then programs the timing generator accordingly, to generate all control pulses necessary to power the receiver and transmitter on and off according to the inventive TDM/FDMA hybrid formats described herein. The control microprocessor also programs the transmit synthesizer 90 to generate an FDMA channel uplink frequency associated with the allocated downlink timeslot with the help of upconvertor 80. The upconvertor 80 can operate in several manners. First, the upconvertor 30 can operate by mixing a fixed modulated frequency (TX IF) with the variable frequency produced by a programmable frequency synthesizer to generate a sum or difference frequency at the desired transmit channel frequency, wherein either the sum or the difference is selected by a filter. In the alternative, the upconvertor 80 can operate by mixing a signal from a voltage controlled oscillator with the synthesizer frequency to produce a difference frequency that is phase-compared to the fixed modulated frequency in a phase error detector, the phase error then being amplified and applied to the VCO in order to lock it to the modulated TX IF, thus causing the VCO phase to follow phase modulation on the TX IF. The determination of which method to select depends on whether the selected transmit modulation technique is pure phase modulation, i.e., constant amplitude modulation, or whether the selected modulation involves a varying amplitude component.
In the reverse direction, a speech signal from the microphone 131 is first amplified and converted to 8 kilobit sample/second PCM using A to D convertor 13 and then compressed to a reduced bit rate using the speech coder 60. Speech compression techniques such as RELP and CELP that compress speech to as low as 4.2 kilobit samples/second generally operate on 40 ms frames of speech samples at a time. A frame is typically compressed to 163 bits, that are then error-correction coded in digital encoder 70 before being modulated onto a radio frequency. The modulated radio frequency may be a fixed intermediate frequency locked to an accurate reference oscillator 100. The signal is then upconverted in upconverter 80 by mixing with transmit synthesizer 90 to the final uplink frequency signal which is then amplified by transmit power amplifier 120 and passed by the switch 20 to the antenna 10. The digital encoder and modulator 70 includes buffering (and if used, interleaving) in order to compress the transmission into the available time left over after receiving the downlink timeslot, so as to implement the aspect of the present invention, thus avoiding simultaneous transmitting and receiving. The timing of this compression, modulation, and activation and deactivation of the power amplifier at appropriate instances is also controlled by timing generator 50 so as to achieve the coordination between transmit and receive timing.
In some applications, the receiver may have to be able to tune to alternative channel frequencies as well as to select between the TDM timeslots on those channels. In those instances, the receiver 30 would also contain a frequency synthesizer programmed by control microprocessor 110 and locked to the accuracy of the reference frequency oscillator 100. The allocated frequency is given over a calling or paging channel at call set-up.
In landmobile radio applications using a push-to-talk operation, the mobile terminal may be a member of a group or net of correspondents sharing a trunked radio system with other groups. In trunked systems, all idle radios listen to a call set-up channel. When a radio transmits by activation of the talk switch, a short message is transmitted on the corresponding call set-up uplink channel requesting a channel allocation. The receiving base station network immediately replies on the downlink call set-up channel with a currently idle frequency/timeslot allocation to which the mobile terminal then adapts for the rest of the transmission. When the press-to-talk switch of the transmitting radio is released, an end of message signal is transmitted to expedite the reversion of the base network and other members of the group to idle mode in which they listen to the call set-up channel. This procedure is fast and automatic, within a fraction of a second, so that it is completely unseen to the human operators.
In cellular or satellite telephone applications, idle mobile terminals listen to a particular timeslot/frequency designated by the calling/paging channel. Moreover, transmissions on the calling/paging channel timeslot may be further submultiplexed to form less frequently repeated slots each associated with particular groups of mobiles, designated, for example, by the last few digits of their respective telephone numbers. These so called sleep mode groups are only paged in a particular submultiplex slot, which control microprocessor 110 is able to identify from received data and can thus program the timing generator 50 to wake up the receiver only at these instances, which results in considerable standby power current consumption savings.
Furthermore, the digital demodulator/decoder 40 can, after processing of each new received timeslot, produce an estimate of the frequency error of the receiver caused by inaccuracies of the reference oscillator 100 as well as Doppler shift, which can be significant in satellite systems. By using broadcast information from a satellite, the microprocessor 110 can correct for the Doppler shift and determine the error due solely to reference oscillator 100. The microprocessor 110 can then correct the error by sending a correction signal such as a tuning voltage to the oscillator, in order to insure that the transmit frequency which is referenced to the reference oscillator by transmit frequency synthesizer 90 is accurately generated. The process of correcting for Doppler shift involves determining the position or bearing relative to the satellite's orbit by utilizing any or all of the following parameters: measured rate-of-change of Doppler shift; satellite and antenna beam identification signals; broadcast information on the satellite's instantaneous three dimensional coordinates; previous mobile terminal position; elapsed time since last position estimate; and mobile terminal velocity.
In addition to the frequency correction mechanism mentioned above, the demodulator produces information on the position of signal samples in the buffer memory deemed to correspond to known sync symbols, which yields information on the accuracy of the timing produced by the timing generator 50. The microprocessor 110 performs sanity checks on this information and then uses it, if deemed valid, to demand small timing corrections of the timing generator 50 so as to correct for any drift.
FIG. 8 illustrates a block diagram of a base station implementation suitable for use in the present invention. A common antenna 210 is connected to a receiver low noise amplifier 230 and a transmit power amplifier 260 by a duplexing filter 220. The low noise amplifier passes the entire uplink frequency band to a bank of FDMA channel receivers 240. After digitizing the signal in each channel using one of the aforementioned complex vector digitizing techniques, the signals are processed in a bank of receive Digital Signal Processing devices 520 in order to perform demodulation and equalizing, error correction decoding, and speech decoding for each active channel. The resulting 8 kilobit samples/second speech signals are then time multiplexed using a standard digital telephone standard such as the T1 format for convenient connection to a digital switch or exchange 280 such as the ERICSSON AXE switch.
An alternative to the analog implementation of the FDMA receiver bank is to digitize the entire composite signal and to process it digitally to separate the individual FDMA signals. This is practical so long as the signal strength differences between the signals are not too great for the A to D convertor's dynamic range. Another aspect of the present invention is the inclusion of power control means to restrict the signal level differences between different FDMA signals in order to facilitate digital implementation of the FDMA receiver filter bank with potential simplification of the base station. The power control means proposed is known to the prior art and is based on the mobile stations assuming correlation between the signal strength they receive from the base station and the signal strength the base station receives from them. Thus, an increase in signal strength received from the base station is acted upon by a mobile station by reducing its transmitter power and vice versa. This is complemented by a slower power control means at the base station which includes up/down power control information in the signalling samples interleaved with voice symbols in each mobile station's timeslot.
The exchange/switch 280 selects between uplink signals received from the public switched telephone network or signals from an operator or control room for transmission on the downlink, according to call set-up information, requested routing, or preset information. The switch 280 supplies the selected signals multiplexed together according to some known digital telephone trunk such as T1 and delivers the signals to the transmit DSP bank 270. The transmit DSP bank separately encodes each speech signal in the multiplex stream using a voice compression algorithm such as RELP or CELP. The transmit DSP bank then error correction codes the signals and remultiplexes the signals into the downlink TDM format for modulation using modulator 290 onto the downlink radio frequency and amplification using high power amplifier 260. The switch 280 also extracts call setup information for the uplink calling channels and inserts call setup information corresponding to paging slots in the downlink TDM format. This information is identified as data and not as speech to the respective DSP devices so that it bypasses RELP coding and instead is subjected to a more powerful form of error correction coding.
A land based system may furthermore include separate antennas and associated receive signal processing in order to effect space-diversity reception to improve range and to combat fading. The combination of signals processed from remote antennas with signals processed with antenna 210 can take place either within the demodulation and equalizing algorithm, or by means of a simple diversity selection on a speech frame by speech frame basis according to signal quality. Likewise, in the transmit direction, a second distant transmitter may receive signals from transmit DSP bank 270 for transmitting on the same frequency so as to improve area coverage. The mobile receiver illustrated in FIG. 7 is able by means of its equalizing demodulator algorithm to perceive delayed signals received from a second transmitter as echoes of the first transmitter and to utilize these signals in order to improve reception.
FIG. 9 illustrates a block diagram of satellite communications system for one embodiment of the present invention. An orbiting satellite 410 is in communication with at least one ground station or called the HUB 400 as well as with a number of portable mobile phones 420. The phones are each serviced by an appropriate antenna beam from a multiple spot-beam antenna on the satellite providing high gain in the direction of each phone. The HUB communicates with the satellite using, for example, C-band or Ka-band frequencies, while the satellite communicates with the phones using, for example, L-band (uplink) and S-band (downlink) frequencies. In most cases, most calls will be between satellite phones and ordinary phones belonging to the public switched telephone network. The HUB station accepts calls from the PSTN and relays them to the mobile phone via the satellite, and conversely accepts calls from the mobile phones relayed from the satellite and connects them to the PSTN. A small percentage of calls can be mobile to mobile calls, and the HUB directly connects them to each other without necessarily involving the PSTN. In some systems, two or more HUBS located in different parts of the world communicate with the same satellite. In this case, mobile to mobile calls may involve Hub-to-Hub connections which can be accomplished through international trunk lines that may be part of the PSTN system. Alternatively, the satellite HUB links can allocate some capacity for Hub-to-Hub communication via the satellite for such occurrences thus avoiding landline tariffs.
FIGS. 10 and 11 illustrate a satellite communications payload suitable for one embodiment of the present invention. FIG. 10 illustrates the downlink to the mobile phones while FIG. 11 illustrates the uplink from the mobile phones. Referring now to FIG. 10, an antenna 360 receives a number of signals from the HUB which are demodulated or coherently downconverted using a bank of receivers 340. The receiver output signals are then coherently upconverted in a bank of upconvertors 320 by mixing with a common local oscillator 330. The upconverted signals are now at the downlink frequency and are amplified by a bank of power amplifiers 310, wherein each amplifier is coupled to one element, a group of elements, or a feed of a multi-beam antenna or phased array. In one embodiment of the present invention, the amplifiers are class C transmit power amplifiers operated at maximum efficiency. In one embodiment of the present invention, the satellite transmitter comprises saturated travelling wave tubes. The HUB is thus able by sending appropriate signals to the satellite antenna 360 to determine what signals will be broadcast by a multi-beam antenna 300 at what time and in what direction. In this manner, it can be determined, for example, that in any particular time slot of the down TDM format only a subset of regions of the earth receive the signals, the regions being sufficiently separated in boresight angle so that they do not suffer interference from one region to another. In this way, independent signals can be sent to one phone in each region in each timeslot without interference. In the next timeslot, a different set of regions, i.e., those in between the first set of regions, are illuminated so that all regions receive the signal from some timeslots in the frame. Copending U.S. Pat. application Ser. No. 08/179,953 entitled "A Cellular/Satellite Communication System With Improved Frequency Re-use", filed Jan. 11, 1994, which is incorporated herein by reference, discloses how one to one re-use can be used for the present embodiment wherein every timeslot is used in all of a number of sub-regions.
When the system is operating at less than full capacity, not all of the timeslots in the frame will be active. Moreover, one half of a two party conversation is generally silent at any time so that an advantage can be gained by turning off the signal in the corresponding timeslot momentarily. When the number of timeslots is large, i.e., 512, it is statistically accurate to assume that only approximately 50% will be active at the same time. The power amplifiers 310 are arranged to draw little or no current during inactive or unallocated timeslots so that the mean consumption from the satellite prime power supply corresponds, even when fully loaded, to only half the power amplifier peak power consumption. For a given size solar array, the power amplifier peak power can thus be dimensioned to twice the value which the solar array otherwise would support.
Furthermore, peak capacity is reached only at certain times of the day, whereas the solar array converts the sun's energy into electrical power during a full 24 hour period. By using a rechargeable battery to average the power consumption in 24 hours, a further factor increase in peak transmitter power can be made relative to the continuous load the solar array can support. An advantage of TDM downlink used in the present invention is that current consumption reduces in direct proportion to the under-utilization factor, in contrast with an FDMA or CDMA downlink which use power amplifiers which only reduce their current consumption by the square root of the under-utilization factor, if at all. Therefore, using a TDM downlink allows the full benefit to be taken of the average under-utilization factor.
In one embodiment of the present invention, the active time slots of any TDM signal are packed together to occupy adjacent time slots in a subframe period which is a portion of the TDM frame period. The inactive time slots form the rest of the TDM frame period. The subframe of any TDM signal retransmitted in one of the multiple satellite antenna beams does not overlap the subframes of the TDM signals transmitted in the neighboring beams.
Referring now to FIG. 11, a multi-beam antenna or multi-element phased array 400 receives signals on the uplink frequency from a plurality of mobiles. Mobiles in the same region of the earth use different FDMA channel frequencies on the uplink and according to the invention do not transmit during their received timeslots on the TDM downlink. Mobiles in a different region of the earth use the same set of frequencies as mobiles in the first region, therefore the antenna 400 receives a plurality of signals on each FDMA channel that arrive from different directions. In the case of a multi-beam antenna such as a parabola with space feeds, the different directions correspond to different beams so that signals on the same frequency appear in different beams and can thus be separated. This may require that adjacent beams do not contain the same frequencies, but that an adequate re-use factor is employed such as the three to one frequency re-use pattern illustrated in FIG. 6. When uplink FDMA channels are associated with corresponding downlink TDMA timeslots, the use of a three-to-one time re-use pattern on the downlink as disclosed above automatically gives rise to a three-to-one frequency re-use pattern on the uplink, thus achieving separation of signals. On the other hand, a one-to-one re-use frequency pattern can be achieved for the uplink using the configuration of FIG. 10 particularly when antenna 400 is a phased array.
The antenna 400, whether a multi-feed parabola or multi-element phased array, presents a number of RF ports containing a plurality of mobile uplink signals. A bank of low noise amplifiers 410 and downconvertors 420 amplify these signals and coherently downconverts them using a common local oscillator 470 to a suitable intermediate frequency for amplification and filtering. The downconverted filtered and amplified signals are then applied to a bank of upconvertors or transmitter modulators 430 which translate the signals to the C or Ka bank while preserving their phase relationships before adding them in a combiner 440 and amplifying them in a traveling wave tube TWT power amplifier 450 for transmission to the HUB station through an antenna 460. It should be noted that the antenna 460 in FIG. 11 may be the same as the antenna 360 in FIG. 10, the C/Ka bank receiver then being separated from the transmitter by means of a duplex filter. Moreover, both polarizations may be used in both directions in order to increase bandwidth utilization. Each polarization would then have associated with it half of the receiver bank 340 and half of the transmitter bank 430 connected to a separate traveling wave tube. Furthermore, a downlink antenna 300 and the uplink antenna 400 can also in principle be one and the same with the addition of transmit/receive duplexing filters for each beam, array element or sub-array, thus achieving double use of the same antenna aperture.
A description of the corresponding HUB station equipment may be found in the aforementioned U.S. Pat. application Ser. No. 08/179,053, entitled "A Cellular/Satellite Communication System With Improved Frequency Re-use", which is hereby incorporated by reference.
It will be appreciated by those or ordinary skill in the art that the number of timeslots, frequency bands and applications mentioned above are primarily for the purpose of illustration and are not meant to imply any limitation of the present invention. The present application contemplates any and all modifications that fall within the spirit and scope of the underlying invention disclosed and claimed herein.
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A radio access method for facilitating communication between at least one first station and a plurality of second stations is disclosed. First, each signal intended for transmission is buffered at a first station. The signals are then divided into equal length segments. The signal segments intended for a particular one of the second stations is transmitted using a corresponding time slot in a regularly repeating time multiplex frame. The signal segments transmitted by the first station are received at at least one of the second stations and the signal segments are assembled from successive corresponding time slots to reconstruct said intended signal. A transmit frequency channel uniquely associated with the corresponding receive time slot is determined at the second station. Finally, a signal intended for transmission to the first station is buffered in the second station and compressed for transmission using the transmit frequency channel during substantially the entire time period that the second station is not receiving.
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This is a divisional of application Ser. No. 09/522,219, filed Mar. 9, 2000, now U.S. Pat. No. 6,524,007.
BACKGROUND OF THE INVENTION
The field of the invention relates to rubber laminated bearings used to support and seal a limited-movement shaft that penetrates the wall of a pressure vessel.
In the prior art, rubber-laminated bearings as disclosed in U.S. Pat. No. 2,900,182, include multiple alternate laminations of metal (or other strong inextensible material) and rubber (or generally any elastomer) bonded together, the rubber layers in particular being thin relative to their width and/or of relatively stiff composition. Lateral motions between succeeding metal laminations are permitted by shearing action within and parallel to the intervening rubber laminations, while the stack of laminations so-formed can often sustain very high normal forces (eg, 20,000 psi or more) with very slight compression because of negligible extrusion of rubber out from between the metal laminations. They can be made with laminations in any shape, with apertures or not, and with various cross-sectional configurations, including truncated planar, conical, spherical, chevron-shaped or cylindrical layers. Often, to provide complete practical bearings, thicker layers of metal are bonded on the outsides to the underlying laminates as described, forming external layers that are load faces. These two outer layers may be shaped to conform with and to seal with respect to mating members and to provide for keying to the latter for orientation and prevention of slipping.
When the external load faces of such a bearing are interposed between complementally-contoured and opposed loading members, it can resist thrust, radial or combined forces normal to its layers, depending upon its configuration. Relative lateral movement between the opposed loading members, which may include pivoting about a normal axis as well as transverse or lateral shifting, results in a distribution of the aforesaid shearing movements between individual rubber layers. These relative motions are accompanied by opposing forces proportional to their extent, caused by shear stress in the rubber laminations.
An additional property of such a load-bearing laminate stack that contains one or more apertures is the capability of sealing the space occupied by the laminations between the opposing members against the lateral or transverse flow of fluids, ie, liquids or gases, between the periphery of the laminate stack and an aperture, and making them essentially impervious even under substantial differential pressure. This is shown in U.S. Pat. Nos. 3,532,174 and 3,610,347, where such bearings for a vibratory drill mechanism were sealed against drilling fluid and were indicated to be of cylindrical (ie, radially loaded) or acute-angled conical (combined loading) configurations. U.S. Pat. Nos. 3,734,546, 4,068,864, 4,068,868, 4,076,284 and others typically show spherically-configured rubber laminate bearings used to seal the joints of submerged oilfield pipe sections while permitting flexibility between them. Further, U.S. Pat. Nos. 3,504,902/3/4 show spherical rubber laminated bearings used in the throat of rocket nozzles to permit control of the thrust vector by tilting the nozzle, while sealing against the lateral escape of the hot gasses.
None of these laminated bearing references were found to provide for sealing a shaft that penetrates the wall of a pressure vessel so that motions applied on one side may be carried to the other to accomplish some purpose. Indeed, all of the patents cited in the previous paragraph are functionally dependent upon a free path for fluid flow through the pipe or nozzle that is surrounded by the bearing-seal that is employed. If their pipe or channel for fluid flow were to be considered a shaft with a longitudinal hole through it, that hole would completely invalidate the present purpose, which involves preventing any such flow from one side to the other of the wall through which the shaft passes.
Existing methods of providing the desired sealing function for a shaft penetrating the wall of a pressure vessel employ a lip seal or face seal, conventional though designed for high pressure, that slides on the surface of the shaft or on a flanged part of it. All such methods must contend with friction torque, all the greater under conditions of extreme pressure even when anti-friction materials such as reinforced tetrafluoroethylene are used. Moreover, because sliding on a surface is involved, its smoothness must be assured and care must be taken to prevent ingress of foreign material or objects that could not only cause rapid wear but could damage the sealing integrity of the seal or shaft surfaces.
BRIEF SUMMARY OF THE INVENTION
In this invention, one of the loading members is an enlarged contoured enlargement or flange at the midsection of a shaft, ie, between its ends, against one or both sides of which enlargement or flange there is seated a complementally-contoured or conforming rubber-laminated bearing-seal having an aperture as described. The shaft extends through a bearing aperture and on through an aperture in a bearing housing or receptacle part of the wall of a pressure vessel. This housing or receptacle comprises a radially inward load-supporting seat or appropriately contoured annular flange against which said bearing-seal is seated, ie, the other loading member of said bearing-seal is part of or connected to the wall. The wall separates two liquid, gaseous or even vacuous media, all considered as fluids herein. The nested laminations or layers of said bearing-seal may be surfaces of revolution about an axis that corresponds to the shaft axis. Hence, the shaft can carry limited movements, rotational or lateral and parallel to the laminations, from one side to the other of the wall while being sealed against any fluid flow between the sides despite substantial pressure differences, and while resisting the resulting thrust. The force or torque reaction is negligible due to friction and small with small movement compared with the relatively high friction of conventional sealing methods.
The reasons for penetrating the wall of a pressure vessel with a sealed movable shaft generally dictate that some functional mechanism be provided at each end of the shaft, coupled with it to impart or receive torque or force and motion to it. Thus, one potential use is in the intense hydrostatic pressure environment of undersea applications at great depths, carrying limited or oscillatory motion through the hull of a manned or robotic submarine craft. Failure to provide the expected sealing effect could be catastrophic. Backup using a second laminated bearing-seal or conventional O-ring seals or their functional equivalent in series can be used for protection against such events.
It is an object of the invention to provide a new means with very low friction and reliable long life for sealing a limited motion shaft that penetrates the wall of a pressure vessel to accomplish some purpose.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a cross-section of a flat-configured bearing-seal assembly according to the invention.
FIG. 2 is an alternate construction of an encircled part of FIG. 1 .
FIG. 3 is an alternate construction of an encircled part of FIG. 1 which shows a cross-section of a shallow-conic-configured bearing-seal assembly according to the invention.
FIG. 4 is a cross-section of a cylindrically-configured bearing-seal assembly according to the invention.
FIG. 5 is a perspective view of a cylindrically-configured bearing-seal according to the invention.
FIG. 6 is a cross-section of a double flat-configured bearing-seal assembly according to the invention.
FIG. 7 is a cross-section of a double spherically-configured bearing-seal assembly according to the invention.
FIG. 8 is a cross-sectional schematic view of a spherically-configured bearing-seal assembly according to the invention with attachments arranged to provide a novel result.
DETAILED DESCRIPTION OF THE INVENTION
In the following disclosure and claims, the terms “top”, “bottom”, “up”, and “down”, etc. are used for convenience only and refer in actuality only to the relative position of parts of the assembly, particularly as they appear in the figures, whereas it should be understood that any orientation of the assembly is possible in practice. “Top” as used here generally corresponds to the high pressure side of the wall of a pressure vessel, and “bottom” the low pressure side.
FIG. 1 is a cross-section (except shaft 4 ) of such a laminated bearing-seal with a circular and annular flat or planar-layered configuration, capable of permitting rotational movement 4 f while withstanding the thrust loads and external radially-inward compressive loads caused by hydrostatic pressure. Higher- and lower-pressure fluid media, 1 and 2 respectively, are situated on opposite sides of the wall or hull 3 of a pressurized vessel. The wall incorporates a bearing housing for admission of the shaft 4 and the laminated bearing-seal 5 that encircles the shaft and includes one or more stacks 5 a of washer-like rubber and metal laminations. The housing is shown with a circular cavity enveloping the bearing-seal and a recess or receptacle 3 a engaging the load face of its bottom outer layer member (ie, its second load-face), the washer or end plate 5 b . Said receptacle 3 a constitutes one of the loading members on bearing-seal 5 . It would obviously not be essential that receptacle 3 a be at the bottom of a cavity surrounding the bearing-seal to be effective; the receptacle could instead be on the top surface of the wall 3 , for instance. The shaft has a larger-diameter circular flange 4 c in its mid-section with a flat-bottomed face that engages the load face of the top end plate 5 e of the bearing-seal (ie, the latter's first load-face) and thereby provides the other loading member.
Unless the gaps between the top and bottom end plates 5 e and 5 b and their mating load members are effectively sealed by direct bonding, some other means of sealing between them must be provided. To do so here, the end plates 5 e and 5 b are both shown with aperture-encircling grooves in their load faces to accomodate O-rings 5 d or functionally-equivalent sealing rings of other cross-sectional shapes than circular, eg, lip seals. With the bearing-seal itself, these seals complete the overall sealing function between the engaging loading members, ie, between the recess 3 a and the flange section 4 c , and thus between the wall 3 and the shaft 4 .
Other possible relative locations of such conventional encircling seals between the mating members are evident. FIG. 2 depicts such a case as an alternate construction of an encircled part of FIG. 1, showing the left cross-section of the symmetric bearing-seal and its mating parts. The seals 5 d reside in annular grooves between the diametral outsides of the end plates 5 b and 5 e and the bores of the cavity and of an annular recess in the downward extended bottom of the flange 4 c , respectively. Flange 4 c is shown partially sectioned for clarity. The top seal could instead or in addition have been placed between a groove at the inside diameter of the end plate 5 e and the outside diameter of the shaft 4 , as indicated by 5 h.
The bearing-seal of FIG. 1 or 2 may also include some means of lateral support or restraint against columnar deflection, if needed, such as taught in U.S. Pat. No. 3,228,673. According to one such method, at least one interposed flat washer plate 5 c forms a thick intermediate lamination or layer that extends radially beyond the outside diameter of the other laminations. Its outside diameter provides a smooth circular surface engaged to slide within the cylindrical cavity of wall 3 . The latter may be lined for that purpose with a suitable thin low-friction sleeve 3 b made of a bearing material such as reinforced TFE which is adequate for the small motion and minimal radial force that might be reacted. Alternatively, such lateral support could be provided by extension of the plate(s) inwardly to bear upon the shaft 4 surface, appropriately lined. As shown, however, the shaft at 4 b is relieved slightly to prevent the laminations from rubbing it directly.
Shaft 4 is maintained in a centered position relative to the housing by radial bearing (eg, needle) or bushing means 6 or 7 at the locations 4 c or 4 a above or below bearing-seal 5 , or both. Item 6 in particular indicates a sleeve-bushing having a shoulder flange 6 a . It is screwed and locked (not shown) in place so that flange 6 a has a slight axial clearance gap from shaft flange 4 c and functions as a positive retainer to prevent inadvertent axially-upward movement of shaft 4 . (Such a restraint might otherwise be applied on the shaft by means located on the bottom side of the wall.) Large radial clearances of items 6 and 7 would permit limited cross-axis or lateral translation of shaft 4 should that be desired. Primarily however, limited circular motions of the shaft as indicated by 4 f will be carried through the wall 3 of the pressure vessel. Instead of extending axially directly, a shaft extension 4 d , secured by breakable bolts 4 e or other means, could be employed to provide protection against inadvertent external side overloads that might otherwise endanger the integrity of the sealing function. Collapsible means (not shown) could also be provided on the top side of the shaft to prevent downward axial overloads. A breakable extension might be desirable on the opposite end of the shaft as well.
Positive mechanical stops to limit the extent of angular travel of the shaft to safe maxima are also indicated. In one of many possible ways, the cross-axis pin 4 g is affixed in a hole drilled through the shaft 4 to create a lever arm that operates freely in an angular range defined by the positioning of two stops 3 e (only one shown, partially occluded by the pin). The angular orientation of these stops relative to the pin would typically be chosen with the halfway point between the stops corresponding to the untorqued position of the bearing-seal.
The orientation of these stops operates in conjunction with the bearing-seal end faces 5 b and 5 e being keyed or tabbed against torsional slippage between the shaft and the wall. The method shown in FIG. 1 comprises a tab-like key 5 f as part of the bottom end plate 5 b , extending radially outward from it into a key slot 3 d cut axially into the bearing housing, while the shaft is keyed to the top end plate 5 e by a pin 4 h permanently fitted into a hole in the bottom of the flange 4 c and projecting downwards into a loose-fitting hole 5 g partway through the top end plate 5 e near the edge. Such keying will ensure that the torsional spring action of the bearing will return it to the initial position when untorqued. In FIG. 2, pins 4 h and 3 h project into holes 5 g on the top and bottom end plates respectively. In general, keys or tabs interlocked with slots and pins interlocked with holes are examples of complemental interlocking mechanisms that relatively restrain the associated parts. Some kind of relative restraint method is assumed to be available as well in the later configurations that will be presented even if not actually shown in the figures, including the possibility that a bearing-seal is directly bonded to a mating load member.
Failure of the bearing-seal's sealing function should be quite unlikely with proper design, but for a potentially critical application, backup protection may be deemed essential. A secondary seal 8 is provided by an O-ring as shown, or a suitable lip or face seal, or some other functionally equivalent means encircling the shaft in the conventional manner to block flow of the high-pressure fluid 1 past it in case of such failure. It would ordinarily be relieved of differential pressure by the bearing-seal and therefore a minor source of friction torque.
Furthermore, failure by axial collapse of the bearing-seal, though very unlikely, could be limited by a physical stop. An annular land or shoulder part 3 c of the bearing housing is provided by making its diameter and the cooperating diameter of shaft flange-section 4 c larger than that of sleeve 3 b , while the thickness of the axial clearance gap at 3 c between the flange-section 4 c and the land is made relatively small. Any downward axial movement of shaft 4 as a consequence of such failure would then be limited by that gap dimension. Although frictional torque on the shaft might be high with the secondary seal called into action, or the shaft even completely immobilized by partial axial collapse, protection against catastrophic fluid flow would be provided.
Consideration of the forces and internal stresses in such a bearing-seal configuration shows that its average static compressive stress Sc due to the downward thrust force induced by differential (high minus low) pressure p is approximately
Sc=p ( Do 2 /( Do 2 −Di 2 )),
where Do and Di are the outside and inside diameters of the laminations and relatively small pressure on the bottom side is ignored. Shear stresses in the rubber have two components: essentially radial stresses resulting from Sc and p and any additional external loading (these shear stresses can be kept reasonably small because of the high width-thickness ratio or stiffness of the rubber laminations); and tangential stresses resulting from the torsional strain applied due to rotation of the bearing-seal. The hydrostatic pressure on the outside of the circular laminate results in compressive circumferential hoop stresses in the metal layers, so that the bearing-seal is self-supporting against them, with Sc acting to prevent buckling of the metal laminations. The peak radial tensile stress in the metal laminations may be of the same order as Sc if metal and rubber layers are equally thick, and can otherwise be adjusted by proper selection of metal thickness relative to rubber thickness.
A typical small flat bearing-seal corresponding to FIG. 1 or 2 could have dimensions Do=2.062 in. and Di=1.000 in., and operate under a pressure differential p=10,000 psi. Sc is then calculated at 13,075 psi. Very thin laminations of unstiffened natural rubber and 100,000 psi-tensile cartridge brass (about 80 of each at 0.002″ thick each) might be used, and could produce torsional stiffness of 9 lb./in. at the end of an 8 in. lever arm, readily moveable by hand through +/−15 degrees. Fatigue life is a consideration in establishing the limits of the applied oscillatory angles of motion and the number of life-cycles. Bearing-seals of these dimensions and loads have been oscillated at +/−15 degrees for almost two million cycles without sealing failure. Many more cycles would be expected with normally smaller angles or more layers to reduce the oscillatory torsional strain in the rubber, while fewer cycles are obtained with higher pressure.
Larger bearing-seals could maintain a large width-thickness ratio (265 in the example above) or could be made with stiffer rubber. Dimensions can be chosen according to known principles to provide adequate strength, prevent buckling, and to select overall torsional stiffness, taking into account the bearing thickness, normal forces, differential pressures, and the extent of movements.
Besides the configurations of FIGS. 1 and 2, it will be appreciated that other configurations of rubber-laminated bearings as taught by U.S. Pat. No. 2,900,182, and other means of external or integrally-preformed lateral support as taught in U.S. Pat. Nos. 3,228,673 and 3,083,065 respectively, may be used in a similar manner to accomplish similar objectives.
The left half of a symmetric cross-section of a shallow conical bearing-seal is shown in FIG. 3 as an alternate construction of an encircled part of FIG. 1, with labels analogous to FIGS. 1 and 2. The conical shape of the laminations would provide the radial-centering action and internal support otherwise provided by one of the radial bearings or bushings 6 or 7 and the central plate 5 c of FIGS. 1 and 2. However, the internal stresses developed in a conical bearing-seal would be higher than those for an otherwise similar flat bearing-seal under the same external pressure, the more so the greater the deviation from flatness. As a consequence, only shallow conical bearing-seals may be practical for high pressure conditions. Bearing-seals with laminations that are chevron-shaped in cross-section could also provide self-support.
An assembly with another variation in shape is seen in FIG. 4 that uniquely does not permit any rotation about the longitudinal axis of the shaft, but rather oscillatory movement 4 f about a transverse axis. It uses a laminate pad, ie, bearing-seal, with laminates that are truncated sections of concentric circular cylinders having a central aperture, as detailed in the perspective view of FIG. 5 . The least and greatest radius layers are preferably thicker than the rest to form external load faces 5 e and 5 b respectively.
In the assembly, FIG. 4, the wall 3 separates the high pressure medium 1 from the low pressure medium 2 as before and has a hemi-cylindrical recess 3 a with a through-aperture for the shaft 4 , thereby forming a radially-inward annular flange in the wall to act as a load member and receptacle. The shaft extends on either side from a bulbous enlarged cylindrical central portion 4 c having a transverse axis and providing the function of a flange as a load member. The bearing-seal 5 is fitted into recess 3 a and supports the bottom load face of the transverse cylindrical portion 4 c . Leakage between the shaft and the wall is prevented by the laminate, together with O-ring seals or equivalent 5 d that encircle the shaft in grooves cut into the convex and concave cylindrical surfaces of 4 c and said recess respectively, thereby sealing the load faces 5 e and 5 b against cross-flow. A conforming hemi-cylindrical cap 6 a with an aperture is fitted as a bearing pad over the top surface of the shaft central portion 4 c to hold it down while permitting 4 c to move under it, and cap 6 a in turn is supported and spring-loaded by a bracket 6 b that is affixed to the wall 3 . Cap 6 a is thereby permitted to move slightly down under the force of the spring 6 c , eg, of the Bellville type. This arrangement prevents upward motion of the shaft, while permitting slight vertical movements due to temperature expansion or contraction or load deflection of the bearing-seal 5 . Although some lateral movement of the shaft along the axis of its cylindrical portion 4 c might be permitted by clearances at the ends of said portion 4 c relative to the ends of recess 3 a , the primary rotational oscillatory movement allowable is indicated by the arrows 4 f.
It is noted that the shaft of the FIG. 4 assembly passes through the bearing-seal aperture from one side of the wall to the other while its axis of revolution does not, ie, the longitudinal extent of the shaft is not substantially aligned with its axis of revolution.
Whereas all configurations according to the invention shown to this point have involved a single rubber-laminated bearing-seal, there are additional features available when two are employed. FIG. 6 indicates a double flat bearing-seal configuration. The bottom bearing-seal S has the same relation to the shaft flange 4 c and the bearing housing recessed seat 3 a as the single bearing-seal in FIGS. 1 and 2, and optionally retains the top and bottom radial bearings or bushings 6 and 7 . The top bearing seal 5 has the same features in mirror opposition to those already discussed for the bottom bearing-seal and is mated in similar relation to the top face of the shaft flange 4 c . Its top load face at 5 b is mated to the downward oriented recessed face of a retainer sleeve 6 a enclosed by the cylindrical bore of the cavity or housing in wall 3 . A seal 6 d , O-ring or equivalent, encircles the sleeve 6 a to prevent ingress of pressurized fluid medium 1 past the clearance in this bore. A bolted hold-down plate 6 b on the top of the housing applies a downward force on the sleeve 6 a through suitable axial spring means such as the Bellville spring 6 c , thereby compressively preloading both bearing-seals and sandwiching the flange 4 c between them. It is essential that retainer sleeve 6 a remain easily slidable within the housing bore so that slight axial movements due to thermal expansion or compression under load in the bearing-seals are not inhibited and so the top seal capability is maintained; anti-friction and anti-corrosion surface treatments to the bore and sleeve may be found desirable for that purpose.
Optional backup from an O-ring or equivalent seal 8 could be provided as before to further enhance sealing integrity. Angular stops on the shaft 4 are assumed as in FIGS. 1 and 2 but not shown, and keying of each bearing-seal to the shaft 4 and to the housing 3 by some means is also desirable. Although the top bearing-seal could be keyed to the housing directly, it could instead be done by using retainer sleeve 6 a as an intermediate link; ie, keying the top plate 5 b to 6 a and that in turn to the housing.
The axial force upon the top bearing-seal depends upon the outside diameter Ds of the retainer sleeve 6 a and the inside diameter Di of the bearing-seal, so the compressive stress on it is aproximately
Sc=p (( Ds 2 −Di 2 )/( Do 2 −Di 2 )),
ignoring the preload and the assumed small pressure between the two bearing-seals. The bottom bearing-seal, in serial loading relation to the top, would additionally see the pressure on the top of the shaft 4 , so that its compressive stress would be given by the formula
Sc=p ( Ds 2 /( Do 2 −Di 2 )),
again ignoring the assumed small effects of the low pressure side and the intervening pressure. It is desirable, in minimizing Sc on both bearings, to make Ds as small as possible.
Whereas the single bearing-seal 5 in FIG. 1 or 2 sees the high pressure on its periphery, the top bearing-seal in FIG. 6 will experience the high pressure in its aperture instead, and this will result in a different radial distribution of radial shear stresses in the rubber layers and create a component of hoop tension rather than compression in the metal layers. The bottom bearing of FIG. 6, however, would normally see no substantial pressure difference between its inside and outside.
Adding the top bearing-seal puts it in a serial primary sealing relation to the bottom bearing-seal. In case the intervening volume between the bearing-seals were filled with an essentially incompressible fluid, some sharing of the sealing function might occur, ie, each might share part of the total differential pressure. In the event of failure of the top seal function, the bottom bearing-seal would become the primary seal and it should function in the same manner and with the same loads as that of the single bearing-seal in FIG. 1 or 2 .
Alternatively, to obtain smaller Sc on the bottom bearing-seal, for instance, the primary and secondary sealing roles could be reversed. That is, the bottom bearing-seal could be made the primary seal and the top the secondary seal by the provision of a small pressure-equalizing port shown schematically by dashed lines 10 from the high pressure medium 1 above the top seal to the intervening space occupied by the flange 4 c , so that the latter space would experience the high pressure. This port would necessarily contain an appropriate overflow shutoff valve 11 such that if the bottom bearing-seal were to begin passing fluid, the high makeup flow through the port would cause it to be closed off, so that the pressure at flange 4 c would drop to the low pressure and the top bearing-seal would then carry the pressure load and provide the seal (this scenario assumes the absence or ineffectiveness of a backup seal 8 ).
Double conical or chevron-shaped bearing-seal configurations could obviously be made in a fashion similar to the flat configuration of FIG. 6, while providing inherent radial centering as in FIG. 3. A combination of a flat bearing-seal and one of those two types could do the same. Moreover, double cylindrical configurations could be made by providing a top bearing-seal of the type in FIG. 5 together with the lower single cylindrical bearing-seal of FIG. 4 .
FIG. 7 represents a double spherical bearing-seal shaft-through-wall configuration that would uniquely permit not only limited rotation of a shaft 4 about its own axis, but also limited angular movement of the shaft about any axis. High and low pressure media 1 and 2 respectively are separated by the wall or hull of a pressure vessel 3 containing two spherical bearing-seals 5 (top) and 5 (bottom), which in turn surround, support and seal the shaft 4 (not sectioned) which penetrates from one side to the other of the wall through an aperture. The two spherical bearings each have a stack 5 a of bonded rubber and metal laminations that are essentially segments of nested concentric spheres that have a common center point on the centerline of the shaft, and each has outer layer plates or fittings that adapt the laminate stack to the cooperating loading members. Relative to the latter outer layer fittings, rather than a separate conforming retainer sleeve (as seen at 6 a in FIG. 6) to transfer thrust to the top bearing-seal, it is elected here for that function to be provided by a shell 5 b that has a top load face 5 i upon which the pressurized fluid medium 1 pushes, and it is bonded directly to the rest of the laminate stack. Thus for both top and bottom bearing-seals, 5 b is a cylindrical metal shell that slips into the bore of the bearing housing 3 and has an inside spherical surface that defines an outer layer concentric and bonded to the underlying lamination of stack 5 a . The shell 5 b of the bottom bearing-seal is seated at 5 i on an inwardly flanged flat receptacle with an aperture at the bottom of the bore. At the least radius of each laminate stack 5 a , the other outer layer member of each bearing-seal is a metal shell 5 e with a concentric spherical surface bonded to the laminate stack 5 a , and its load face is made concave-conical to fit on a tapered load face 4 h of the flange. (Otherwise, these tapered load faces could have been made spherical at 4 h for contiguous support or even direct bonding to the least radius of the stacks 5 a ). O-rings 5 d or equivalent seals are indicated around the outer shells 5 b to seal against fluid flow through the bore at their respective locations. The bottom shell seal 5 d also prevents flow of fluid relative to, with respect to, or across the mating load face with the seat at 5 i . An O-ring or other seal could instead be arrayed at the mating load face with the seat as in FIG. 1 . O-ring seals 5 j or the like are also on the tapers 4 h to seal against the shells 5 e . A bolted-down retainer plate 6 b together with an axial force spring 6 c (eg, Bellville type) pushing down against the top load face 5 i of top shell 5 b is used to contain the bearing-seal assembly and provide a compressive preload upon it.
This configuration would sustain the differential pressure and provide a seal against passage of fluid from medium 1 to medium 2 because of the sealing capability primarily of the top bearing-seal and secondarily of the bottom bearing-seal. Obviously, the reversing of primary and secondary sealing roles by the small self-checking port shown in FIG. 6 could also be applied in this double bearing-seal configuration. The shaft apertures at top and bottom provide direct means for limitation of non-twisting angular motion. For the case of shaft twisting, anti-slip keying of shells 5 b and 5 e respectively to the wall 3 and shaft 4 and angular stops may be provided but are not shown.
The tapered sections 4 h on both the top and bottom of the shaft flange expand into a central circular part 4 c that extends radially toward, but with clearance gap 4 i from, the inside spherical surfaces of shells 5 b . Because of this small radial clearance, flange 4 c provides a further backup safety function of maintaining the shaft essentially centered in the unlikely event that either bearing-seal should fail in a crushing mode. If that were to happen to the bottom bearing-seal, the pressure on the top bearing-seal would cause it and the shaft to move downwards somewhat until flange 4 c jammed against the internal spherical surface of the outer shell 5 b on the bottom. The clearance gap 5 k between the top and bottom outer shells 5 b should be large enough to permit this axial shift without closing up, or the top seal could be lost. However, this jamming event itself could have the beneficial effect of sealing between the flange 4 c periphery and the inside surface of bottom shell 5 b , especially if the materials of the two are relatively selected (or coated) to permit slight plastic deformation that could absorb any small gaps between them.
In a single bearing-seal variation, the top spherical bearing-seal 5 a could be eliminated and replaced by a concentric half-ball surface on the shaft in place of the tapered section at 4 h and a low-friction apertured socket acting upon it from above as an axial retainer similar in function to the threaded sleeve shoulder 6 a of FIG. 1 or 2 .
FIG. 8 is a schematic cross-section view (except for the shafts) of an configuration that could transfer continuous rotation through the wall of a pressure vessel. As indicated, such a wall 3 separates two fluid media 1 and 2 that may have a substantial pressure difference between them. A spherical bearing assembly 5 is mounted through the wall as shown in FIG. 7 and has a shaft 4 that extends on both ends into the ball of a ball joint 10 . A rigid structure is attached to the wall 3 on each side to support radial bearings 3 g on axes that are colinear with the center of bearing-seal assembly 5 . A crankshaft 11 is supported by the bearing 3 g on each side of the wall and has a crank arm 11 a oriented toward the wall in each case. Each crank arm further has a socket part of the joint 10 at an appropriate radius that accepts the ball end of shaft 4 to complete the ball joint. Obviously the roles of the ball and the socket could be interchanged without affecting functionality.
It can be seen that if continuous rotation is applied to the crankshaft on one side, it will cause circular but non-twisting motion to be imparted on that end of shaft 4 , which, acting as a beam pivoting on the spherical bearing-seal 5 will cause the other crankshaft to rotate as well, but at 180 degrees relative to the first.
It is desirable to provide a restraint by means of a linkage attached on one end of shaft 4 to physically prevent it from twisting very far in case a ball joint should seize. One method of doing so is shown: a circular rod 9 extending loosely through a bushed hole 9 a in the supporting structure on one side and having a fork or clevis end 9 b pinned to shaft 4 so that the rod can pivot relative thereto while the ends of shaft 4 move in circles.
It will be understood that the embodiments described above are merely exemplary and that persons skilled in the art may make many variations and modifications without departing from the spirit and scope of the invention as defined in the appended claims.
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A rubber laminated bearing-seal, consisting of multiple flat or curved alternate laminations of metal and rubber bonded together and having an aperture, is seated in an apertured receptacle in the wall of a pressure vessel and supports a shaft that penetrates the apertures, extending from one side of the wall through to the other side. Shear strains in the rubber laminations permit the shaft to carry limited movements through the wall while the laminations seal against any flow of the liquid or gaseous medium on one side toward the other side and withstand the resulting thrust caused by large pressure differences. The torque reaction of this bearing-seal is essentially proportional to rotation angle. A potential use is in the intense hydrostatic pressure environment of undersea applications at great depths, carrying limited motion through the hull of a submersible craft.
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This is a Continuation-in-part of application Ser. No. 177,375 filed Apr. 4, 1988 and entitled Adhesive Backed Business Card for Mounting on a File Card, now U.S. Pat. No. 4,905,392.
BACKGROUND OF THE INVENTION
This invention relates to information bearing cards such as business or calling cards (hereinafter referred to as "business cards") and more particularly to a business card having an adhesive backed panel which may be mounted upon the file card of a file card storage system.
Many file card systems are available for use in storing, indexing, and retrieving information such as names, addresses, telephone numbers and the like. Typically, the user of such file card systems is required to remove a particular file or index card, and either print or type information upon same, the file or index card thereafter being reinserted into its holder or frame therefor. These conventional file card systems do not readily accommodate persons who may receive business or calling cards and the like (all such cards being generically referred to hereinafter as "business cards"), which persons may desire to not only file the information on such business card, but to retain the business cards per se'. Such a person is required to remove a conventional file or index card from its frame or holder and print or type thereon the information obtained from a business card, with the business cards being thereafter stored in a haphazard fashion or even disposed of.
In the typical business setting, the transfer of information from a business card to a file or index card therefore requires a significant amount of effort, so much so that same is oftentimes overlooked. Further, the retention and storage of business cards is quite unorganized and such business cards are readily misplaced as a result. Also, the improved business cards, herein disclosed, may be used in other ways, such as pasting the cards on bulletin boards, affixing them to special correspondence and the like.
OBJECTS
A need clearly exists for a mechanism or system which eliminates the typical problem of haphazard storage of business cards and, at the same time, assures that the information on such business cards is readily and effectively available for storage and retrieval. It is the primary objective of the instant invention to provide an apparatus which satisfies this need, an apparatus which serves to readily and efficiently retain and display business cards.
A further objective of the instant invention concerns the provision of an apparatus which can markedly reduce the work effort involved in transferring pertinent information from a business card onto a file or index card.
Yet another objective of the instant invention is the provision of an apparatus which allows a business card to be directly affixed to a file or index card, thus eliminating the opportunity for a typist or secretary to make an error in transcribing information from the business card to the file or index card.
A further need exists in that business cards constructed according to the disclosure set forth in the prior Application Ser. No. 177,375 herein referred to, "Adhesive Backed Business Card For Mounting On File Card," can, when used in a general manner and not as therein disclosed, be mishandled and abused to the point where the protective release sheet becomes separated from the adhesive backing. Bending the card or folding or `dog-earring` the corners can cause this. Another object of the invention is, thus, to provide a novel and improved business card which is sufficiently stiff and rigid and otherwise constructed as to retain its integrity, with the release sheet remaining in place until the card is ready for use.
BRIEF SUMMARY OF INVENTION
These as well as other objectives are implemented by the instant invention which, as aforementioned, is directed to the provision of an adhesive-backed business card which may be affixed to a file or index card which may, in turn, be carried in a frame means capable of holding a multiplicity of filed cards. Business cards and file cards are in extensive use throughout the country and, to a great extent, have become standardized in size and form. Thus, it becomes essential that the attachment of a business card to a file card be accomplished without requiring a variation of one or the other from a standardized size.
The difficulty in accomplishing this is clearly demonstrated by comparing the size of a standard business card with the size of a most popular file card of the type which is commonly carried upon a card-holding frame means. A common business card is 31/2 inches wide by 2 inches high. The popular file card has a usable face surface which is 4 inches wide and 13/4 inches high. Unless the business card is trimmed, it will not fit on the file card.
In essence, the present invention solves this problem by providing a business card having a contact-adhesive back surface normally covered by a release sheet which is to be removed when the card is to be mounted. The release sheet actually carries the business card, and the card is score-cut about its edge portion to provide a rectangular lift-out panel no more than 13/4 inches high and is proportioned to properly fit the available usable surface of the popular file card. All of the printed information on the business card is in the lift-out panel and thus, the lift-out panel forms a novel and useful combination with the popular sized file card in a simple, effective manner.
The problem brought about by the protective release sheet accidentally separating from the contact-adhesive back surface of the business card when the card is used for other purposes is minimized or substantially eliminated by eliminating the release sheet and providing a backing sheet treated with a release agent only at its central portion, at the area of the lift-out panel of the face sheet of the business card, with the untreated marginal edge portions of the backing sheet tightly and permanently to the marginal edges of the face sheet of the business card.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention itself will be better understood, and further features and advantages thereof will become apparent from the following detailed description of a preferred inventive embodiment, such description making reference to the appended four sheets of drawings wherein:
FIG. 1 is a perspective illustration of a file or index card displaying apparatus constructed in the form of a tray or box;
FIG. 2 is a perspective illustration of a file or index card displaying apparatus constructed in the form of a rotary "flipfile";
FIG. 3 is a perspective illustration of a file or index card suitable for use with the present invention;
FIG. 4 is a perspective illustration of a common business card modified for use in the present invention;
FIG. 5 is an elevational view of the business card shown in FIG. 4 but with a face score-cut being specifically illustrated;
FIG. 6 is a transverse section of the card as taken from the indicated line 6--6 in FIG. 5 but on a greatly enlarged scale and with the center portion broken away to conserve space;
FIG. 7 is a fragmentary portion of the section shown at FIG. 6 but on a further enlarged scale;
FIG. 8 is an elevational view of the backing sheet which is mounted at the back of the face sheet, as would appear from the indicated line 8--8 at FIG. 6;
FIG. 9 is a perspective illustration similar to FIG. 4 but with the lift-out panel of the business card being partially removed;
FIG. 10 is a perspective illustration similar to FIG. 3 but showing the lift-out panel being mounted upon the file card;
FIG. 11 shows a stock sheet of business cards having a plurality of scores marked thereon suitable for supply to a printer;
FIG. 12 shows a portion of the sheet of FIG. 11 cut to a convenient size by the printer with custom printing thereof;
FIG. 13 shows a printed card being trimmed to size;
FIG. 14 shows the backing sheet portion of the stock sheet shown at FIG. 11 with cross hatching indicating areas treated with a release agent;
FIG. 15 is an elevational view of a business card similar to FIG. 5 but with a modified face score cut;
FIG. 16 is a fragmentary view, similar to FIG. 14 but showing an alternate arrangement of the release treated areas;
FIG. 17 shows a release sheet for a single card similar to FIG. 8 but with the alternate arrangement shown at FIG. 15;
FIG. 18 shows an elevational view similar to FIG. 15 but with a further modification of the face sheet, and with portions of the face sheet broken away to show parts otherwise hidden from view.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawings, and particularly to FIG. 1 thereof, one form of an apparatus is disclosed suitable for use in retaining and displaying business cards. The apparatus will be seen to comprise a frame means or card holder generally designated by reference numeral 10 adapted to receive and hold a multiplicity of planar sheets generally designated by reference numeral 20 which comprise file or index cards constructed in the manner depicted in FIG. 3, for example.
An alternative construction of a frame means is that depicted in FIG. 2, wherein the frame means 30 therein is constructed as a rotary "flip-file" containing a central wheel 40 having rods or channels 50 disposed thereon so as to hold the multiplicity of file or index cards 20 therein. As the rotary wheel 40 is turned, the multiplicity of file or index cards "flip" and the information upon each card is readily visible to the user. Frame means such as is shown in FIGS. 1 and 2 are generally known to the public and can be obtained from most office supply sources.
With reference now to FIG. 3 of the application drawings, a typical planar sheet 60 constituting a file or index card is shown, the card being constructed of relatively stiff paper material. The card has a plane, flat surface consisting of two portions, an information carrying surface 65 and a mounting edge means 70 wherein means such as slots 75 may be provided for removably attaching the planar sheet or card 60 to the frame means 10 or 30 as shown in FIG. 1 or 2. The mounting edge means 70 can include attaching means other than slots 75, such as tabs, for example (not shown). The dashed line 80 between the information carrying surface 65 and the mounting edge means 70 defines the extent of the height `a` of the information carrying surface which on a popular sized file card 60 is 13/4 inches high. The width `b` of the card is normally 4 inches.
FIGS. 4, 5 and 6 show the improved business card 85 which is preferably proportioned the same as standardized business cards, having a height `c` of 2 inches and a width `d` of 31/2 inches. This card is formed as a laminate of relatively stiff paper material including an information-carrying face sheet 85' and a backing sheet 90. These sheets are secured together by a contact adhesive 95, FIG. 6.
A rectangular score 100 is cut in the face sheet 85' about marginal edge portions of the face sheet to define a lift-out panel 105 and a marginal edge strip 110 about the panel. The lift-out panel 105 will contain the information printed on the face sheet and can be removed from the body of the card as hereafter described. To fit the usable face surface 65 of a file index card 60, the vertical space between the horizontal line positioned 115 of the score cut 100 must not be more, and preferably slightly less, than the height `a` shown at FIG. 3. Also the horizontal space between the vertical line portions 120 of the score cut 100 must not be more, and preferably slightly less, than the width `b` shown at FIG. 4. In a standard file card 60, where the width `b` is 4 inches and in a standard business card the width `d` is 31/2 inches, the vertical line portions 120 of the score cut 100 are unnecessary when used with standard file card 60. However, both the horizontal and vertical portions of the marginal edge strip 110 are desirable whenever the improved business card 85 is used for other purposes as hereinafter described.
The application of the lift-out panel 105 of the business card 85 to the file card 60 is very simple. As shown in FIG. 9, this panel 105 may be lifted from the business card 85 with the contact adhesive intact as will be described and simply affixed to the usable surface 65 of the file card 60 as shown in FIG. 10. It is to be noted that the panel 105 may also be used in a like manner with file cards larger than the file card 60 and for other similar purposes.
The backing sheet 90 of the business card 85 is adapted to be secured to the face sheet 85' as a laminate by the contact adhesive 95 with this laminate forming a business card which in ordinary use is sufficiently stiff to resist inadvertent bending, especially at the corners. However, to permit the lift-out panel 105 to function as above described, the central portion of the backing sheet 90 is treated with a release agent to provide a release surface 125 which will not adhere with the contact adhesive layer 95 of the lift-out panel 105. At the same time, the edge margins 130 of the backing sheet 90 will be tightly and permanently bonded to the corresponding edge margins 110 of the face sheet 85'
FIGS. 5, 6, 7, and 8 illustrate the construction and components of the laminated business card 85. The face sheet 85, FIG. 5, includes printed information 135 within the liftout panel 105, the score cut 100 defining the panel and the marginal edge strip 110. The backing sheet 90, FIG. 8, includes the treated release surface 125 and the untreated edge margins 130. The release surface 125 is shaped and proportioned to match the lift-out panel 105 to permit the panel to be removed from the body of the card. Preferably, this release surface 125 will extend beyond the panel 105 surface defined by the score cuts 100 as indicated by `x` at FIG. 7. The extension or lap `x` need be only enough to assure easy removal of the lift-out panel.
It is to be noted that many types and grades of contact adhesives are available and a skilled technician can easily select a suitable contact adhesive for the purpose at hand. Release sheets and release agents are also well known to the art. However, applicant does not adopt the standard practice of treating an entire sheet with a release agent. Instead, applicants backing sheet 90 is of untreated cardboard or paper having a selected thickness and stiffness, and of a type which will accept and tightly adhere with the contact adhesive 95 at the back of the face sheet 85. A printing or lithographing operation is necessary to place the release agent on the backing sheet 90 to form the release surface 125 opposite the lift-out panel 105. A skilled printer or lithographer can select a suitable release agent material for this purpose, such, for example, a silicone-based oil having the general properties of an oil based ink.
With reference now to FIGS. 11 through 14, a manufacturing and assembly technique is depicted. Finished business card stock supplied by the manufacturer will include paper face card stock 140, FIG. 11 with the contact adhesive 95 at the back side. A protective backing sheet stock 145 FIG. 14 against the contact adhesive surface, and the score cuts 100 defining the lift-out panels 105. The business card stock 140 may be furnished as 81/2 by 11 inch sheets, which are suitable for printing a dozen cards. This card stock may be cut into smaller sections for printing as shown at FIG. 12 and finally as individual cards 85 as shown at FIG. 13. Other convenient sizes of stock and even continuous coils may also be furnished as desired depending upon the type of press available. In any event, in accordance with the invention the positioning of the cards on the sheet is predetermined. For example, FIG. 11 shows an 81/2 by 11 inch sheet 140 wherefrom twelve conventionally sized 2 by 31/2 inch business cards 85 may be produced with a minimum of stock loss. The panels 105 on this sheet may be cut by score dies after assembly of the face sheet and backing sheet with the sheet being precisely positioned by registration as other registration means at the edges of the sheet.
The backing sheet stock 145, FIG. 14, must be prepared in advance to its positioning on the face card stock 140 to form and properly locate the release surface areas 125. Precise registration of the backing sheet stock 145 with the face sheet 140 is thus essential; however, such is not beyond the ability of a manufacturer. A backing sheet stock 145 is sized to match the paper face sheet card stock 140, shown at FIG. 11, and with suitable registration means 150 to provide perfect registration therewith. A similar procedure is possible when other sizes of stock are used.
FIGS. 15, 16 and 17 illustrate an alternate construction of a business card 85a. As shown at FIG. 15, in this arrangement vertical line portions 120a of the score cuts 100a are used to provide vertical edge margins 110a, while the horizontal line portions and horizontal edge margins are omitted. Accordingly, the lift out panel 105a extends from the top to the bottom of the card. This arrangement may be reversed with vertical edge margins being eliminated and horizontal edge margins being provided.
The advantage of this arrangement lies in a significant simplification of the printing, scoring and application of a release agent 125a. To the backing sheet 90a for some, or even all of these, operations may be done continuously on a coater roll-type press in the arrangement illustrated at FIG. 16. The backing sheet stock 145a received continuous strips of release agents to provide continuous release surfaces 125a. Accordingly, registration in the vertical dimension is not critical. As long as the vertical edge margins 130a, as shown at FIG. 17 register with the vertical marginal edge strips 110a shown at FIG. 15, the height of the card may be optional. Although the construction of the card 85a will not be as rigid as card 85, the corners of the card 85a and the vertical edges 110a will be reinforced and protected from separating.
A further modification of the invention is illustrated at FIG. 18 where the business card 85b is formed with the backing sheet 90a having opposing vertical edge margins 130a and a release agent 125a in the area between the edge margins. A modified face sheet 85b' having a contact adhesive at its back side secures the face sheet 85b' to the backing sheet 90a at the edge margins 130a as illustrated. However, the score cut 100b is not at these edge margins 130a as heretofore described but well within the area of the central portion of the backing sheet which is treated with a release agent. This score cut 100b defining a lift-out panel 105b may extend completely around the panel 105b as illustrated or otherwise as desired.
In use, a business card formed as described herein is affixed to a file or index card, which file or index card would then be placed within the frame means or holding mechanisms 10 or 20. No laborious transfer of information from the business cards to the file or index cards is required, and the business cards are safely stored in a well-organized manner. Also, the business cards may be used in an ordinary manner without the edges of the backing sheet being unintentionally separated from the face sheet before the panel is ready to be lifted from the body of the card to affix it to a file or index card or to any other surface, such as a bulletin board or the like.
It should now be recognized that the objectives set forth at the outset of this specification have been successfully achieved.
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A business card is formed as a laminate comprising an information-carrying face sheet and a protective backing sheet which enhances the rigidity of the face sheet. The face sheet has a contact adhesive at its back surface which bonds the face sheet and backing sheet together, and is provided with a score cut about its edge portions which defines a lift-out panel whereon the information is printed and margin portions at the edges of the card. The backing sheet has a release surface engaging the lift-out panel permitting the lift-out panel to be removed and be affixed to other surfaces such as a file card while the marginal surfaces of the backing sheet engage the margin portions of the face sheet and are tightly and permanently adhered thereto. In the preferred embodiment, the release surface extends a short distance beyond the score cut to facilitate removal of the lift-out panel. The panel may be proportioned to properly fit the surface of file cards of standard sizes. Card stock for manufacturing the business card is also disclosed.
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